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NAYARA ENERGY LIMITED Refinery Division, Vadinar Excellence in Energy Management- 2018 Presenter: Nitinkumar Chokshi - General Manager Arpankumar Panchal - Manager
NAYARA ENERGY LIMITEDRefinery Division, Vadinar
Excellence in Energy Management- 2018
Presenter:Nitinkumar Chokshi - General ManagerArpankumar Panchal - Manager
49 %
24.5 % 24.5 %
Brief introduction –Nayara Energy Limited
24.5 %
49.0 %
Brief introduction –Nayara Energy Limited / Refinery Division
• 20 MMTPA Refinery / 11.8 Complexity
• Oil Terminal - Jetty and SBM Operations
• CPP (Captive Power Plant) – 600 MW
• Storage Facility
Nayara Energy Limited- Refinery Process Flow
VGO MHC
DHDT
DCU
ISOM
CDU 2
CDU
CN
Blending
Mangala
NHT/CCR
Unique Design Features
• Tallest crude column (90 metres height, 76 trays)
CDU 18 MMTPA
• Low pressure steam ejectors & vacuum pump.
VDU
• Converted to CDU from VBU.
• Capable to process ultra heavy crude on standalone basis.
CDU-II2 MMTPA
• Very high pressure hydro treatment
• Capable of producing Euro VI diesel
DHDT5.0 MMPTA
• 6 Coker drums
• One of the largest Coker unit in the world
DCU7.5 MMTPA
• First refinery to use Coal fired Boilers for meeting Steam and power demands of the refinery
CPP (Captive power plant)
• 2 Stage Regenerators
• Running on Maximizing Middle Distillate Mode
FCCU-3.9 MMTPA
• Producing Reformate with 101 RON
• NHT Revamped to 2.15 MMTPA in Feb’18.
NHT/CCR2.15/1.22 MMTPA
• Capable to processing feed with 5% Benzene and 10% C7+
• Revamped to 0.9 MMTPA in Feb’18.
ISOM Unit 0.9 MMTPA
• Converted to Mild Hydrocracker in Sept’2015 Turnaround Shutdown
VGO-MHC 6.5 MMTPA
1. Specific Energy Consumption of Nayara Energy Limited
Refinery’s SEC in terms of MBN (MBTU/BBL/NRGF)
63.84
62.77
58.69 58.87
55
60
65
2014-15 2015-16 2016-17 2017-18
MB
N
MBN (MBTU/BBL/NRGF )
Refinery Turn Around was in FY 2015-16 & next Turn Around planned in FY 2018-19.
• Reduced from 63.84 to 58.87
• PAT Target is 60.35 for FY 2018-19
Data Source : Ready Reckoner Jun’18 on www.ppac.org.in
58
.87
63
.2
64
.7
66
.7
68
.3 72
.4
72
.8 77
.1
77
.3
77
.7
79
.2
80
.8 84
.4 88
.6
91
.7
10
5.5 10
8
12
3.7
40
60
80
100
120
140
MB
N
Note: Reliance, HMEL & BORL MBN data not available
2a. Specific Energy Consumption of NAYARA -Comparison with other Indian Refineries
Specific Energy Consumption of Indian Refineries FY 2017-18
2b. Specific Energy Consumption of NAYARA-Global Benchmarking
• Data Source : Global benchmarking study conducted by Solomon for Nayara.
92.00
80.01
78.0032
10
1
2
3
4
75.00
80.00
85.00
90.00
95.00
2012 2014 2016
QU
AR
TILE
EII
Refinery’s SEC in terms of EII (Energy Intensity Index)
Solomon study is done every alternate year.
• Reduced from 92.00 to 78.00
Benefits
Investment
3a. List of ENCON Projects in last 3 years2017-18 (With Investment)
Increase in FCCU WGC compressor suction pressure.HPS reduced by 0.5 TPH
04.09
0.1
Desalination water Feed to CPU unit Pump - impeller trimming to min diameter (510mm). 79 KWH
04.25
0.5
Benefits
Investment
Installation of energy efficient Fan blades in Cooling Tower 210 KWH
11.30
9.1
LGO product Heat utilization in CDU-1 for increasing Desalter inlet temperature 1 Gcal/Hr.
12.51
6.6
Power saving in Sea water return pump 426 KWH
22.91
2.3
New exchanger train provided in reactor feed-effluent exchanger circuit in NHT. 2 Gcal/Hr.
25.96
90
LED installation at different locations in refinery.
545 KWH
14.67
11
In Base SRU – trap bypass &Desuperheater isolation passing valves replaced. 4 TPH of HPS
32.72
1.0
All figures are in Million Rupees.
