Eeis - Final Report (Rev.1) - Iocl HR

FINAL REPORT
COMPREHENSIVE STUDY
FOR
ENERGY & PERFORMANCE IMPROVEMENT
IOCL- HALDIA REFINERY
SUBMITTED TO:
&
IOCL- HALDIA CENTRE FOR HIGH
REFINERY TECHNOLOGY
PREPARED BY:
APRIL- 2018
COMPREHENSIVE STUDY FOR Document No.
A981-0000-03-41-SR-011
IOCL- HALDIA REFINERY Rev. 1
FINAL REPORT
COMPREHENSIVE STUDY
FOR
IOCL- HALDIA REFINERY
SUBMITTED TO
IOCL HALDIA
&
CENTRE FOR HIGH TECHNOLOGY
PREPARED BY
ENGINEERS INDIA LIMITED
NEW DELHI
EIL JOB No: A981

REPORT No. A981-0000-03-41-SR -011
APRIL- 2018
CLIENTS COMMENTS INCORPORATED & FINAL

1 19.04.2018 BL/AP NB/VY SCG/SRS
REPORT RE-ISSUED
CLIENTS COMMENTS INCORPORATED & FINAL
0 16.03.2018 BL/AP NB/VKJ SCG/SRS
REPORT ISSUED
A 13.11.2017 DRAFT REPORT AP/PT NB/VY SCG
Reviewed Approved
Rev. No Date Purpose Prepared by
by by
Template No. 5-0000-0001-T2 Rev. 2 / 28.11.2014 Copyrights EIL – All rights reserved
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Rev. 1
IOCL-HALDIA REFINERY
ACKNOWLEDGEMENT
Engineers India Ltd. takes this opportunity to thank Centre for High Technology
(CHT) and IOCL-Haldia Management, their EnCon Group / Technical Services &
Operations Departments for extending their extensive co-operation and logistic
support to EIL team during the execution of the Energy & Performance Improvement
Study.
Collection of data and operating characteristics of the unit is a major and most time
consuming exercise. The co-operation and efforts of refinery personnel in providing
the requisite data for the study as well as their valuable suggestions are highly
appreciated. EIL also thanks IOCL-Haldia personnel who have contributed directly or
indirectly in the compilation & analysis of the data and made available the relevant
documents / records as and when required by EIL team.
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IOCL-HALDIA REFINERY Rev. 1
CONTENTS
SECTION DESCRIPTION
EXECUTIVE SUMMARY…………………………………………………..01
1.0 INTRODUCTION……………………………………………………………19
2.0 OBJECTIVE OF THE STUDY…………………………………………….24
3.0 BASIS OF THE STUDY……………………………………………………27
4.0 METHODOLOGY ADOPTED…………………………………………......30
5.0 ENERGY & PERFORMANCE ANALYSIS -
5.1 PRIMARY PROCESSING UNITS …...…………………….……………..37
5.2 MS BLOCK………………………. ………………….……………………..60
5.3 SECONDARY PROCESSING UNITS ……..……………………….…....66
5.4 TREATING UNITS…………………………………………….……………77
5.5 SULPHUR BLOCK…………………………………………………….…...80
5.6 HYDROGEN GENERATION UNIT…………………………………….....85
5.7 STEAM & POWER NETWORK…………………………………………...93
5.8 UTILITY & OFFSITES.........................................................................112
6.0 SUMMARY OF RECOMMENDATIONS………………………………..129
7.0 GENERAL RECOMMENDATIONS & BEST PRACTICES…………...135
ANNEXURE-I: OBSERVATIONS OF PERFORMANCE AUDIT TEAM
ANNEXURE-II: MANDATORY ENERGY AUDIT SUMMARY BY PCRA
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EXECUTIVE SUMMARY
I. Background:
Climate change by global warming has made it obligatory to all the Nations to
reduce the carbon emission for saving the Earth and Environment. Energy
consumption by industries, in which refineries are part of, contributes
substantially to carbon emissions. Further, Energy constitutes a major operating
cost and hence reduction in fuel & loss offers great potential and incentive to
improve unit performance as well as overall refinery profitability, thereby,
reducing harmful emissions.
Bureau of Energy Efficiency (BEE) along with Centre for High Technology (CHT
has developed a mechanism of PAT cycles, to reduce the MBN (Million British
Thermal Unit per Thousand barrels per Energy Factor) of refineries along with
other high energy consuming industries. The targeted reduction in MBN is
calculated in terms of Metric Ton of Oil Equivalent (MTOE) corresponding to
refinery’s performance in FY 2015-16 and should be achieved by FY 2021-22
as per PAT-II Cycle.
IOCL-Haldia Refinery which operates at 7.5 MMTPA refinery was given an

energy reduction target of 96,000 MTOE/Yr. which includes a short-term target
of 19,000 MTOE/Yr.
CHT intended to have comprehensive study for all PSU refineries carried out in
two parts – Part-A & Part-B. Under Part-A study (current study), the major
objectives include identification of energy saving areas, performance evaluation
(of process units, Utilities, off-sites & major energy guzzler equipment) and
developing Energy Saving Schemes (ESS) covering Quick wins, projects with
minor investment (short-term) and projects with major investment (medium-
term), order-of-magnitude cost with a straight-line payback period. Under Part-
B, refineries will identify energy saving schemes selected from Part-A
recommendations for further evaluation and feasibility. The Part-A study has
been awarded to EIL
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Accordingly, IOCL-HR entrusted EIL for carrying out “Comprehensive study on

Energy and Performance Improvement” to meet the targets set by BEE / CHT
vide a separate Purchase Order.
II. EIL’s Execution Methodology:
As a part of the study, EIL conducted a KOM to finalize the List of Units, Base
case month (January, 2016) for operating data, utility cost, Fuel Oil Equivalent
(FOE) of utilities, and other considerations. IOCL-HR also provided a list of Base
line ENCON schemes, for reference, which are not required to be pursued by
EIL under Part-A.
Following sequential stages have been adopted by EIL to carry out Part-A
energy study:
i. Data collection
ii. Data screening, analysis and reconciliation
iii. Technical interaction & refinery site visit
iv. Study and identification of potential EnCon areas
v. Development of Interim EnCon schemes and submission to Refinery
vi. Engineering evaluation and costing
vii. Submission of Draft Report
viii. Submission of Final Report.
III. Summary of Study and Analysis

The Energy study is carried out for various refinery sections which include
Primary processing units, Secondary processing units, Bottom processing units,
Treating units, Sulphur block, Hydrogen management, Steam & Power network
and Utilities & Off sites.
a. Primary Processing Units
Crude distillation and vacuum distillation are the primary units producing
direct fuels feedstock to downstream secondary units. These are the major
energy consuming units in the refinery. The energy efficiency improvement
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areas have been identified and recommended in CDU’s & VDU’s are as
follows:
 Replacement / Up-gradation of existing CDU-1&2, VDU- 1&2 with new,

integrated, state of the art, efficient CDU/VDU
 Crude Preheat temperature improvement by pinch analysis and
modification in preheat train
 Heat recovery from product rundown in VDU
 Reduction in VDU’s column top pressure
 Stoppage of stripping steam to LGO & HGO strippers
 Conversion of heaters from predominant FO to NG/FG firing
 Stack temperature optimization of the heaters by hardware changes
 Excess air optimization of the heater by replacement of O2 analyser /
burner components
The total Energy Savings (Option-1): 58, 155 MTOE/Yr
Note:
1. Option-1 includes Replacement/Up-gradation of existing CDU-1 & 2, VDU-
1 & 2 with new, integrated, state of the art, efficient CDU/VDU and other
quick wins pertaining to CDU-1, 2 and VDU-1, 2 (preferred by IOCL HR)
2. Option-2 includes all other EnCon schemes except the Replacement of
CDUs/VDUs and replacement of CDUs heaters. Savings under Option-2:
10, 540 MTOE/Yr.
b. MS Block
In MS Block, energy losses are mainly due to cold feed processing by

disposing off heat to atmosphere through air coolers in upstream units. The
energy saving schemes that are proposed include:
 Maximizing Feed Preheat Temperature by considering Hot Feed in NHT
(CRU) unit
 The total Energy Savings: 550 MTOE/Yr.
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c. Secondary Processing Units
OHCU is processing Heavy gas oil (HGO) and vacuum gas oil (VGO) from
VDU. FCCU is processing VGO from VDUs. In this unit, the major heat
losses are thorough heater & boiler flue gases and also through condensing
turbine drive of WGC. The following are the energy efficiency improvement
areas:
 Installation of hot separator in OHCU to produce MP steam.

 Excess air optimisation of the heater by operational improvement / new
O2 analyser
 Replacing the WGC’s condensing turbine drive to motor drive
 Replacing the MAB’s condensing turbine drive to motor drive
The total Energy Savings: 26, 210 MTOE/Yr.
d. Treating Units
Treating Units in IOCL-HR consists of DHDS and KHDS to meet the diesel
and kerosene product specifications as per BS-IV norms. It is observed that
there is potential for improving the inter and intra unit heat integration, by hot
feed maximisation. The recommended schemes is:
 Maximising preheat temperature by considering hot feed in KHDS unit

The total Energy Savings: 150 MTOE/Yr.
e. Sulphur Block
In Sulphur block, energy losses are mainly due to amine supply system to
DHDT & OHCU, and cooling & reheating of streams in TGTU. The energy
saving schemes that are proposed in this block include:
 Increasing the inlet temperature of rich amine feed to amine regeneration
units
 Installation of plate type heat exchangers to increase the sour water
temperature.
The total Energy Savings: 3,200 MTOE/Yr.
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f. Hydrogen Management
Hydrogen network runs throughout the refinery complex to cater to the

hydrogen demand of different units. Invariably, a part of the valuable
hydrogen is lost to the fuel gas system / flare as purge gas stream. As per
existing configuration, hydrogen rich off-gases from DHDS, DHDT, OHCU,
MS Block units are being routed to fuel gas header. A scheme is
recommended to recover the hydrogen from the off-gases using PSA.
g. Steam and Power Network
From the study and analysis of the overall refinery, it has been observed that
major energy loss, in this section, are due to improper condensate recovery
/ steam network management and HRSG / boiler blow downs. Accordingly,
based on overall heat and mass balance, loss of condensate and steam from
the system and energy potential in terms of steam to de-aerator are
quantified. Recommended schemes are:
 Recovery of steam/condensate loss in refinery complex.

 Recovery of steam from Blow Down
 Replacing PRDS with turbo generator for generation of power
 Rationalization of Boilers operation
 Heat Recovery from Boiler’s & HRSG’s blow-down
h. Utility and off-sites:
It is observed that the entire area is traced with steam and due to inherent
inefficiencies in steam network, high amounts of steam/condensate loss is
observed. Under this section following schemes are recommended:
 Electrical tracing of offsite area
 Employing latest technology like fan less cooling tower in place of
conventional induced draft cooling towers
 Flare Gas Recovery
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 Rationalization of Air Compressors

 Low end heat Recovery from flue gases of Furnaces
Total energy savings: 26,400 MTOE/Yr.
Table 1: Savings of Energy Schemes- Refinery Section-wise

Sl. No. Sections in the Refinery Energy Savings
(MTOE/Yr.)
1 Primary Processing Units 58155
2 MS Block 550
3 Secondary Processing Units 26210
4 Treating Units 150
5 Sulphur Block 3200
6 Steam and Power Network 35500
7 Utility and off-sites 26400
8 Hydrogen Management 6600
Savings 1, 56, 765
Block Wise Energy Savings (% Contribution)

4.2% Primary Processing Units (37.1)
MS Block (0.4)
16.8% 37.1% Secondary Processing Units (16.7)

Treating Units (0.1)
Sulphur Block (2.0)
22.6%
0.4% Steam and Power Network (22.6)
0.1%
Utilities and offsites (16.8)
2.0% 16.7% H2 Management (4.2)
Figure 1: Energy Savings Contribution-Refinery Block-wise

(Excluding option-2)
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IV. Summary of Recommendations
The recommended schemes under energy study can be summarized under

various energy study areas like Heat integration, Low level heat recovery,
Intervention of new technologies, Rationalization & up gradation of facilities,
Steam & Power network optimization, Fired heaters and Optimization of
operating parameters.
a. Heat Integration
This is an energy study area in which the potential of inter unit and intra unit heat
integration is explored. Under inter unit heat integration, it is observed that most
of the heat potential in the streams is lost through the air-coolers/ trim coolers
during their routing to storage or due to the existing configuration / operating
philosophy. So, wherever possible, emphasis is given to increase the preheat
temperature of feed to the unit / equipment. Under this category, various schemes
like feed preheat improvement in CDU, NHT CRU, KHDS and heat recovery from
product rundown of VDU-I are studied and recommended.
Under intra unit heat integration, emphasis is given to identify areas in which heat
potential in streams / system is not utilized due to the inherent unit configuration.
The potential schemes recommended in this area include installation of hot
separator for heat recovery from stripper bottoms in OHCU.
The total Energy Savings (excluding option-2) = 10,000 MTOE/Yr.
b. Low Level Heat Recovery
This energy study area mainly focuses on the effective utilization of low level heat
available with different streams in the refinery viz. unit rundowns, flue gases from
boilers/heaters and boiler blow-downs. It is observed that these streams have
significant heat potential which is currently disposed off to atmosphere directly (in
case of flue gases) or lost through air coolers / trim coolers.
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The schemes recommended under this category are heat recovery from boiler’s
& HRSG’s blow down and Low End Heat Recovery from Exhaust Gas of GT-
HRSGs & flue gas of furnaces.
c. Intervention of New Technologies
This is an important area of energy saving explored during the study. Under this,
thrust is given to implement the new technologies and also to replace the existing
inefficient system with a new and efficient systems. Refinery is losing substantial
energy through hydrogen rich fuel gas to flare, loss due to condensation of steam
and inefficient condensate recovery systems.
As a part of this, new energy saving schemes like use of electrical tracing / heating
in place of steam tracing / heating, plate type heat exchangers in SWS/ARU, flare
gas recovery, and fan less cooling towers in place of conventional induced draft
cooling towers are also recommended.
The total Energy Savings = 19,200 MTOE/Yr.
d. Rationalization & Up-gradation of facilities
In the category of Rationalization & up gradation of facilities, importance is given

to reduce specific energy consumption to produce unit quantity of product. It is
observed that in the refinery, old systems / configurations are being used with
inherently lower efficiencies and use of drives linked to operating philosophies.
Refinery is also losing substantial energy through hydrogen rich fuel gas to fuel
gas systems
The schemes that are recommended, as part of this area of energy study are
recovery of hydrogen from refinery off gases, change of condensing turbine / back
pressure drives to motor drives in FCC, reduction of VDU-I column top pressure,
rationalization of air compressors.
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e. Steam and Power Network Optimization
Any energy saving scheme, if implemented in the refinery will most of the time
affect the steam network and / or power network. Therefore, these facilities need
to be optimized. In the current scenario, a complete steam and power network
balance has been carried out for the scenario in which all the energy schemes
accepted by IOCL-HR are assumed as implemented. The energy saving
measures identified in this area are
 Recovery of steam/condensate loss in refinery complex

 Replacing PRDS with turbo generator for generation of power
f. Fired Heaters’ Efficiency Improvement
Fired heaters contributes considerable part of the energy consumption in a

refinery. A comprehensive study and optimization of fired heaters will greatly
reduce the specific energy consumption of a refinery. The areas which are
evaluated under this category are excess air optimization by incorporating reliable
O2 analysers, thermal Efficiency improvement by augmenting APH system based
on predominant gas firing, changing worn-out burner components for improved
combustion performance and replacement of critical dampers.
g. Optimization of Operating Parameters
Optimizing the operating parameters is expected to contribute greatly for the

reduction in energy consumption without significant impact on product pattern
and with no investment. The recommended scheme is stoppage of stripping
steam to LGO & HGO strippers, optimization of stripping steam to crude column
The total Energy Savings = 915 MTOE/Yr.
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Area-wise Energy Savings (% contribution)

0.6%
4.9% Heat Integration (6.4)
6.4%
7.0% 6.1% Low Level Heat Recovery (6.1)
12.2%
Interventation of New Technologies
(12.2)
Rationalization & Upgradation of
Facilities (62.8)
Steam and Power Network
Optimizaton (7.0)
62.8% Fired Heaters Efficiency
Improvement (4.9)
Optimisation of operating
Parameters (0.6)
Figure 2: Energy Contribution- Energy Category-wise

Apart from the above recommendations, general recommendations and best
practices are listed which are being followed by various refiners internationally
& which can be adopted in IOCL-HR as well. These will also contribute to the
overall energy savings and can help to sustain the benefits of implementation
along with other recommended energy efficiency schemes.
V. Summary of Recommendations by Performance Audit Team

Further, as part of study, Walk-through Performance Audit has been carried out
during site visit dated 3rd - 4th Nov ’17 by expert team constituted by CHT. The
committee comprises representatives from various refineries, CHT and EIL. The
observations have been analysed and concluded. Approximate savings for
selected schemes are worked out and is equivalent to 5000 MTOE/Yr. The
details are provided in Section 6.0 & Annexure-I.
VI. Summary of Recommendations by PCRA

PCRA conducted the Mandatory Energy Audit (MEA) for IOCL HR in January
2017. Primarily, scope included was on electrical systems, Power & utilities. The
details are provided in Annexure-II. The following are the energy saving
potential areas identified and recommended by PCRA:
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 Power saving by replacing existing motors with energy efficient motors

 Switching off Transformer by shifting load to standby to eliminate no load
loss
 Saving from improvement of power factor from equivalent monetary
savings
 ID and FD Fan Power reduction by arrest of air leakages in APH
 Install Temperature based ON/OFF control system for CT Fans in TPS,
DHDS, OHCU and Process CT
 Operational controls of HVAC system in various locations
 Install VFD for pumps and motors
 Elimination of distribution loss
 Power saving by replacing existing lights with energy efficient i.e. LED
 Saving by voltage optimization in lighting transformers
 Steam Turbine operation at optimized extraction to improve heat rate
 GT’s operating at Optimum heat rate
The total energy savings under MEA by PCRA is 7,456 MTOE/Yr.
The total Energy Saving Schemes (ESS) along with the MTOE/Yr. saving and
payback are listed in the Table 2. In other form, the savings equal to
approximately INR 376 Crores / Yr. which results in a saving of ~ INR 502 /Ton
of Crude processed.
Table 2: List of Recommended Energy Saving Schemes
MTOE Payback
S. No Unit ENCON Scheme
Savings period
Stoppage of Stripping steam to LGO & HGO

1 CDU-I 475 (**)
stripper in CDU I
Excess air optimization of the Heater 11-F-01 by

2 CDU-I replacement of O2 Analyzer / burners’ fine tuning 1480 1 month
/ replacement of burner components
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Thermal Efficiency Improvement of the CDU-I

heater (11-F-01) by stack temperature 6 months
3 CDU-I 830
optimization through replacement of hardware (Note 1)
and operational and maintenance improvement
Crude Preheat Temperature Improvement by

(**)
4 CDU-II Pinch Analysis and modifications in Preheat train 6000
(Note 1)
in Crude Distillation Unit II (CDU II)

5 CDU-II 440 (**)
strippers in CDU II
Excess air optimization of the Heaters 16-F-01

and 16-F-101 by replacement of O2 Analyzer /
6 CDU-II 470 5 months
burners’ fine tuning / replacement of burner
components
Thermal Efficiency Improvement of the CDU-II

heater (16-F-01) by stack temperature 3 years
7 CDU-II 620
optimization through replacement of hardware (Note 1)
Reduction of Vacuum Distillation Column (31-C- (**)

8 VDU-I 1100
01) Top Pressure in VDU I (Note 1)
Heat Recovery from SR & IO Product Rundowns (**)

9 VDU-I 1300
in VDU I (Note 1)

10 VDU-I 190 1 Year
components
Thermal Efficiency Improvement of the VDU-I

heaters (31-F-01 and 31-F-02) by stack
4 months
11 VDU-I temperature optimization through replacement of 690
(Note 1)
hardware and operational and maintenance
improvement
Excess air optimization of the Heater 82-F-01 by

12 VDU-II replacement of O2 Analyzer / burners’ fine tuning 100 1 Year
/ replacement of burner components
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Replacement / Up-gradation of existing CDU-I,

CDU I-
13 VDU-II, CDU-II and VDU-I with a brand new 55000 (**)
VDU II
state-of-the-art efficient unit
NHT Maximizing Feed Preheat Temperature in NHT

14 550 1 year
(CRU) (CRU) unit
Replacement of Full condensing Turbine of

15 FCC 4400 1 year
WGC to motor
Replacement of Full condensing Turbine of MAB

16 FCC 12000 1 year
to motor
Installation of hot separator in OHCU to produce

3 year 4
17 OHCU M.P. Steam from Reactor Effluent & also 9300
months
reduction in reactor effluent air cooler duty

18 OHCU 510 4 months
components
Hot feed to KHDS unit at 700C Directly from B/L

19 KHDS & Increasing the Pre-heat by 150C thus reducing 150 (**)
the Furnace Duty
Increasing the inlet temperature of Rich amine 1 year 8

20 ARU 1500
feed to Amine regeneration unit of ARU-93 units months
Increase of Inlet Temperature of sour water feed

21 SWSU 1700 1 year
to Sour water Strippers of 29 & 94 units
22 H2 Mgt. Recovery of Hydrogen from Refinery Off-gases 6600 (**)
Recovery of steam/condensate loss in refinery

23 Refinery 11000 (**)
complex
Low End Heat Recovery From Exhaust Gas of 2 year 6

24 CPP 7500
GT-HRSGs months
Heat Recovery from Boiler’s & HRSG’s blow-

25 CPP 1200 8 months
down
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Replacing PRDS with Turbo generator for

26 Refinery 5800 6 months
generation of Power
4 years 4
27 CPP Rationalisation of Boiler operations 10000
months
Application of Electrical Tracing in Offsite Piping 4 years 6

28 Refinery 13000
and Tank Farm in Place of Steam Tracing months
Replacing existing cooling towers with new fan

29 Refinery 3000 1 year
less cooling tower technology
30 Refinery Rationalization of Air Compressors 800 6 months
2 year 2
31 Refinery Flare Gas Recovery 3800
months
Low End Heat Recovery From Exhaust Gas of 2 years 2

32 Refinery 800
CIDW and DHDS furnace months
Thermal efficiency improvement of the fired

heaters by designing / modifying APH system
33 Refinery 5000 (**)
and / or converting from dual firing to 100% fuel
gas / RLNG firing
Sub-Total (MTOE/Yr.) excluding the option-2 1, 56,765
Savings: Walk-Through Performance Audit (MTOE/Yr.) 5,000
Total Savings (MTOE/Yr.) 1,61,765
Savings: PCRA study (MTOE/Yr.) 7, 456
Grand Total (MTOE/Yr.) 1,69,221
Note 1: This scheme is alternative to the scheme No.13 titled “Replacement / Up-
gradation of existing CDUVDU with a brand new state-of-the-art efficient unit” and the
energy savings are not included in total MTOEs.
(**) Schemes are part of revamp / implemented during study / require detailed study /
Quick-wins/strategic-investment
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The list of Recommended Energy Saving Schemes is segregated w.r.t schemes

already initiated by HR, schemes which are partly implemented, implemented during
ongoing study, detailed feasibility requirement under part-B, and on-going project
schemes under BS-VI/ strategic investment and provided in the following Table.
Table 3: List of Recommended Energy Savings Schemes
Scheme MTOE Payback

Unit ENCON Scheme
No Savings period
SECTION-A: Detailed feasibility required (under Part-B)
Heat Recovery from SR & IO Product (**)

9 VDU-I 1300
Rundowns in VDU I (Note 1)
Excess air optimization of the Heater 82-F-01
12 VDU-II by replacement of O2 Analyzer / burners’ fine 100 1 Year
tuning / replacement of burner components
NHT Maximizing Feed Preheat Temperature in
14 550 1 year
(CRU) NHT (CRU) unit
15 FCC 4400 1 year
WGC to motor
18 OHCU 510 4 months
components
Hot feed to KHDS unit at 700C Directly from
19 KHDS B/L & Increasing the Pre-heat by 150C thus 150 (**)
reducing the Furnace Duty
Increasing the inlet temperature of Rich amine
1 year 8
20 ARU feed to Amine regeneration unit of ARU-93 1500
months
units
Increase of Inlet Temperature of sour water
21 SWSU 1700 1 year
feed to Sour water Strippers of 29 & 94 units
Low End Heat Recovery From Exhaust Gas of 2 year 6
24 CPP 7500
GT-HRSGs months
Heat Recovery from Boiler’s & HRSG’s blow-
25 CPP 1200 8 months
down
4 years 4
27 CPP Rationalisation of Boiler operations 10000
months
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Scheme MTOE Payback

Unit ENCON Scheme
No Savings period
Application of Electrical Tracing in Offsite
4 years 6
28 Refinery Piping and Tank Farm in Place of 13000
months
Steam Tracing
Replacing existing cooling towers with new fan
29 Refinery 3000 1 year
30 Refinery Rationalization of Air Compressors 800 6 months
2 year 2
31 Refinery Flare Gas Recovery 3800
months
Low End Heat Recovery From Exhaust Gas of 2 years 2
32 Refinery 800
CIDW and DHDS furnace months
SECTION-B: Schemes initiated by HR, partly implemented /implemented during

ongoing study
Excess air optimization of the Heater 11-F-01
2 CDU-I by replacement of O2 Analyzer / burners’ fine 1480 1 month
tuning / replacement of burner components
Thermal Efficiency Improvement of the CDU-I
6 months
heater (11-F-01) by stack temperature
3 CDU-I optimization through replacement of hardware 830
and operational and maintenance (Note 1)
improvement
Crude Preheat Temperature Improvement by (**)
4 CDU-II Pinch Analysis and modifications in Preheat 6000
(Note 1)
train in Crude Distillation Unit II (CDU II)
and 16-F-101 by replacement of O2 Analyzer
6 CDU-II 470 5 months
/ burners’ fine tuning / replacement of burner
components
Thermal Efficiency Improvement of the CDU-II 3 years
heater (16-F-01) by stack temperature
7 CDU-II optimization through replacement of hardware 620
(Note 1)
and operational and maintenance
improvement
(**)
Reduction of Vacuum Distillation Column (31-
8 VDU-I 1100
C-01) Top Pressure in VDU I (Note 1)
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Scheme MTOE Payback