Benefits
Investment
3a. List of ENCON Projects in last 3 years2016-17 (With Investment)
HSD tank side stream mixture provision and stopping high capacity pump for circulation. Saving: 42 KWH
2.03
0.50
VFD drive installation in both boilers bottom ash submerged drag Chain conveyor. Saving 3.78 KWH
0.18
0.05
Benefits
Investment
Replacement of total 500 conventional lamps with high efficiency LED lamps. Power saving of 82.26 KWH
2.00
2.94
PIT- Higher Capacity blending pumps replaced with lower capacity pumps. 40 MWH/Month.
2.64
0.87
PIT - Impeller trimming for MS-III to Dispatch transfer pumps
Saving - 11 KWH
0.53
0.08
DCU - Replacement of MF overhead condenser
HP STEAM reduced by 5.96 TPH (4.71 Gcal/hr)
36.55
10.00
CDU-2 Pre heat improvement through Pinch study
FO Saving is 0.102 TPH, Net savings : 1 Gcal/hr
8.08
42.42
All figures are in Million Rupees.
3a. List of ENCON Projects in last 3 years2015-16 (With Investment)
Cooling Tower stoppage
5.78
1.00
Benefits
Investment
Installation of liquid ring compressor in DCU unit
87.53
40.00
Use of Hydrogen rich sat gas as HMU feed resulted in increased yield and reduction in fuel gas requirement
434.45
60.50
All figures are in Million Rupees.
Benefits
3b. List of ENCON Projects in last 3 years2017-18 (Without Investment)
Optimization of DHDS operating parameters.Stripper & Drier inlet temp reduction. 2.6 Gcal/Hr
34.03
Avoid sub-cooling of suspect condensate below 100°C.in ISOM unit through operational control 1.28 Gcal/Hr
11.93
Benefits
All figures are in Million Rupees.
Changing tap setting of lighting voltage transformer to lower the single phase voltage to 210 – 215V 0.7 KWH
0.04
Connecting under-loaded motors in star mode
0.01
Benefits
3b. List of ENCON Projects in last 3 years2016-17 (Without Investment)
Vacuum Residue (VR) run down temperature increase in CDU-2 unit.
Saving - 0.21 Gcal /hr
2.58
Blow down optimization in FCCU unit.
Saving - .0.11 Gcal/Hr
5.93
Benefits
All figures are in Million Rupees.
Stoppage of Additional Lean Amine pump in DHDT unit
Power saving of 185.2 KWH
8.94
CPP - Optimisation of running drives through operational changes
Additional running drives were stopped.
84.76
Steam consumption reduction. By increasing amine concentration.Saving - 8 ton/hr
42.05
Benefits
3b. List of ENCON Projects in last 3 years2015-16 (Without Investment)
One pump stopped in DM water transfer service by Pressure reduction.
1.79
Main Air blower amps reduced by 10 amps optimizing the IGV opening/closing blow off valve.
0.54
Benefits
All figures are in Million Rupees.
In Sulphur Recovery Unit, LP condenser Two fans of 22KW stopped.
0.23
Cold VR from PIT to DCU one pump stopped.
1.84
VGO Pressure Recovery Turbine-1 strainer replaced to improve the reliability and thus save energy.
11.30
Lighting optimized in Mini HMU as the unit is in idle condition.
0.54
In DCU, one condensate pump stopped and 15 M3/hr cold condensate consumption reduced by using stripped water consumption.
0.31
In DCU, LCGO side stripper MP steam reduced.
3.80
Total Savings
Savings
With Investment
Without Investment
2017-18
128.41
46.01
2016-17
947.98
144.26
2015-16
535.58
27.40
Total
1611.97
217.67
All figures are in Million Rupees.
3c. Road Map FY 2018-19
CDU-1: Impeller trimming of raw crude
booster pump
150.67
CDU-2: Vacuum Distillate (VD) low heat recovery. Potential: 2.0
Gcal/Hr
1752.00
Benefits
All figures are in SRFT/ANNUM.
Benefits
CPP PH-2 CW Pump (1 nos) bowl assembly
replacement
37.67
CDU-1: STEAM SYSTEM -Flash vessel provision.
Additional LPS generation : 0.311 TPH
174.35
CDU-1: Thermo-compressor provision.
Additional LPS generation : 0.85 TPH
476.50
CDU-1: HN product heat utilization as per pinch study report for
BFW heating
1927.20
Electrical: Optimizing distribution
transformer voltage level by adjusting
transformer tap setting
90.40
CCR Higher capacity Packinox replacement.
5256.00
4a. Innovative Projects - CDU Column high delta P
❖ Issue: In CDU Column Increased pressure drop (ΔP) across Kero zone trays resulting Energy loss and quality failure of Kerosene and Heavy Naphtha due to suspected Phosphorous compounds typically used in Crude oil production deposition in Kero zone
• The only available option to overcome the issue was to shut down the unit and clean the section tray off any chocking which would have resulted both in throughput/Energy loss by adopting the concept unit shut down was avoided till planned turnaround and both quality and throughput requirement were met.