Unit ENCON Scheme
No Savings period
10 VDU-I 190 1 Year
components
Thermal Efficiency Improvement of the VDU-I
4 months
heaters (31-F-01 and 31-F-02) by stack
11 VDU-I temperature optimization through replacement 690
of hardware and operational and maintenance (Note 1)
improvement
Recovery of Hydrogen from Refinery Off-
22 H2 Mgt. 6600 (**)
gases
Recovery of steam/condensate loss in refinery
23 Refinery 11000 (**)
complex
26 Refinery 5800 6 months
generation of Power
Thermal efficiency improvement of the fired
heaters by designing / modifying APH system
33 Refinery and / or converting from dual firing to 100% 5000 (**)
fuel gas / RLNG firing
SECTION-C: Schemes which may be considered as part of major revamp/post-BS VI

scenario / Modernization/ strategic investment
1 CDU-I 475 (**)
stripper in CDU I
5 CDU-II 440 (**)
strippers in CDU II
Replacement / Up-gradation of existing CDU-
CDU I-
13 I, VDU-II, CDU-II and VDU-I with a brand new 55000 (**)
VDU II
state-of-the-art efficient unit
16 FCC 12000 1 year
MAB to motor
Installation of hot separator in OHCU to
produce M.P. Steam from Reactor Effluent & 3 year 4
17 OHCU 9300
also reduction in reactor effluent air cooler months
duty
17
A981-0000-03-41-SR-011
Note 1: This scheme is alternative to the scheme No.13 titled “Replacement / Up-
gradation of existing CDUVDU with a brand new state-of-the-art efficient unit” and the
energy savings are not included in total MTOEs.
(**) Schemes are part of revamp / implemented during study / require detailed study /
Quick-wins/strategic-investment
18
Rev. 1
IOCL-HALDIA RFINERY
SECTION 1.0
INTRODUCTION
19
Rev. 1
IOCL-HALDIA RFINERY
1.0 INTRODUCTION
Petroleum refinery while being a vital source of fuel and energy to various end
users, consume a part of the crude for its captive use as fuel and power. In
addition, processing losses often accounted as “loss” add to the normal
operating cost. Refinery configuration and complexity, process technology
employed as well as its product slate & specifications are the major contributing
factors towards energy consumption. However, inter-unit heat integration, use
of energy efficient equipment and addition of energy saving devices/ schemes
etc. can reduce fuel consumption and loss leading to the improved performance
of a refinery.
Depending upon the various factors outlined above, typical fuel and oil losses
vary from 7 to 10% of the crude processed (expressed as fuel oil equivalent)
based on their complexity. The fuel & loss figures tend to increase as more and
more secondary processing units are added either for meeting stringent fuel
specifications or for upgrading bottom of the barrel for converting heavier
fractions to more & more light & middle distillates for improving profit margins.
In terms of economic evaluation of the refinery, energy consumption constitutes

a major operating cost and hence reduction in fuel consumption and losses
offers great potential and incentive to improve unit as well as overall refinery
profitability.
Though, the Indian refineries have long understood the importance of energy
optimization & effective management as cornerstone for sustenance, the energy
study’s outcome often suggests that there are still considerable number of
potential areas that can be taken-up by the refinery for further reduction in
energy consumption.
Climate change by global warming has made obligatory to the Nations to reduce
the carbon emission to save the earth and environment. Industries are the major
source of carbon emission and accordingly BEE developed a mechanism for
monitoring and control of the carbon emission in the industry by introducing PAT
Cycle system. Under PAT Cycle-I very high energy intensive and polluting
industries were included. Whereas, under PAT Cycle-II, some more industries
and Petroleum refinery sector are added.
20
Rev. 1
IOCL-HALDIA RFINERY
Bureau of Energy Efficiency (BEE) along with Centre for High Technology
(CHT) has set the refinery specific MBN (Million British Thermal Unit per
Thousand barrels per Energy Factor) reduction targets. On the basis of MBN,
energy savings target in Metric Ton of Oil Equivalent (MTOE) for medium term
(2021-22) have been worked out considering the refinery’s performance
corresponding to FY 2015-16. For IOCL-HR, same is finalized as 96,000
MTOE/Yr. which includes short term (2018-19) target of 19,000 MTOE/Yr.
Accordingly, CHT intended to have comprehensive study for all PSU refineries
carried out by EIL to reduce the specific energy consumption in both short term
and Medium term in line with final proposal dated 23rd Sept 2016.
IOCL HR entrusted EIL for carrying out the Comprehensive study on Energy
and Performance improvement to meet the targets set by BEE / CHT vide Work
Order No. 24950205 dated 12th Dec 2016. The study includes the Process
Plants and Utilities (Steam and Power) for its Refinery.
The various milestones in the projects include Kick off meeting with IOCL-HR
on 12th Dec 2016, subsequently Refinery Specific Data Formats were submitted
to IOCL HR; Technical interaction & refinery site visit was made; ENCON
schemes were developed & interim report on Energy Saving Schemes (ESS)
were submitted to refinery on 30th May 2017. Interaction and approval of
ENCON schemes & Finalization of ENCON schemes were done thereafter.
Draft Report was submitted to refinery on 13.11.2017. Comments on draft report
from HR was received in 3 stages during Dec.17 and Jan.18 and response to
all consolidated comments on draft report was sent to HR on 7th Feb. 2018.
This Study Report covers various sections - Section-2 mentions the objective of
the study. Section 3 & 4 cover the Basis of Study and Methodology Adopted,
respectively. Section 5 discusses the Energy / Performance study & analysis of
various schemes under different units. Each sub-section describes the energy
schemes of the respective units which include the recommended configuration,
energy savings and order of magnitude cost. Section-6 summarises the energy
savings employing unique areas explored. Also included in the report are
21
Rev. 1
IOCL-HALDIA RFINERY
General recommendations and best practises for further consideration by

refinery
IOCL-HALDIA REFINERY COMPLEX
Haldia Refinery, the 4th Refinery of Indian Oil was commissioned in January
1975. It is situated 136 km down-stream of Kolkata in the district of Purba
Medinipur, West Bengal, near the confluence of river Hooghly and Haldia.
It is also one of the two refineries of Indian Oil Group companies producing Lube
Oil Base Stocks (LOBS). The Refinery is spread over an area of about 500 acres
and comprises of four blocks viz. Fuel Oil Block (FOB), Lube Oil Block (LOB),
DHDS and OHCU Blocks besides Oil Movement & storage (OM&S) and Utilities
block.
Initially installed with a crude processing capacity of 2.5 MMTPA, capacity of the
Refinery was increased to 2.75 MMTPA through de-bottlenecking in 1989-90,
and 3.75 MMTPA in 1997 with the installation/commissioning of the 2nd CDU of
1.0 MMTPA capacity. The Refinery has subsequently been augmented to its
present capacity of 7.5 MMTPA.
Haldia Refinery is currently the only coastal Refinery of the Corporation (till such
time Paradip Refinery is commissioned) and one of the two Indian Oil Group
companies producing LOBS, apart from being the sole producer of Jute Batching
Oil.
A Catalytic Dewaxing Unit (CDWU) was installed and commissioned in the year
2003 for production of high quality LOBS meeting the API Grade-II standard of
LOBS. Haldia Refinery also produces eco-friendly Bitumen emulsion and Micro-
Crystalline Wax. Refinery has recently introduced new products viz. API Gr-III
LOBS and 380 cSt Bunker Furnace oil. Typical block diagram of IOCL Haldia
Refinery highlighting various units, feed & product routing is as shown in figure
1.1
22
Rev. 1
IOCL-HALDIA RFINERY
Figure-1.1: IOCL-Haldia Refinery Block Diagram
23
SECTION 2.0
OBJECTIVE OF THE STUDY
24
2.0 OBJECTIVE OF THE STUDY
Based on the greenhouse gases emission considerations as per climate change,

Bureau of Energy Efficiency (BEE) has set the target for reduction in refinery specific
MBN (Million British Thermal Unit per Thousand barrels per Energy Factor).
Accordingly, Metric Ton of Oil Equivalent (MTOE) saving target of short term and
medium term has been worked out, based on the refinery’s performance
corresponding to FY 2015-16 as shown in figure 2.1.
Subsequent to the inception of IOCL-HR about four decade ago, a number of

secondary process unit / utilities have been added in stages as a part of capacity
enhancement, product quality improvement and meeting the statutory norms.
Presently, some of the process units / utilities are quite less energy efficient primarily
attributed to the following reasons:
i. Deterioration of health over a period of time.
ii. Change in the feed / product pattern
iii. Phase-wise integration
iv. Advancement in the Technology
v. Un-economical size/capacity
Above factors also result in, lower profitability and adverse impact on the
environment.
MTOE REDUCTION TARGET

Medium Term
Target
Short Term 1,96000

40, 000
Target
Already being
implemented by
Refinery 19000
28, 000
35893
45, 981
2015-16 2018-19 2020-21
Figure 2.1: MTOE Reduction Targets
25
The objective of this study is as follows:

 Evaluation w.r.t energy performance of:
 Process units
 Utilities and off-sites
 Major energy guzzler equipment’s
 Identification of the potential area of energy saving
 Developing suitable ENCON schemes by heat integration / modification in the
process / equipment’s/ Provision of waste heat recovery system
 Rationalisation of the highly energy inefficient units/utilities/equipment
Thereby, meeting the energy saving target as well as increasing the refinery
profitability.
**********
26
SECTION 3.0
BASIS OF THE STUDY
27
3.0 BASIS OF STUDY
The basis for energy efficiency improvement study (EEIS) has been finalized
with IOCL-HR subsequent to the award of job after a detailed discussion
during kick-off meeting on 12th Dec 2016. Following basis has been agreed &
adopted for the study:
3.1 List of Units
The entire list of the units that are in operation were finalized for the study.
Subsequently, the units which are less energy intensive or not intended to be
operated in future (shut down) were excluded from the final list of units that
have been considered for the study.
For units under revamp
 Study/recommendations are to be based on revamp design documents.

Further, energy saving schemes (ESS) considered in the revamp have
been noted.
 Short term/quick win schemes are proposed if revamp is planned to be
implemented within ~ 2 years.
3.2 Base Case Month for Operating Data
Refinery sector has been covered under PAT (Perform, Achieve and Trade)
Cycle-II starting from 1st April, 2016. Refinery specific energy saving target is
decided based on performance data of the refinery in the year 2015-16 data.
IOCL-Haldia has decided the base case month as January, 2016 for operating
data evaluation based on the optimum throughput and running of maximum
number of process units in the refinery.
3.3 Baseline ENCON Schemes
Various energy saving schemes that are already identified / implemented by

IOCL-HR have been noted. EIL has not pursued these schemes which were
28
already submitted to BEE and pursued by refinery. However, further

augmentation / value addition of some schemes have been considered.
3.4 Fuel Oil Equivalent (FOE)
Refinery consumes various utilities which are generated by consuming oil or

gas. So for comparison between utilities, the following basis has been adopted
to convert them into a common reference:
 Different fuels vary in quality and calorific value. For uniformity, the
Standard Reference Fuel (SRF), with net calorific value of 10,000 kcal/kg,
has been used for all energy number calculations.
 The Fuel Oil Equivalent (FOE) used for various utilities are as follows.
1 Ton SRF = 14.0 Tons of Steam
= 5500 KWH of Power
= 20,000 m3 of circulating Cooling Water
3.5 Other considerations for the Study
In order to establish the energy consumption for various process units, the
following approach has been adopted:
 Energy study has been carried out considering operating data suitably
prorated for design loads
 Design data has been considered for units under revamp
 PGTR reports and DCS graphics have also been considered as per
requirement during evaluation/calculation to have a consistent data
wherever required
 The energy estimation for each unit has been done based on the normal
operation of the unit without taking into account start-ups/shut downs,
intermittent utility requirements, emergencies, operational upsets etc.
 For calculating straight-line payback, value of 1 SRFT is considered as

INR. 24,000
29
SECTION 4.0
METHODOLOGY ADOPTED
30
4.0 METHODOLOGY ADOPTED
As per the final techno-commercial proposal document agreed with CHT and
refineries, the energy study was planned to be carried out in two parts - Part A
and Part B. Identification of the potential areas and developing the EnCon
schemes are covered under Part-A.
The schemes have been classified into three categories:
a. Quick-wins: These include schemes which require operational

improvements with no investment or additional hardware.
b. Projects with minor investment: These include short-term schemes which
require minimum down time.
c. Projects with major investment: These include medium-term schemes
with reasonable down time, such as rationalization of old energy inefficient
facilities/equipments and unit revamps.
Present study pertains to part A, and the following sequential stages have been
adopted to carry out the techno-economic feasibility analysis of different energy
improvement schemes:
i. Data collection
ii. Data screening, analysis and reconciliation
iii. Technical interaction & refinery site visit
iv. Study and identification of potential EnCon areas
v. Development of Interim EnCon schemes and submission to Refinery
vi. Engineering evaluation and costing
vii. Submission of Draft Report
viii. Submission of Final Report.
4.1 Data Collection
Data collection is the most important and crucial phase of the project. It is not
only the most time consuming activity but also demands significant information
about the unit’s present status as well as its trend. The success of any Energy
Efficiency Improvement Study greatly depends on the accuracy of the data.
31
Therefore, it is important to have the right and authentic data to achieve the
desired results.
To handle the huge data/documents required for the study covering various
units, offsites and utilities, a systematic methodology has been adopted as
described below:
i. Initially, FTP server was created for uploading & downloading of the
data/documents.
ii. During project kick-off meeting, EIL explained the type of data/documents
required for the study, document handling procedure in FTP server and also
explained sample format for filling the operating data.
iii. Refinery has uploaded required basic documents (PFD, stream summary
etc.) for preparation of Unit/Equipment specific data formats for obtaining
operating data.
iv. EIL prepared Refinery Specific Data Formats (RSDF) and uploaded on FTP
server. EIL has also facilitated the refinery by providing audio/video
guidelines to fill the operating data in RSDF.
v. IOCL-HR uploaded filled-in RSDF and additional supporting Data/
documents on FTP server
4.2 Data Screening, Analysis and Reconciliation
The next phase of the study is data screening, analysing and reconciliation of
filled-in data based on design data, past trend, in-house technical data bank and
design tools. Steps followed are mentioned as below:
o All the data and information collected have been analysed thoroughly to
check their consistency, completeness and correctness.
o Clarifications and additional data were sought from refinery wherever

required.
o In case of units which were not running at full capacity/had some operational
upsets during the base case month; operating data near to base case month
was considered for such units.
32
o Test run data/DCS graphics have also been used where-ever deemed fit.
o In case of non-availability of data, it was decided mutually to use the relevant

in-house data/documents available with EIL.
Based upon the information consolidated as per above steps, a consistent set
of data adequate for the study was compiled.
4.3 Technical Interaction and Site Observations
For complete understanding of the operating data and documents submitted

and to understand the site feasibility of the recommended schemes, EIL visited
IOCL-HR to have a close technical interaction followed by site visit as described
below :
o Energy team consisting of various domain experts from EIL visited IOCL-HR
for technical discussion on the filled-in operating data with EnCon team,
personnel of technical department and to get feedback from plant operating
personnel of various units.
o Brain storming session along with EnCon, technical services and unit
operational Heads/managers for better understanding of the unit operating
performance and constraints, if any.
o Preliminary site observations of various units and offsites along with the
refinery personnel were carried out. Collection of balance data/documents
was done from technical services/EnCon team that was required further
based on the outcome of these interaction.
4.4 Development of EnCon Schemes
The key to the study is to identify various energy conservation schemes along
with their energy saving potential , a brief site feasibility and costing based on
the operating/design data. This is further explained as below:
o Energy conservation schemes were identified and thoroughly evaluated

along with domain experts.
33
o Design documents, filled-in operating data, test run reports and DCS screen
shots, in-house data bank and design tools have been used for developing
the schemes. In house data base was used only in absence of data or
inconsistency.
o Technical interaction with IOCL-HR was done, for adequacy and

consistency checks as mentioned above.
o Various Software tools/ technologies available with EIL have been used for
developing and evaluating the schemes.
4.5 Finalisation of Interim EnCon Schemes
An interim phase has been created to fulfil the requirement of Refineries to

submit energy saving schemes to BEE as per PAT-II requirement. A format
capturing interim EnCon Schemes is prepared and submitted to IOCL-HR, also
for obtaining their suggestions to proceed further with remaining phases of site
feasibility and costing as detailed below:
o An interim EnCon Saving Scheme (ESS) format having various details like
existing arrangement, observations, recommended arrangement,
envisaged savings has been shared with IOCL-HR for their comments/
discussions and also to obtain in-principal approval on prima-facie
technically viable schemes for further evaluation.
o IOCL-HR team visited EIL office for technical discussion on the proposed
schemes followed by EIL’s site visit for further clarification/broad site
feasibility checks of approved schemes.
o Based on study of remaining areas, additional EnCon schemes were
identified and submitted to IOCL-HR for discussion/approval in addition to
already submitted interim schemes.
Final interaction was held subsequently for detailed discussion and acceptance
of all these recommended schemes during the visit of EIL team to IOCL-HR.
34
4.6 Engineering Evaluation and Costing
EnCon schemes that are finally approved by IOCL-HR have been further
evaluated and broad based feasibility has been done. Further, order-of-
magnitude cost and straight-line payback period has been estimated for all the
schemes.
4.7 Report Preparation & Submission
The study recommendations, after complete analysis and evaluation of the

energy saving schemes, have been elaborated and summarised in the form of
a study report and submitted to IOCL-HR. The report covers brief introduction
of refinery, units, Offsites and Utilities and details of all energy saving schemes.
Each recommended scheme has individual subsections covering various details

like present configuration, observations and analysis, recommendations, energy
savings, implementation aspects, order-of-magnitude-cost, pay-back and
remarks, if any. Initially a Draft Report is submitted before for client’s
observations, if any. The Final Report, incorporating the resolved comments
/suggestions is submitted.
***********************
35
IOCL HALDIA REFINERY Rev. 1
SECTION 5.0
ENERGY & PERFORMANCE ANALYSIS
36
5.1 ENERGY & PERFORMANCE ANALYSIS OF PRIMARY UNITS
CDU, VDU and associated heat recovery systems from pump-around are the
prominent part of primary operating units in a refinery as they provide many
direct distillate products as well as feedstock to secondary process units like
once-through Hydro-Cracker Unit, Fluid Catalytic Cracking (FCC), etc. IOCL HR
has two stand-alone CDUs (CDU-I & CDU-II). The reduced crude oil (RCO) from
CDU-I and CDU-II are routed to VDU-II and VDU-I respectively.
5.1.1 Crude Distillation Unit - I (CDU I)/Vacuum Distillation Unit – II (VDU II)
CDU-I was originally designed by Technip, France and it was revamped for a
throughput of 3.5 MMTPA in 1996. At present, unit is operating at 100%
throughput and feed to the unit is heavy crude. The RCO of CDU-I is routed to
VDU-II for further fractionation.
Energy Saving Scheme:
1. Stoppage of Stripping steam to LGO Stripper & HGO stripper in CDU I
a. Existing Configuration
At present, 580 kg/h and 180 kg/h of stripping steam is being used in
LGO stripper (11-C-02B) & HGO stripper (11-C-02C), respectively to
maintain the flash points of LGO and HGO products.
b. Observations & Analysis

Under BS-VI operation, 100 % of HN has to go to hydro processing units
as feed in order to meet the sulphur specification, so the final flash point
correction should occur at hydro processing end for both HN and diesel
products.
However, based on observations, in case of complete stoppage of
stripping steam to LGO stripper (11-C-02B) & HGO stripper (11-C-02C),
flash points will still be achieved above their typical values of 12 oC and
38 oC, respectively.
37
There is a scope of energy savings by stopping the use of stripping steam

in LGO & HGO strippers completely.
c. Recommended Scheme
Use of stripping steam to LGO stripper & HGO stripper can be stopped
completely under BS-VI operation. The stripping steam may be reduced
gradually while maintaining products specification.
The reduction in the stripping steam will also reduce the sour water
generation from the unit, thereby reducing the energy (LP Steam)
required for heating in sour water strippers.
d. Energy Savings
Energy savings w.r.to the recommended ENCON scheme is estimated

to be ~ 475 MTOE/Yr (Quick win).
The break-up of the energy savings is as follows:

 Saving in LGO Stripper – 330 MTOE/Yr
 Saving in HGO Stripper – 100 MTOE/Yr
 Saving in Sour Water Stripper – 45 MTOE/Yr
Remark: It is recommended that the use of stripping steam to LGO stripper &
HGO stripper to be stopped completely for BS-VI scenario.
2. Excess air optimization of the Heater 11-F-01 by replacement of O2

Analyzer / burners’ fine tuning / replacement of burner components
11-F-01 is a balanced draft, dual fired crude heater, has design absorbed
duty of 35.0 MMkcal/h & provided with outboard CAPH and SAPH.

Based on operating data, following observations are made and analysed:
38
 O2 contents in flue gas is on higher side (8.13 %)

 Installed O2 analyser is of old Zirconia based technology and
provide localized content of the O2 in flue gas.
 It is difficult to control excess air properly by an unreliable O2
analyser.
 There may be wear and tear, coking in burners’ components which
require higher excess air for proper combustion.
 High excess air may also be due to poor air distribution to multiple
burners from hot combustion air duct. Sufficient combustion air
quantity has to be provided for proper combustion in air starved
burners which leads to much higher combustion air to other burners.
In order to optimize the excess air, recommendations are as given below:
 Replace the existing O2 analyser (which gives localized/point

reading only) with latest Tuneable Diode laser Spectroscopy
(TDLS) type analyser, which has the capacity to measure average
content of O2 with better accuracy in flue gas all the way through
firebox.
 Inspect and change the faulty components of the burner / fine tune
the burners.
 Computational Fluid Dynamics (CFD) study for combustion air
distribution duct.
d. Energy Savings
There is a scope of energy saving by optimizing the excess air and to
bring down O2 content in the flue gas from 8.13% to 3.0% (near to
design). With this, nearly 1480 MTOE/Yr. saving is possible.
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
39
 Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
 Change the faulty components of the burner during shutdown.
f. Order-of-magnitude Cost / Straight-line Payback

The cost estimation is carried out considering the new items /
modifications & payback period is worked out accordingly. These are
listed as following:
Estimated cost of new TDLS type O2 analyser : 20 Lakhs
Savings from this EnCon scheme : 356 Lakhs/Yr.
Straight-line payback : < 1 Month
3. Thermal Efficiency Improvement of the CDU-I heater (11-F-01) by stack

temperature optimization through replacement of hardware and
operational and maintenance improvement
duty of 35.0 MMkcal/h & provided with outboard CAPH and SAPH.

 Stack temperature of the heater is 219°C. Existing APH system was

designed based on FO firing with flue gas exit temperature of 180°C
 CAPH having heat transfer problem.
 Critical dampers are not working properly
In order to optimize the stack temperature, recommendations are as
given below:
40
 Replace CAPH.
 Replace stack dampers with control/TSO type dampers.
 Replace combustion air dampers by control/TSO type dampers.
 Cleaning of convection section
 Inspect and replace faulty burners/burner parts
 Inspect and repair/replace faulty soot blowers.
d. Energy Savings
With the help of above mentioned hardware improvement, there will be

substantial gain in the efficiency of the heater as mentioned below:
Improvement in the thermal efficiency : ~ 2.0%
Savings of the fuel : 830 MTOE/Yr.
 Replace the APH during shutdown
 Augmentation of convection section, replacement of stack damper
and combustion air bypass damper job to be planned during shorter
shutdown
 Convection section tubes cleaning to be taken up during heater shut
down
 Soot blowers to be repaired as per maintenance schedule

Cost of New APH : 400 Lakhs
New Stack Damper : 12 Lakhs
New Combustion air bypass Dampers (2Nos) : 20 Lakhs
Savings from this EnCon scheme : 200 Lakhs/Yr.
Straight-line payback : ~ 6 Months
41
Remarks: IOCL-HR has taken the appropriate action during TSRD in Dec 2017.
4. Excess air optimization of the Heater 82-F-01 by replacement of O2

Analyzer / burners’ fine tuning / replacement of burner components
82-F-01 is a balanced draft vacuum heater, has design absorbed duty of
34.35 MMkcal/hr.

 O2 contents in flue gas is on slightly higher side (3.5 %)

analyser.

firebox.
the burners.
d. Energy Savings
42

bring down O2 content in the flue gas to 3.0% (near to design). With this,
nearly 100 MTOE/Yr saving is possible.

Estimated cost of new TDLS type O2 analyser : 20 Lakhs
Savings from this EnCon scheme : 24 Lakhs/Yr
Straight-line payback : < 1 Year
5.1.2 Crude Distillation Unit - II (CDU II) and Vacuum Distillation Unit I (VDU I)
1. Stoppage of Stripping steam to LGO stripper & HGO stripper in CDU II
At present, 385 kg/h and 300 kg/h of stripping steam is being used in
LGO stripper (16-C-02B) & HGO stripper (16-C-02C), respectively to
maintain the flash points of LGO and HGO products.
43

Under BS-VI operation, 100 % of HN has to go to hydro processing units
as feed in order to meet the sulphur specification, so the final flash point
correction should occur at hydro processing end for both HN and diesel
products.
However, based on observations, in case of complete stoppage of
stripping steam to LGO & HGO strippers, flash points still will be achieved
above their typical values of 12 oC and 38 oC, respectively.
There is a scope of energy savings by stopping the use of stripping steam
in LGO & HGO strippers.
Use of stripping steam to LGO stripper & HGO stripper can be stopped
completely under BS-VI operation. The stripping steam may be reduced
gradually while maintaining products specification.
The reduction in the stripping steam will also reduce the sour water
generation from the unit, thereby reducing the energy (LP Steam)
required for heating in sour water strippers.
d. Energy Savings
Energy savings w.r.to the recommended ENCON scheme is estimated

to be ~ 440 MTOE/Yr (Quick win).
The break-up of the energy savings is as follows:

 Saving in LGO Stripper – 220 MTOE/Yr
 Saving in HGO Stripper – 170 MTOE/Yr
 Saving in Sour Water Stripper – 50 MTOE/Yr
Remark: It is recommended that the use of stripping steam to LGO stripper &
HGO stripper to be stopped completely for BS-VI scenario.
44
2. Reduction of Vacuum Distillation Column (31-C-01) Top Pressure in