❑ Impact:
• Throughput Reduction and Energy loss
• Quality Impact
• Light Kerosene (LK) flash point low and high
freezing point affecting Jet fuel production
• Higher end point of Heavy Naphtha (HN) making
it unfit for OMPL grade naphtha production
❑ Action Taken
• Pressure survey carried out indicates trays 31-32
may be partially fouled/blocked
• Gamma Scanning by BARC
• Scheme to bypass tray 31-32 executed (LK PA
return to HK PA return at tray 37) . Piping
modifications carried out to further increase HK PA
duty
Simplified Sketch of LK PA to HK PA Bypass Modification
Schematic diagram of innovation After and before modification data
4a. Innovative Projects - CDU Column high delta P
4a. Innovative Projects - CDU Column high delta P
3.5
1704.3
1 Day
Savings
InvestmentMillion Rs
ImprovementMillion Rs
Payback
❖ Benefits achieved:
• Significant reduction in Column DP
observed post commissioning of LK PA
to HK PA bypass.
• T’put normalized
• Quality specs of LK and HN met
• Non productive energy requirement
was avoided.
❖Further Action
• Installation of new design Kero trays in
TA 2018
SAVINGS
4b. Innovative Projects – Maximizing HN to Gasoline pool
❑ Limitation faced
• NHT charge heater capacity was found limitingwhich was decided to address by providingadditional heat exchangers in feed effluentcircuit.
• Temperature cross (17°C) observed in feed /effluent exchanger train.
• Sizing of over-head condenser for DIP columnat high reflux rate.
❑ Action Taken
• NHT-To get the required preheat, best suitable option
found was to provide the three common exchanger for
both trains without mixing Recycle Gas with feed.
• ISOM-Two drum configuration was used for DIP overhead
circuit this resolved the sizing problem and also resulted in
energy saving as reflux was diverted to the column at 15
Deg Higher temp than the run down.
Challenge: To upgrade maximum possible Heavy naphtha produced to gasoline pool with minimum possiblechange in existing facility.
• 18% of capacity revamp was found possible in NHT unit without change in existing reactor shell size andthe using the existing recycle gas compressor.
• Light Naphtha feed contains about 15% iC5, (RON 93) & 20% increase in ISOM capacity was possible by justremoving iC5 in De-Isopentanizer (DIP) at upstream of PENEX reactor.
RG from RGC
To RGC separator
FEED
P-001A/S
E-001A-F
F-001
110°C68.0 °C
280 °C
335 °C
330 °C
40 °C
EA-001
Reactor
4b. Innovative Projects – NHT Revamp
RG from RGC
To RGC separator
FEED
P-001A/S/B
E-001A-F
F-001
93 °C
68.0 °C
287 °C
335 °C
330 °C
40 °C
EA-001
390 M3/Hr
330 M3/Hr
Heater
Heater
Before
After
Reactor
Light Naphtha From NHT
Feed Treater
PENEX Reactor
Stabilizer
LPG Stripper
DIH Column
DIP Column
LPG
Fuel Gas
Isomerate
LPG
iC5 – iso Pentane
4b. Innovative Projects – ISOM Revamp
140 M3/Hr
170 M3/Hr
➢ Benefits :
• 16% of Heavy Naphtha product was
converted to high value gasoline pool.
➢Energy savings effect:
• 2 Gcal/Hr. fuel saved in NHT charge
heater by additional HE train
• Operation of Iso-Pentane side stripper
using DIP bottom hot stream for
reboiler resulted in 1.5 Gcal/Hr of
energy saving.
90
45.4
2 Years
InvestmentMillion Rs
ImprovementMillion Rs
Payback
SAVINGS 3.5 MMkcal/Hr
4b. Innovative Projects – Maximizing HN to Gasoline pool
5. Renewable Energy Utilization
• Solar photovoltaic cell in security watch
tower in remote location.
• Small windmill installed to provide lights to
security cabin
• Solar Operated Traffic Flasher Lights
installed near Refinery Main gate &
Township gate.
• Solar Heater provided at Oil Club.
• Emission free- electrically powered Golf
Carts and Fuel Free- Bicycles are used in the
Refinery.
• Bio gas plant based on canteen food waste.
• Day light harvesting in warehouse.
6. Utilization of waste material as fuel - Bio Gas plant
• Bio-gas plant is installed to dispose Kitchen waste, which also produce Natural gas and
manure. Natural gas is utilized as fuel in Kitchen and manure in Greenbelt.
• Capacity : 500 kg/Day kitchen waste
• Bio Gas generation about 50 m3 / day equivalent to 20 Kg of LPG.
6.Utilization of waste material as fuel- Spent Carbon Disposal
Project Title :-
• Disposal of Spent Carbon by reusing it as Alternate Fuel in CPP coal based Boiler.