VDU I
At present, vacuum distillation column (31-C-01) in VDU I is operating

at around 95.8 mmHg top pressure and column pressure drop is around
36 mmHg.
Vacuum column is operating at around 20.8 mmHg top pressure which

is higher than the design value (i.e. 75 mmHg). This may be due to
fouling in condensers or nozzle erosion in ejectors. There is a scope of
energy savings by reducing the vacuum column top pressure as
recommended.
Reduction of column top pressure close to the design value i.e. 75

mmHg is recommended. Thus, by maintaining the column top pressure
at 75 mmHg and flash zone pressure at 111.2 mmHg by keeping the
same operating pressure drop (i.e. 36 mmHg), 6oC reduction in COT
will be achieved. This leads to duty reduction of 1.46 MMkcal/h in
vacuum heater. It is also recommended to have detailed study of
overhead ejector system.
d. Energy Savings
Energy savings potential w.r.to the recommended ENCON Scheme is

estimated to be ~ 1100 MTOE/Yr. The recommended ENCON scheme
is considered as Medium term measure.
Remarks: IOCL HR has taken action on the recommended EnCon scheme.
45
3. Crude Preheat Temperature Improvement by Pinch Analysis and

modifications in Preheat train in Crude Distillation Unit II (CDU II)
CDU-II consists mainly of preheat exchanger train, Atmospheric
column, Naphtha stabilizer, Naphtha Splitter. The Preheat Train has
three parts:
 Preheat train I – up to desalter
 Preheat train II – desalted crude to Prefractionator column
 Preheat train III – pretopped crude to crude furnace inlet

The crude flow to the Atmospheric Distillation column (16-C-01) is
around 625 m3/h and final crude preheat temperature is 249 °C against
the design value of 274 °C (Arab Mix). There is scope in the energy
savings by optimizing the approach temperatures in the exchangers in
preheat train and recovering maximum heat from the product rundowns
streams.
Considering optimum approach temperature in exchangers, and
maximum heat recovery of products (lower temperature at the cooler
inlet) it is recommended to achieve the design preheat temperature of
274 °C for this crude in CDU-II. Prima facie, increase in preheat
temperature will be ~ 25 °C, which reduces the furnace duty by ~ 8
MMkcal/hr. However, a detailed pinch analysis is to be carried out for
holistic preheat optimization study.
d. Energy Savings
The energy savings w.r.to preheat improvement in CDU-II is estimated
to be ~ 6000 MTOE/Yr.
Remarks: IOCL HR informed that subsequently preheat temperature is

improved to 268 °C due to cleaning of exchangers during M&I.
46
4. Heat Recovery from SR & IO Product Rundowns in VDU I (U-31)
A recirculating tempered water circuit is provided in the unit to avoid over
cooling of products SR & IO. Tempered water at 60 oC is pumped to SR
Tempered Water Cooler (E-124 A/B/C) & IO Tempered Water Cooler (E-
125 A/B/C). The heated tempered water at 80 oC is then returned back
to tempered water drum after cooling to 60 oC in Tempered Water Air
Coolers. (Refer Figure No.-5.1.1)
Existing Arrangement:
T 190 T 120
SR In SR Out
E-124 A/B/C
T 230 T 85
IO In IO Out
E-125 A/B
Product-Tempered Water Coolers
Figure No. 5.1.1: Existing Arrangement in VDU I
b. Observations & analysis

Temperature of SR and IO products at the inlet of Tempered water circuit
is 190 oC & 230 oC, respectively. These products are leaving Tempered
water circuit at 120 oC & 85 oC, respectively.
c. Recommended scheme
Based on EIL’s recent design practices, it is recommended to recover the
heat from these products, which are currently being cooled in Tempered
water circuit in VDU I preheat network. Recoverable heat from SR and
IO streams is around 1.127 MMkcal/hr & 1.65 MMkcal/hr respectively.
47
Prima facie, if 60% of the total recoverable heat is assumed to be

recovered/absorbed in the VDU I preheat and significant amount of
energy savings can be achieved. Energy saving potential is estimated to
be around 1.666 MMkcal/hr. However, a detailed pinch analysis is to be
carried out for holistic preheat optimization study (Refer Figure No. 5.1.2).
There is a scope of energy savings by recovering the heat from SR and
IO streams in VDU I preheat network.
Recommeded Arrangement:
VDU I Preheat
Network
T 190 T 120
SR In SR Out
E-124 A/B/C
T 230 T 85
IO In IO Out
E-125 A/B
Product-Tempered Water Coolers (Bypassed)
Figure No. 5.1.2: Recommended Arrangement for TW circuit in VDU I
d. Energy Savings
The energy saving potential w.r.to the recommended ENCON scheme
is estimated to be ~ 1300 MTOE/Yr.
This scheme is considered as Medium term measure.
The break-up of the energy savings as follows:

 Savings from SR Stream – 540 MTOE/Yr
 Savings from IO Stream – 796 MTOE/Yr
48
5. Excess air optimization of the Heaters 16-F-01 and 16-F-101 by

replacement of O2 Analyzer / burners’ fine tuning / replacement of burner
components
16-F-01 and 16-F-101 are balanced draft, dual fired crude heaters,
having design absorbed duty of 28.8 MMkcal/h and 16.1 MMkcal/h,
respectively, provided with outboard APH system.

 O2 contents in flue gas is on higher side (3.9 % for 16-F-01 and

8.0% for 16-F-101)
analyser.
burners which leads to much higher combustion air to other burners

firebox.
49
the burners.
distribution duct.
d. Energy Savings

Estimated cost of new TDLS type O2 analyser (2 nos.): 40 Lakhs
Straight-line payback : < 5 Months
50
6. Thermal Efficiency Improvement of the CDU-II heater (16-F-01) by stack

temperature optimization through replacement of hardware and
operational and maintenance improvement
duty of 28.8 MMkcal/h & provided with outboard CAPH and SAPH
system.
 Stack temperature of the heater is 218°C. Existing APH system was

designed based on FO firing with flue gas exit temperature of 180°C
 CAPH having heat transfer problem.
 Critical dampers are not working properly
given below:
 Replace CAPH.
 Replace stack dampers with control/TSO type dampers.
 Replace combustion air dampers by control/TSO type dampers.
 Cleaning of convection section
 Inspect and replace faulty burners/burner parts
 Inspect and repair/replace faulty soot blowers.
d. Energy Savings

substantial gain in the efficiency of the heater as mentioned below:
Savings of the fuel : 620 MTOE/Yr
51
 Replace the APH during shutdown
 Augmentation of convection section, replacement of stack damper
and combustion air bypass damper job to be planned during shorter
shutdown
down

Estimated cost of
New APH : 400 Lakhs
New Stack Damper : 12 Lakhs
Straight-line payback : < 3 year
Remarks:
IOCL-HR has taken the appropriate action during TRSD in Dec’17.
7. Excess air optimization of the Heaters 31-F-01 and 31-F-02 by replacement

of O2 Analyzer / burners’ fine tuning / replacement of burner components
31-F-01 and 31-F-02 are balanced draft vacuum heaters, having design
absorbed duty of 22.41 MMkcal/hr and 11.0 MMkcal/hr, respectively.

52
 O2 contents in flue gas is on higher side (~4.0 %)

analyser.
burners which leads to much higher combustion air to other burners

firebox.
the burners.
distribution duct.
d. Energy Savings
53

Straight-line payback : < 1 Year
8. Thermal Efficiency Improvement of the VDU-I heaters (31-F-01 and 31-F-

02) by stack temperature optimization through replacement of hardware
31-F-01 and 31-F-02 are balanced draft vacuum heaters, having design
absorbed duty of 22.41 MMkcal/hr and 11.0 MMkcal/hr, respectively.

 Stack temperature are high (31-F-01: 229 0C and 31-F-02: 195 0C).
 31-F-01, APH having heat transfer problem.
 Convection section cleaning is required
 Critical dampers are not working properly.
 31-F-02, Convection section/APH cleaning is required
54
given below:
 31-F-01:
a. Cleaning/Replacement of CAPH
b. Replace stack dampers with control/TSO type dampers.
c. Replace combustion air dampers by control/TSO type
dampers.
d. Cleaning of convection section
e. Inspect and replace faulty burners/burner parts
f. Inspect and repair/replace faulty soot blowers.
 31-F-02:
a. Convection section/APH cleaning is required
d. Energy Savings

substantial gain in the efficiency of the heaters as mentioned below:
Savings of the fuel : 690 MTOE/Yr
 Cleaning of APH during shutdown
 replacement of stack damper and combustion air bypass damper job
to be planned during shorter shutdown
down
55

Estimated cost of
New Stack Damper (2Nos) : 24 Lakhs
Straight-line payback : < 4 Months
Remarks: IOCL-HR has implemented the recommended scheme during the

study.
9. Replacement / Up-gradation of existing CDU-I, VDU-II, CDU-II and VDU-I

with a brand new state-of-the-art efficient unit
CDU-I was originally designed by Technip, France and it was revamped
for a throughput of 3.5 MMTPA in 1996. At present, unit is operating at
100% throughput and feed to the unit is heavy crude. The RCO of CDU-
I is routed to VDU-II for further fractionation.
CDU-II was originally designed by Technip, France and it was revamped
for a throughput of 4.1 MMTPA in 1996. At present, unit is operating at
100% throughput and feed to the unit is mix of light and heavy crude. The
RCO of CDU-II is routed to VDU-I for further fractionation.

Energy consumption for operating throughput for CDU-I & VDU-II is
tabulated in Table 5.1.2 and also presented in bar charts in Figure 5.1.3.
56
Table 5.1.2: Energy consumption of CDU-I & VDU-II
Basis CDU I (425 TPH) VDU II (250 TPH)

S.N Utility 1 tonne Utility Fuel oil Utility Fuel oil
fuel eq. Consumption Eq., t/h Consumption Eq., t/h
1 Power, kw 5500 3000 0.55 2100 0.38

Fuel,
2 MMkcal/hr 9.8 48.0 4.90 32.3 3.30
3 Steam, TPH 14 11 0.82 29 2.06
4 Water, m3/hr 20000 3478.0 0.17 4654.0 0.23
Calculated Energy
6.44 5.97
Consumption, TPH
Design Energy
Consumed 1.51 2.39
(FOE / MT of crude in %)
Energy consumption for operating throughput for CDU-II & VDU-I is

tabulated in Table 5.1.3 and also presented in bar charts in Figure 5.1.3.
Table 5.1.3: Energy consumption of CDU-II & VDU-I
Basis CDU II (525 TPH) VDU I (143.8 TPH)
S.N Utility 1 tonne Utility Fuel oil Utility Fuel oil

fuel eq. Consumption Eq., t/h Consumption Eq., t/h
1 Power, kw 5500 2950.0 0.54 1340.0 0.24

Fuel,
2 MMkcal/hr 9.8 60.8 6.20 20.8 2.12
3 Steam, TPH 14 12 0.82 12 0.84
4 Water, m3/hr 20000 4210.0 0.21 3086.0 0.15
Calculated Energy
7.77 3.36
Consumption, TPH
Design Energy Consumed 1.48 2.34

(FOE/MT of crude in %)
From current pattern of energy consumption, it is observed that CDU-I,

CDU-II, VDU-I and VDU-II are consuming more energy compared to
latest high efficient CDU which is processing similar feeds. This may be
57
attributed to poor heat integration, old and in efficient equipment’s/units,

etc.
Utility Consumptionin FOE, TPH

7.00
6.00 CDU-I
5.00 CDU-II
FOE, TPH
4.00 VDU-I
3.00 VDU-II
2.00
1.00
0.00
POWER FUEL STEAM WATER
Figure 5.1.3: Energy consumption of CDUs & VDUs
c. Recommended Arrangement
Installation of new state-of the art, high efficient integrated CDU/VDU

which will be designed, considering the following key aspects will lead to
higher energy efficiency:
 Maximizing the Preheat temperature
 Maximizing heater efficiency
 Lower operating Pressure of Crude column
 Pump selection criteria
 Use of hybrid vacuum system in place of the conventional ejector
Energy consumption w.r.to design capacity of existing units and high

efficient new CDU/VDU is tabulated in Table 5.1.4 and also presented in
bar charts in Figure 5.1.4.
Table 5.1.4: Energy consumption of CDUs, VDUs & new CDU
CDUs & VDUs New CDU/VDU

Design Throughput (TPH) 7.5 7.5
58
FOE (%) 2.48 1.75
Comparison of Energy Consumption

3
2.48
2.5
2 1.75
FOE (%)
1.5
0.5
0
New CDU/VDU
CDUs & VDUs
Figure 5.1.4: Energy consumption of CDUs/VDUs and new CDU/VDU
From above data, it is clear that existing CDUs &VDUs are consuming
2.48 % of FOE to process combined flow of 950 TPH feed. In contrast,
high efficient new CDU/VDU is consuming around 1.75 % FOE for
processing the same throughput and also keeping the same product
pattern.
d. Energy Saved
Based on analysis, it is envisaged that by installing new high efficient

new CDU/VDU, around 55,000 MTOEs would be saved per annum.
Remarks: This scheme is considered for alternative to various schemes

recommended for CDU-I, CDU-II, VDU-I and VDU-II (as revamp /
modifications)
59
COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
5.2 ENERGY STUDY AND ANALYSIS OF MS BLOCK
Energy study and analysis of Naphtha Hydrotreating Unit (NHT) and Catalytic
Reforming Unit (CRU) of MS Block is explained below:
NHT-CRU was built by M/S Technip using a process licensed jointly by Indian
Institute of Petroleum, India & Institute Francais du Pet role, France for
processing 196 TMT of Naphtha. A major revamp was carried out, with
process licensed by M/S Axens France, to increase capacity, enhance product
quality. The complete replacement of catalysts with UOP catalysts was carried
out to meet Euro-IV specifications in year 2012. CRU Block consists of
Naphtha Hydrotreating Unit (NHDT) and Catalytic Reformer Unit (CRU).
5.2.1 Naphtha Hydrotreating Unit and Catalytic Reformer Unit
Purpose of this Naphtha Hydrotreating unit (NHDT) is to remove impurities;

mainly Sulphur and Nitrogen that would affect performance and life of CRU
Reformer catalyst. NHT is designed to treat a feed (heavy straight run naphtha
and heavy FCC gasoline) in order to produce naphtha containing less than 0.5
wt ppm sulphur and less than 0.1 wt ppm nitrogen so as to make it able to be
processed in the downstream unit (Catalytic Reforming unit). The capacity of
this unit is 0.216 MMTPA.
Heavy SR naphtha and Heavy FCC gasoline are taken as feed in the
revamped NHDT unit. Heavy SR naphtha comes from the bottom of naphtha
splitter (unit-85). Feed naphtha is reacted with hydrogen in the presence of a
Nickel- Molybdenum (Ni-Mo) catalyst in a reactor at elevated temperature and
pressure. Sulphur and Nitrogen in feed naphtha are reduced to as low as 0.5
wt ppm and 0.1 wt ppm respectively in this unit. After the reaction process, the
naphtha is stripped to remove light ends, impurities like Hydrogen Sulphide
and water (Moisture).
The hydro treated naphtha from the stripper bottom is routed to the Reformer
unit as a hot feed. A capacity of Catalytic Reforming unit is 0.216 MMTPA.
Purpose of Catalytic Reformer Unit is to improve octane number of
Template No. 5-0000-0001-T2 Rev. 2 / 28.11.2014 Copyrights EIL – All rights

reserved
60
A981-0000-03-41-SR-011
Rev. 1
hydrotreated gasoline to meet higher-octane (Research Octane Number)

specifications.
The Catalytic Reforming unit of IOCL HR consists of the following sections:
 Reaction Section
 Stabilization section
Energy saving Scheme (ESS)
1. Maximizing Feed Preheat Temperature in NHT (CRU) unit (U-21)
The objective of the proposed ENCON Schemes is to maximize the Feed

Preheat Temperature in NHT (CRU) unit by recovering heat from the
reactor effluent.
a. Existing Arrangement
Naphtha hydrotreating section (Unit No.-21) operates on cold feed.

One of the feed streams is SR Naphtha coming from Naphtha
Splitter Unit. The feed is routed to heavy FCC Gasoline Feed surge
drum (21-B-201). The naphtha is charged by heavy FCC Gasoline
Feed pumps (21-P-201 A/B) to Reactor Feed/Effluent exchangers
(21-E-01 A/B/C) where it is preheated by the effluent from the 2nd
Hydrotreating Reactor (21-R-201). SR Naphtha stream gets mixed
with Heavy SR Naphtha stream coming from blanketed storage
before entering a Reactor Feed/Effluent Heat Exchangers (21-E-01
A/B/C). Mixed stream is further heated to the required reaction
temperature in Reactor Feed Heater (21-F-01), before it flows to the
1st Hydrotreating Reactor (21-R-01). (Refer Figure No. 5.2.1).

reserved
61
A981-0000-03-41-SR-011
Rev. 1
Existing Arrangement
2nd 1st
Hydrotreating Hydrotreating
Reactor Reactor
21-R-201 21-R-01
Naphtha
from NSU T = 40 Heavy FCC
Gasoline Feed
Surge Drum
21-B-201 T 305
T 331
T 44 T 233
Reactor
T 40 Feed/Effluent Reactor Feed
T 139 Exchangers Heater
21-E-01 A/B/C 21-F-01
Heavy FCC Gasoline
Feed Pumps Heavy SR Q = 4.94 Q = 1.37
(21-P-201 A/B) Naphtha from
blanketed
storage
Figure. 5.2.1: Existing arrangement/configuration of NHT (CRU)
b. Observations & analysis

It is observed that the feed streams are cooled in upstream units by
air coolers/ trim coolers. The feed streams are available at the B/L at
40 oC and preheated to 233 oC by the 2nd Hydrotreating Reactor
effluent which is at 331 oC. The preheated Naphtha is then heated to
305 oC in a Reactor Feed Heater, which is required for the reaction
conditions.
As per the recommended scheme, the inlet stream (Feed) to the
Reactor Feed/Effluent exchangers (21-E-01 A/B/C) will be available
at 70 oC. This can be achieved by recovering the heat from 2nd
Hydrotreating Reactor effluent which is disposing heat to a water
cooler (21-E-201). To recover this heat, an additional heat exchanger
is proposed before existing Reactor Feed/Effluent exchangers. The
temperature at the Reactor Feed heater inlet will increase and the
energy requirement in the Reactor Feed heater will come down
accordingly. Savings envised is in terms of fuel oil. (Refer Figure No.
5.2.2).

reserved
62
A981-0000-03-41-SR-011
Rev. 1
Recommended Arrangement
2nd 1st
Hydrotreating Hydrotreating
Reactor Reactor
21-R-201 21-R-01
Naphtha
from NSU T = 40 Heavy FCC
Gasoline Feed
Surge Drum T 116
21-B-201 T 305
T 331
T 44 T 70 T 268.8
New Reactor
T 40 Exchangers Feed/Effluent Reactor Feed
21-E-XXX Exchangers Heater
21-E-01 A/B/C 21-F-01
Heavy FCC Gasoline Q = 0.678
Feed Pumps Heavy SR Q = 5.20 Q = 0.69
(21-P-201 A/B) Naphtha from
blanketed 129
T
storage
Figure. 5.2.2: Recommended scheme/arrangement for NHT (CRU)
The recommended ENCON schemes will increase the feed preheat

temperature from the existing value of 233 °C to the higher value i.e.
268.8 °C. Summary of the effect of proposed ENCON scheme is
mentioned in the Table 5.2.1 given below:
Table 5.2.1: Summary of the effect of proposed ENCON Scheme
Additional
Reactor
Reactor Feed/Effluent Exchangers Energy
Case Feed
Recovered
Heater
(MMkcal/h)
Inlet Temp. Outlet Duty Duty
(oC) Temp. (oC) (MMkcal/h) (MMkcal/h)
Existing 44 233 4.94 1.37 ---
Revised 70 268.8 5.20 0.69 0.68

reserved
63
A981-0000-03-41-SR-011
Rev. 1
d. Energy Savings
Based on the recommended scheme, the reduction in the Reactor

Feed heater duty by ~ 0.68 MMkcal/h will be observed, as shown in
the Table 5.2.2:
Table 5.2.2: MTOE Calculations
Existing Revised
Parameters Unit
Conditions Conditions
Reactor Feed/Effluent Exchangers
(21-E-01 A/B/C)
o
Feed I/L Temperature C 44 70
o
Feed O/L Temperature C 233 268.8
o
Reactor Effluent I/L Temperature C 331 331
o
Reactor Effluent O/L Temperature C 139 129
Duty MMkcal/h 4.94 5.20
Reactor Feed Heater (21-F-01)
o
Feed I/L Temperature C 233 268.8
o
Feed O/L Temperature C 305 305
Duty MMkcal/h 1.37 0.69
Reduction in Heater duty MMkcal/h 0.68
New Proposed Exchanger
o
Feed I/L Temperature C --- 44
o
Feed O/L Temperature C --- 77
Duty MMkcal/h --- 0.678
Equivalent Savings (for fuel) MTOE/Yr 550
1. Estimated Energy savings =550 MTOE/Yr (Approx.)
2. Based on the hydrocarbon saving (in terms of MTOE/Yr), Net

savings have been estimated as below:
Net Savings (Rs/Yr) = Fuel saved (Ton/Yr) * Cost of Fuel
(Rs/Ton)
Net Savings = Rs. 132 Lakhs/Yr

reserved
64
A981-0000-03-41-SR-011
Rev. 1
e. Implementation aspects
Preliminary site feasibility is done, and it is found that the
recommended scheme is prima facie feasible. Following
implementation aspects to be taken care:
1. An additional, Naphtha vs 2nd Hydrotreating Reactor Effluent heat

exchanger with a duty of 0.678 MMkcal/h is to be installed.
2. Reactor Feed/Effluent exchangers (21-E-01 A/B/C) area needs to
be augmented. Additional surface area required will be around
50% of the existing surface area.
3. Feed Pumps (21-P-201 A/B) are found adequate for the
recommended ENCON Schemes.
4. Feed Surge Drum (21-B-201) is found adequate for the
recommended ENCON Schemes.
These schemes are considered as short term for implementation.
5. Order-of-magnitude Cost/Straight-line Payback
Based on additional area of Reactor Feed/Effluent exchangers (21-

E-01 A/B/C), an additional Naphtha vs 2nd Hydrotreating Reactor
Effluent heat exchanger and necessary piping modifications, Order
of magnitude cost has been estimated.
 Estimated cost: Rs. 130 lakhs
 Energy Savings: 550 MTOE/Yr.
 Savings: Rs. 132 lakhs/Yr
The straight line Pay-back period for the recommended ENCON

scheme is estimated to be ~ 1 year

reserved
65
A981-0000-03-41-SR-011
IOCL -HALDIA REFINERY Rev. 1
5.3 ENERGY & PERFORMANCE ANALYSIS OF SECONDARY

UNITS
Secondary processing units in IOCL-HR comprises of Residue Fluid Catalytic

Cracking Unit (RFCCU) and Once Through Hydrocracking Unit (OHCU).
5.3.1 RESID FLUID CATALYTIC CRACKING UNIT
The function of this unit is to catalytically crack mixtures of vacuum tower gas
oils, vacuum tower bottoms, de-asphalted gas oils, slack wax gas oils and
furfural/MMP extracts. These feed stocks crack into low boiling, high value
products, primarily LCO, C3-C4 LPG and Gasoline.
Fluid Catalytic Cracking Units consists of three sections:

i. Catalyst Section
ii. Fractionation Section
iii. Gas Concentration Section
The Catalyst Section consists of the Reactor and Regenerator that, together
with the Standpipes and Riser, form the “Catalyst circulation circuit”. In the
Fractionation Section, the Reactor vapours are separated into Wet Gas,
Unstabilized Gasoline, Light Cycle Oil (LCO), Heavy Cycle Oil (HCO) and
Clarified Oil. The Compressed Wet gas and Unstabilized Gasoline are sent to
Gas Concentration Unit where they are separated into Fuel Gas, LPG &
stabilised Gasoline. Further fuel gas and LPG are sent to amine treating unit for
removal of H2S. LPG and gasoline are treated in LPG and gasoline merox units
for RSH removal before sending to storage.
66
A981-0000-03-41-SR-011
1. Replacement of Full condensing Turbine of WGC to motor
a. Existing Configuration:
In the existing configuration, Wet Gas Compressor (WGC) in FCCU is
driven by condensing turbine which is consuming MP steam of 14
Kg/cm2g Pressure & temperature is around 300 OC.
b. Observations & Analysis:

At present, turbine is consuming 11.5 TPH of MP steam to drive the Wet
Gas Compressor. This can be replaced with Motor consuming power as
the Energy consumption in motor Vis-à-vis Turbine is less.
c. Recommended Arrangement:
It is recommended that the existing Turbine drive is to be replaced with
motor having shaft horse power (SHP) of 1.5 MWH with efficiency of
motor greater than 96 %.
d. Energy Savings:
The Energy saving by implementing this scheme is as shown below:
 Total Steam consumed : 11.5 TPH
 Total Power Required by Motor : 1.5 MWH
 Steam MTOE : 6571 MTOE/Yr
 Power MTOE : 2150 MTOE/Yr
The calculated energy saving by Conversion of turbine driven to motor is
~ 4400 MTOE /Yr.
e. Implementation aspects:
To implement this scheme, motor and driven equipment shafts are
connected and synchronized with minimum downtime.
67
A981-0000-03-41-SR-011
f. Order-of-magnitude cost & Straight-line Payback:

Based on the motor rating, cost estimation of Motor, auxiliaries and
installation has been carried out and estimated the order of magnitude
cost.
 Estimated cost :Rs. 1000 Lakhs
 Energy saved MTOE : 4400 MTOE/Yr
 Savings : Rs. 1050 Lakhs
Thus, estimated Straight-line payback comes to be 1 year.
2. Replacement of Full condensing Turbine of MAB to motor
In the existing configuration, Main Air Blower (MAB) in FCCU is driven by
condensing turbine which is consuming MP steam of 14 Kg/cm2g
Pressure & temperature is around 300 OC.