Spent catalyst disposal method:-
• Spent Carbon is generated from Kerosene Merichem Unit, Sulphur Recovery Unit
and Utilities.
• Normal mode of the Disposal is outside parties by incineration. It was decided to
dispose it by using as a fuel in CPP coal based Boilers
Total savings per year = Rs. 39,24,000
CO2e (MT) Emissions
Scope 1
Scope 2
Scope 3
Scope 1 +2
2017-18
5.8620
0.0022
0.0013
5.8640
2016-17
5.9580
0.0026
0.0003
5.9610
2015-16
5.5810
0.0122
0.002
5.5930
Scope 1: Direct GHG emissionsScope 2: Electricity indirect GHG emissionsScope 3: Other indirect GHG emissions
7. GHG Inventorisation
7. Green Belt at NAYARA
Horticulture at Refinery (1064 Acres)
Type Description Total No.
Gre
en
Be
lt(8
47
Acre
s)
Mango trees 1,07,137
Pomegranate trees 1,960
Forest Species 1,91,298
Total Plants 3,00,395
Land
scape
(21
7 A
cres)
Refinery Landscape area(m2) 3,37,443
Avenue & Mass Plantation(m2)
3,59,955
Township & city based (m2) 1,82,204
Total Landscape 8,79,602
9. Team work, Employee Involvement & Monitoring
1.Daily monitoring system -
Daily ENCON report unit wise
2.Review meeting chaired by –
Director and head of Refinery
MRM – Management Review Meeting (Quarterly)
MPR - Monthly Performance Review (Monthly)
3. Separate budget for Energy Conservation -
Yes
4. Energy efficiency / awareness training program -
Quarterly ENMS 50001:2011 training
Brain storming session unit wise and with ENMS co-ordinator.
10. Implementation of ISO 50001:2011-EnMS
• First certified in 2014
• Recertified in 2017
ISO 45001:2018 Certificate
Other information- Awards
Awards Issuing Authority
Nayara Energy Ltd. received the “Excellent Energy Efficient Unit” award in 18th National Award for Excellence in Energy Management 2017
Confederation of Indian Industry (CII)
Nayara Energy Ltd. won First Prize in CII (WR) Safety, Health and Environment (SHE) Excellence & Innovation Award 2017
Confederation of Indian Industry (CII)
Nayara Energy Ltd. won Oil & Gas Conservation Fortnight Award 2016 for Furnace/Boiler Installation Effectiveness in Lowest Heat Loss from Furnace/Boiler Shell(BTU/hr/ft²)
Ministry of Petroleum & Natural Gas
Nayara Energy Ltd. won International Safety Award in the category of Health and Safety Management 2016
British Safety Council
Nayara Energy Ltd. won Skoch BSE Award - Merit of Certificate for Petroleum Refining in the category of Occupational Health and Safety
SKOCH Group
Nayara Energy Ltd. won the National Safety Award for Performance Year 2015 based on Accident-free Year
DGFASLI, Ministry of Labour and Employment, Government of India
Nayara Energy Ltd. Awarded for “Excellence in Management of Environment” for the year 2016
Indian Chemical Council (ICC
Best Practices Implemented on Energy Front
• Involvement of Top Management by putting forward ”Energy” as one of the elements contributing
towards achieving “World Class refinery” tag.
• Dedicating energy task force team formed comprising of experts from various cross functional roles
to promote energy initiatives.
• Promoting culture for continuous EnCon idea generation/ out of the box/ innovation quest for
energy optimization at each unit level.
• APC module implemented to optimize the operation in various unit.
• Indirect losses on slop processing, yield loss and product quality giveaway minimized by diligent
Operation.
• Minimizing power consumption through optimum selection/loading of drives.
• Monitoring all Fluid coupling drives & variable frequency drives.
• Distillation temp, pressure adjustments with changing feed rates /qualities
Best Practices Implemented on Energy Front
• Close monitoring of high energy intensive equipment performance, e.g.
Furnaces & Boilers, rotating equipments distillation columns.
• Carrying out a comprehensive Hydrocarbon Loss Audit.
• Online monitoring of all Flare valves to minimize flare loss.
• Third party audit (Energy, F&L, Electrical) in Refinery.
• Prepared Energy mapping of each unit.
• Developed energy Metrics of each unit.
• Low grade heat utilization.
• Outsourcing steam traps management to minimize steam losses.
• Improved accuracy of loss estimation.
Best Practices Implemented on Energy Front
Encouragement/ Information
Idea Generation –MOC Portal
GRM/Energy/
HSEF
ENCON Team
RLT
Arpankumar PanchalManager Process(M) [email protected]
Nitinkumar ChokshiGeneral Manager Lead EnCON(M) [email protected]