At present, turbine is consuming 32.5 TPH of MP steam to drive the Wet
Gas Compressor. This can be replaced with Motor consuming power as
the Energy consumption in motor Vis-à-vis Turbine is less.
It is recommended that the existing Turbine drive is to be replaced with
motor having shaft horse power (SHP) of 4.2 MWH with efficiency of
motor greater than 96 % along with Gear Box and VFD.
d. Energy Savings:
The Energy saving by implementing this scheme is as shown below:
 Total Steam consumed : 32.5 TPH
 Total Power Required by Motor : 4.2 MWH
 Steam MTOE : 18571 MTOE/Yr
 Power MTOE : 6077 MTOE/Yr
68
A981-0000-03-41-SR-011
The calculated energy saving by Conversion of turbine driven to motor is

~ 12000 MTOE /Yr.
e. Implementation aspects:
To implement this scheme, motor and driven equipment shafts are
connected through Gear Box and to control the speed, VFD should also
be installed and synchronized with motor with minimum downtime

Based on the motor rating, cost estimation of Motor, Gear Box, VFD,
auxiliaries and installation has been carried out and estimated the order
of magnitude cost.
 Energy saved MTOE : 12000 MTOE/Yr
 Savings : Rs. 2880 Lakhs
Thus, estimated Straight-line payback comes to be 1 year.
Remarks: Considering the energy saving potential /steam network reduction, this
scheme could be considered suitably under long term plan w.r.t major revamp,
modernization/expansion of the unit. Same may be pursued subsequently for detailing
with the post BS VI steam & power balance scenario.
69
A981-0000-03-41-SR-011
5.3.2 ONCE THROUGH HYDROCRACKING UNIT
Hydrocracking is an important unit in today’s modern refinery as it is one of the

three primary conversion processes available to the refiner along with FCC and
Coker. FCC is considered as gasoline making machine, although it also produces
olefins, and delayed coking has been the primary technology of choice for
converting vacuum gas oil to lighter products. Hydrocracking unit is flexible – it can
produce a range of products as light as liquefied petroleum gas (LPG) to heavy
diesel and lube oil base stock or ethylene cracker feed. Hydrocracking provides
value uplift, converting heavier low-value stream such as vacuum gas oil (VGO),
Coker gas oil (CGO), and LCO to a better quality and high-value product stream.
Hydrocracking is a versatile process that takes many different feed streams to
convert into range of desirable products.
The unit design capacity is 1.7 MMTPA and is presently operating at 100 % of the
design capacity having a throughput of ~1.7 MMTPA. It is a once through process
with 75 % conversion. The unit is having two reactors in series and operates at a
pressure of 171 kg/cm2g. It is designed to process VGO and HGO. The flow scheme
of reaction loop is in line with DHDS and DHDT processes in which the feed mixes
with recycle hydrogen and make-up hydrogen and enters the reactor through
preheat train and charge heaters. The reactor effluent exchanges heat with the
combined feed and flows through reactor effluent air cooler to cold high pressure
separator. The vapours are recycled back to reactor through RGC and liquid is
routed to stripper for H2S removal through stripper feed bottom exchanger and
reactor effluent stripper feed exchanger. The off gas from stripper is routed to amine
absorption system. The liquid from stripper is routed to fractionator to separate
multiple products like LPG, naphtha, kerosene, diesel and UCO.
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ENERGY SAVING SCHEMES (ESS)
1. Installation of Hot Separators in OHCU to Produce MP Steam from

Reactor Effluent & also Reduction in Reactor Effluent Air Cooler Duty
Reactor effluent from reactor outlet, enters the last feed/ effluent exchanger (91-
E-02) at 390◦C and exits at 296◦C. It further exchanges its heat in heat
exchangers and gets cooled in air cooler (91-AC-01) up to 55◦C and enters into
cold high pressure separator where the hydrocarbon liquid is separated from its
vapours. Diesel from the low pressure flash drum bottom exits at 55◦C, which
gets preheated from first stripper feed/reactor effluent exchanger (91-E-03) and
91-E-04, up to 269 ◦C). The schematic of the existing arrangement is shown in
figure 5.3.1
To Stripper
226 oC 269 oC
R/E
91-AC-01
390 0C 296 oC 245 oC 196 oC 155 oC 55oC To RGC H2 Rec.
91-E-02 A/B 91-E-04 91-E-01 A/B 91-E-03 23.7 MMkcal/h

6.6 MMkcal/h 10.49 MMkcal/h
352 oC HP Cold MP Cold
Separator Separator
To Charge Heater 172 oC
Feed from Charge

Pump 182 0C
Recycle gas from
RGC 91 0C
55 oC
Figure-5.3.1: Existing Arrangement of Cold Separator in OHCU Unit

In absence of hot separators, total reactor effluent is cooled in reactor effluent
air cooler (91-AC-01), disposing off heat to atmosphere and routed to cold high
pressure separator (91-V-05). The vapour from MP cold separator is sent to H2
membrane package and the liquid is routed to stripper through stripper feed
71
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reactor effluent exchangers (E-03 & E-04) to raise the temperature up to 269◦C.
Due to this stripper feed is being cooled initially and reheated to desired
temperature levels leading to loss of energy through air coolers.
c. Recommended Scheme:
It is recommended to install a hot separator and a hot flash drum after last
feed/effluent exchanger and MP steam generator at 260◦C. By installing the hot
separator at high temperature as mentioned above, the outlet temperature of
the vapours from hot high pressure separator will be around 260◦C which will
heat the feed and recycle gas from 200◦C to 226◦C in existing exchanger (91-E-
01) along with one additional exchanger. The net liquid from cold flash drum
will be heated with hot separator vapours up to 150◦C with existing exchanger
91-E-03. Due to this, excess heat of 9.73 MMkcal/h will be available in reactor
effluent to generate nearly 16 tons of MP steam. The schematic of the
recommended scheme is shown in Figure-5.3.2.
Feed from Charge

RG+Make-up @
Pump @ 200 0C
91 0C
To Stripper @
150 0C
136 oC
To Charge Heater
New Ex
91-E-03
3.1 MMkcal/h
BFW 2.47 MMkcal/h
91-E-01 A/B
MP Steam 3.1 MMkcal/h 55 oC To RGC To H2 Rec.
New Steam Gen.
390 oC 296 oC 91-AC-01
R/E 6.0 MMkcal/h HP cold Cold flash
Separator drum
91-E-02 A/B
MP Steam
260 oC
HP Hot Separator
AC-XX
0.7 MMkcal/h
91-E-04
BYPASS
Hot flash drum
New HPRT
To stripper @ 260 0C
Figure-5.3.2: Recommended Configuration of Hot Separator in OHCU Unit.
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d. Energy Savings:
Presently the reactor effluent exchanges heat with stripper feed which will be by
passed after hot separator installation and MP steam will be generated from
excess heat in reactor effluent. Thus steam generated is worked out to be 16
tons/h and equivalent savings of MTOE will be around ~9300 MTOE. The
energy saving calculations are provided in Table 5.3.1.
Table-5.3.1: Summary of Operating Conditions and Calculations

Stripper Feed/ Reactor Duty, Shell Side Tube side
Effluent Exchanger (91-E- MMkcal/hr
Inlet, oC Outlet, oC Inlet, oC Outlet, oC
04)
Existing conditions 13.78 172 269 296 245
Steam generator 9.73 110 200 296 260
Latent heat, Kcal/kg 504
Steam quantity, Kg/hr 16353
Steam Eq. MTOE 9344
Total MTOE savings 9300
Total duty available of the 13

vapours from hot separator
(MMkcal)
New exchanger (EE-XX) & Duty Tube Side shell side
91-E-01 Recycle gas & available (Recycle gas) (Hydrocarbon
Feed heating from hot MMkcal/hr vapours)
o o o
separator vapours Inlet, C Outlet, C Inlet, C Outlet, oC
Modified conditions 7.5 200 226 260 -
Exchanger (91-E-03) Duty Tube side Shell side
Stripper feed heating from available (Stripper feed ) (Hydrocarbon
cold flash drum bottoms MMkcal/hr Vapours)
Inlet, oC Outlet, oC Inlet, oC Outlet, oC
Modified conditions 3.36 55 150 - 136
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e. Implementation Aspects:
The scheme involves installation of a new high pressure and low pressure hot
separators, additional exchanger for recycle gas heating from hot high pressure
separator vapours, a new MP Steam generator after last feed/ effluent
exchanger and (91-E-02) and new PRT at hot separator bottom.
f. Order-of-Magnitude Cost and Straight-line Payback Period:

Based on preliminary size of the hot separator vessels, exchanger for recycle
gas heating from hot separator vapours, area of steam generator and necessary
piping modifications, Order of magnitude cost has been estimated.
 Estimated cost: Rs. 7500 Lakhs
 Energy Savings: 9300 MTOE/Yr.
 Savings: Rs. 2232 Lakhs
Straight-line payback: 3 Year 4 months
Remarks: Considering the energy saving potential /steam network reduction, this
scheme could be considered suitably under long term plan w.r.t major revamp,
modernization/expansion of the unit. Same may be pursued subsequently for
detailing.
2. Excess air optimization of the Heaters 91-F-01 and 91-F-02 by

replacement of O2 Analyzer / burners’ fine tuning / replacement of burner
components
91-F-01 and 91-F-02 are balanced draft heaters, having design absorbed
duty of 12.04 MMkcal/hr and 28.15 MMkcal/hr, respectively.

 O2 contents in flue gas is on higher side (~6.0 %)
74
A981-0000-03-41-SR-011

analyser.

firebox.
the burners.
d. Energy Savings

75
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Straight-line payback : ~ 4 Months
76
IOCL-HALDIA REFINEY Rev. 1
5.4 ENERGY STUDY AND ANALYSIS OF TREATING UNITS
Hydro treating has gained paramount importance due to growth in middle

distillates demand and the imposition of stringent environmental regulations on
product specifications to achieve future goals of sustainability and cleaner
environment considering increased processing of heavier and high sulphur
crudes. To meet the objective, IOCL HR has employed processes such as
diesel hydro desulphurisation (DHDS) and Kero Hydro desulphurization
(KHDS) to reduce sulphur and improve the cetane number in diesel to meet
the required product specifications.
5.4.1 KERO HYDRODESULFURIZATION (KHDS)

Kero hydrodesulphurization is a general class of catalytic process which takes
place under hydrogen environment at moderate pressures to hydro desulfurize
the straight run kero stream in order to produce a low sulphur content
Kerosene meeting the ATF product specifications.
The original unit design capacity is 0.6 MMTPA, and is presently operating at
100 % of the design capacity having a throughput of 0.6 MMTPA. The existing
unit has one reactor and is operating at a pressure of 28 kg/cm2g.
The flow scheme is in line with DHDS process scheme described above. The
feed mixes with hydrogen and enters the reactor through preheat train and
charge heater. The reactor effluent exchanges heat with the combined feed
and flows through reactor effluent air cooler to cold high pressure separator.
The vapours are recycled back to reactor through RGC and liquid is routed to
stripper for H2S removal through stripper feed bottom exchanger and reactor
effluent stripper feed exchanger. The off gas from stripper is routed to
compressor suction and the liquid from stripper bottom after heat recovery is
routed to storage.
1. Hot feed to KHDS unit at 700C Directly from B/L & Increasing the Pre-heat
by 150C thus reducing the Furnace Duty
a) Existing Configuration:
77
Cold feed at 40o C coming from B/L is passed through the preheat
exchangers (23-E-02 A/B/C/D), where temperature is raised upto 230 o
C, and finally to reactor through feed charge heater. The schematic of
the existing configuration is shown in figure. 5.4.1
2890C
KHDS Reactors
23-R-01
289 0C
245 0C
2300C
40 0C
23-E-02B 23-E-02A DHDT Charge Heater

23-E-02 C/D
23-F-01
4MMkcal/h
FeedPump
23-P-01
TO R/E air Cooler
128 0C
Figure. 5.4.1: Existing Configuration of Cold Feed in KHDS Unit
b) Observations & Analysis:

Straight run Kero. from the CDU gets cooled in its battery limit up to 35-
40oC and is sent to storage tanks, which is feed to KHDS unit at 40oC
where heating of the feed is done again in the preheat train as specified
above in the existing arrangement thus disposing the heat of the CDU
rundown by air coolers into atmosphere.
c) Recommended Scheme:
Instead of cooling the CDU rundown up to 40o C by air coolers, it can
be directly routed to KHDS unit at 60o C thus increasing the preheat
temperature by 3-40C and reducing the furnace duty. The schematic of
recommended scheme is shown in Figure 5.4.2
78
2890C
KHDS Reactors
23-R-01
289 0C
245 0C
2340C
60 0C
23-E-02B 23-E-02A DHDT Charge Heater
23-E-02 C/D
23-F-01
3.75MMkcal/h
FeedPump
23-P-01
TO R/E air Cooler
1370C
Figure. 5.4.2: Recommended Configuration of Hot Feed in KHDS Unit
d) Energy Saved:
Based on operating conditions, furnace inlet is at 234o C and outlet is
289o C and the corresponding duty is around 4 MMkcal/h. By taking hot
feed at 600C from upstream CDU (around 80%), the furnace inlet temp
can be increased by 2-30C to 2370C leading to reduction in furnace duty
by 0.2 MMkcal/h. The corresponding energy saved is around 150
MTOEs.
e) Implementation Aspects:
Feed filter, feed coalescer and feed pumps (23-P-01 A/B) are found to
be adequate for the recommended ENCON scheme.
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IOCL - HALDIA REFINERY Rev. 1
5.5 ENERGY & PERFORMANCE ANALYSIS OF SULPHUR BLOCK
The Sulphur block comprises of Sulphur Recovery Unit (SRU-28 & 83: 60 TPD
each and SRU-95: 80 TPD each), common Tail Gas Treating Unit (for SRU-28, 83
& 95 unit), Amine Regeneration Unit (ARU-26:139 m3/h and ARU-93: 453 m3/h)
and Sour Water Stripping Unit (SWS-29: 75 m3/h and SWS-94: 25 m3/h).
5.5.1 SULPHUR RECOVERY UNIT (SRU)
SRU is designed to recover the sulphur from Acid gases from ARU and Sour gases
from the SWSU. SRU has Thermal section, Catalytic sections, Liquid sulphur
handling section and Incineration section. The tail gas leaving SRUs is further
processed in TGTU.
5.5.2 TAIL GAS TREATING UNIT (TGTU)
Tail gas from SRUs is routed to TGTU to increase the sulphur recovery to 99.9%.
It consists of Hydrogenation and Amine sections. In Hydrogenation section all
sulphur species are converted to H2S and H2S is absorbed in Amine. Regeneration
of amine produces H2S, which is routed back to front end of SRU.
5.5.3 AMINE REGENERATION UNIT (ARU)
The Amine Regeneration unit includes feed handling section, Regeneration

section and lean amine section.
In feed handling section, rich amine from various units is collected in a surge drum.
After flashing in surge drum to remove light hydrocarbon gases, the rich amine is
pumped to Regeneration column via Rich/Lean exchanger. In Rich/Lean
exchanger, rich amine is heated by lean amine coming from Regeneration column
bottom.
In Regeneration section, the rich amine is regenerated in a column by LP steam

supplied to Reboiler. The hot vapours from column top are cooled in overhead
condenser and sent to downstream SRU. The reflux from reflux drum is routed
back to top of the column.
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Energy Saving Scheme/s
1. Increasing the inlet temperature of Rich amine feed to Amine

regeneration unit of ARU-93 units
a. Existing Configuration :
In ARU (93), currently shell and tube module is in operation as Lean-Rich
Amine heat exchanger. The rich amine flow and temperature to column is
280 m3/h and 103oC, respectively.

It can be observed that the inlet temperatures to regenerators can be
increased further to reduce the load on the respective reboiler’s. By
adopting welded plate type heat exchangers the temperature approach can
be narrowed and thus the inlet temperatures to columns can be increased.
Proposed new inlet temperatures to Regenerators:

 ARU (Unit-93) = 110oC
It is recommended to bypass shell and tube heat exchanger with new plate
type heat exchanger. So that, LP steam supply to reboiler’s is reduced.
d. Energy Savings:
In Unit 93: Duty saved in reboiler = 280*1000*7/10^6 = 1.96 MMkcal/h
MTOEs saved = (8000*1.96*10^6)/10^7 = 1568
Total energy savings corresponding to this scheme is ~ 1500 MTOE/Yr.
Foot print of new plate type heat exchanger (L x W x H), in m:
 ARU-93: 1.5 x 1.5 x 3.3
Detailed study is required before implementation.
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f. Order-of-magnitude Cost/Straight-line Payback:

Based on the above recommended scheme, economic evaluation is carried
out and estimated energy savings.
 Total savings= 360 lakhs/Yr.
 Total cost of all plate type heat exchangers due to this scheme = 600
lakhs
Straight-line pay back worked out as ~1 Year 8 Months
.
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5.5.4 SOUR WATER STRIPPING UNIT (SWSU)
Sour water from various units in the refinery is collected in a sour water surge
drum. The collected sour water is pumped to sour water stripper of single stage
stripper via feed/bottom exchanger. Separated sour gases from the single stage
stripper is sent to sulphur recovery unit for recovering elemental sulphur and
stripped water from sour water stripper is sent to unit as make-up for wash water
and partly to ETP for disposal. LP steam is used to provide the heat in the reboiler
in the single stage sour water stripper.
Energy Saving Scheme/s
1. Increase of Inlet Temperature of sour water feed to Sour water Strippers

of 29 & 94 units
a. Existing configuration:
In SWSU (29 & 94), currently shell and tube module is in operation as Feed-
bottom heat exchanger. The sour water temperature to column is 90oC and
87oC for SWSU-29 and SWSU-94, respectively.

It can be observed that the inlet temperatures to strippers can be increased
further to reduce the load on the respective reboiler’s. By adopting welded
plate type heat exchangers the approaches can be narrowed and thus the
inlet temperatures to columns can be increased.
Proposed new inlet temperatures to Strippers:

 SWS (Unit-29) = 110oC
 SWS (Unit-94) = 110oC
It is recommended to replace shell and tube heat exchanger with plate type
heat exchanger. So that, LP steam supply to reboiler’s is reduced.
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d. Energy Savings:
Duty saved in reboilers:
In Unit 29 = 75*1000*(110-90)/10^6 = 1.5 MMkcal/h
In Unit 94 = 30*1000*(110-87)/10^6 = 0.69 MMkcal/h
Total duty saved = 2.19 MMkcal/h
MTOEs saved = (8000*2.19*10^6)/10^7 = 1752
Total energy savings corresponding to this scheme is ~ 1700 MTOE/Yr.
Foot print of new plate type heat exchanger (L x W x H), in m:
 SWS-29:1.5 x 1.5 x 2.0
 SWS-94:1.2 X 1.2 X 2.0
Detailed study is required before implementation.

Based on the above recommended scheme, economic evaluation is carried
out and estimated energy savings.
 Total savings= 408 lakhs/Yr.
 Total cost of all plate type heat exchangers due to this scheme = 400
lakhs
Straight-line pay back worked out as ~1 Year
84
5.6 HYDROGEN MANAGEMENT

The recent increase in the demand of hydrogen in refineries can be attributed to the
following reasons:
 The availability of the lighter crude oils has gone down and refiners are
forced to process heavier crude oils.
 In order to produce light and middle distillates, hydro-cracking of heavier
bottom of the barrel products is required to be carried out.
 The market for heavy fuel oil is shrinking and upgrading the same to lighter
value-added components requires hydro-processing.
 Tighter fuel specifications due to stringent environmental norms have also
increased the need of hydro-treating to remove sulfur.
 Limit on the aromatic contents in the gasoline has led to less severe
conditions in catalytic reformers, resulting in reduced production of hydrogen
as by-product in the reformer.
 In addition to hydro-cracking and hydro-treating, there are other processes
like Isomerization, lube processing, etc in the refinery, which also consume
hydrogen.
Hydrogen is produced in the hydrogen generation units and also as by-product in

the catalytic reforming unit. In addition to hydrogen generation and consuming units,
hydrogen purification units form an important part of the hydrogen distribution
system. Hydrogen is therefore considered as utility and complex network of
hydrogen runs throughout the refinery connecting these different components of the
system. The interaction among these hydrogen producers, consumers and purifiers
define the behavior of the refinery hydrogen distribution network and establish the
overall demand of hydrogen.
The design and operation of refinery hydrogen distribution system usually begins
with a consideration of number of sinks and available sources of hydrogen at site.
The hydrogen used in the refinery can have different origins.
Catalytic reformer is one of the cheaper sources of hydrogen in refineries. This

process increases the octane number of heavy naphtha by cyclisation and
dehydrogenation of aliphatic hydrocarbons and at the same time generates large
85
amount of hydrogen as a by-product. The additional hydrogen demand in the

refineries is met by specific hydrogen generation units.
Hydrogen generation units generally are based on either steam-reforming of

naphtha / natural gas or on partial oxidation of hydrocarbons. In most of the
refineries, hydrogen production is supplemented by hydrogen recovered from the
off-gases from different hydrogen consuming processes. These off-gases usually
contain significant amount of hydrogen along with light hydrocarbons such as
methane, ethane and propane, etc. The off-gases with high hydrogen purity can be
used directly as hydrogen source, if the contaminants are within acceptable limits.
The off-gases with low hydrogen purity generally are routed to fuel gas header and
the streams with intermediate hydrogen purity can be purified provided it is
economical. There are three purification technologies, which are commonly used
viz PSA, cryogenic separation and membrane separation. The choice of the
purification operation depends on many factors such as capacity, pressure and
purity of inlet gas and hydrogen purity required at outlet.
a. Existing Hydrogen Network
In IOCL Haldia Refinery, hydrogen is consumed in the following units:

i) Diesel Hydro Desulphurization unit (DHDS-25)
ii) Once-though Hydrocracker Unit (OHCU-91)
iii) Kero Hydro Desulphurization Unit (KHDS-23)
iv) Naphtha Hydro Treating Unit (NHDT-85)
v) Isomerization Unit (ISOM-86)
vi) MSQ – FCC Gasoline Desulphurization Unit (PRIME G – 87)
vii) Naphtha Hydro Treating Unit (NHDT-21)
viii) Catalytic De-waxing unit (CDWU-84)
The hydrogen is produced in the following units:

i) Hydrogen Generation Unit (HGU-2)
ii) Catalytic Reformer Unit (CRU)
Hydrogen Purifiers
i) PSA in Hydrogen Generation units (HGU)
ii) PSA for CRU off-gases
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Rev. 1
The existing hydrogen distribution network is shown in the figure-5.6.1 below:
Fuel Gas Header

Pure Hydrogen Header (99.9
% mol H2) MP off-gas
LP off-gas
DHDT
LP off-gas
Under Shutdown
HGU-1
DHDS
HP & LP off-gas
HGU-2 OHCU
LP off-gas
MQU-ISOM
LP off-gas
CRU CRU PSA
MSQ- PRIME
G
LP off-gas
NHDT
LP off-gas
CRU
CDWU
KHDS
Figure- 5.6.1 Hydrogen distribution network
87
It is understood that, the hydrogen requirement in all consumer units are satisfied
by HGU, CRU off-gas. The off-gas from CRU unit is routed to CRU PSA to produce
hydrogen of 99.99% purity.
The LP off-gases from units like DHDT, DHDS, OHCU, MSQ (ISOM), MSQ
(PRIME-G), KHDS, NHDT, CDWU are being routed to fuel gas header.
The compositions of the hydrogen rich off-gases from various units routed to fuel
gas header are tabulated below in Table. 5.6.1
Table. 5.6.1: Compositions of Hydrogen rich off-gas streams
Flow, Hydrogen
Units H2 Rich Off-gases
TPH Purity (mol%)
DHDS DHDS LP off-gas 0.560 44.4

DHDT MP off-gas 0.520 87.0
DHDT
DHDT LP off-gas 1.635 70.0
OHCU OHCU LP off-gas 0.973 73.3
MSQ-ISOM MSQ-ISOM LP Off-gas 0.572 80.1
MSQ PRIME G MSQ PRIME G LP Off-gas 0.170 70.0
MSQ NHDT MSQ NSU/NHDT LP Off-gas 0.050 53.7
NHDT CRU NHDT CRU LP Off-gas 0.210 90.0
CDWU CDWU LP Off-gas 0.430 56.5
LHFU LHFU LP off-gas 0.200 54.4
CRU PSA CRU PSA Tail gas 0.279 50.0
88
The quantity of hydrogen required in the refinery may be satisfied by hydrogen

from HGU and CCR off-gas. However, LP off-gases from DHDT, DHDS, OHCU,
MSQ (ISOM), MSQ (PRIME-G), KHDS, NHDT, CDWU units are hydrogen rich
streams, which are routed to fuel gas header. The hydrogen from these streams
can be recovered.
For recovering hydrogen from these streams, a scheme is being proposed. The
presence of H2S content in NHT off gas is to be removed before being routed to
PSA system. In the proposed scheme, the off-gases from the DHDT, DHDS,
OHCU, MSQ (ISOM), MSQ (PRIME-G), KHDS, NHDT, CDWU are routed to new
PSA system.
The off gases are available at a pressure of 5 kg/cm2, which has to be compressed
to a pressure of 30 kg/cm2 to process in PSA. Even though, there is one PSA
(CRU-PSA) available in IOCL HR for processing the off gases, new PSA
considered for this scheme as the existing PSAs are being operated at the design
throughput. The recommended hydrogen scheme is given in Fig. 5.6.2
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Rev. 1
The recommended scheme for hydrogen recovery is shown in the figure -5.6.2 below:
Offgas
Compressor
Inter Stage
Cooler
XX-E-01
Offgas
Compressor
2nd Stage
KOD
XX-V-02
12 kg/cm2
H2
30 kg/cm2 g Product
PSA
5 kg/cm2 g Unit
Treated LP off- 3 kg/cm2 g

gases
Offgas Reject
Offgas Compressor
Compressor KOD
1st Stage Offgas Offgas Trim
Cooler XX-V-03
KOD Compressor
XX-V-01 XX-K-01 A/B XX-E-01
Offgas
Compressor
1st Stage
To KOD
Blowdown XX-V-01
Figure 5.7.2 Recommended Hydrogen Recovery scheme
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Rev. 1
d. Energy Saved
Based on the recommended scheme, the hydrogen recovered from the H2 rich off-
gases is around 720 kg/hr. The net energy savings is calculated as
Net Energy Savings = Hydrocarbon savings − Alternate fuel gas − Operating cost
Table 5.6.3. Energy saved
Parameters Units Values

Total Hydrogen available in LP off gases kg/hr 909.2
Hydrogen Recovered through PSA kg/hr 727
Savings in Hydrocarbon (in terms of
kg/hr 2909
Naphtha)
SRFT/hr 3.05
Savings in Hydrocarbon
SRFT/ yr 24439
kg/hr 1771
Alternate fuel gas for recovered hydrogen
SRFT/ yr 14876
KW/hr 2000
Operating cost (Compressor Power)
SRFT/ yr 2909
Net Energy savings MTOE 6600
Basis:
1. The hydrogen recovery of 80% is considered in PSA

2. It is considered that, 4 kg of Naphtha is required for producing 1 kg of H2.
3. The NCV of Naphtha is considered as 10500 kcal/kg
e. Implementation aspects
The following Major equipments are envisaged for recommended scheme:

 2 Nos. Heat exchangers
 3 Nos. Vessels
 1 No. Two-stage compressor
 1 No. of PSA
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Rev. 1
f. Economic Analysis
Typically hydrogen is generated in a refinery by steam reforming of Gas /Naphtha.

Hydrogen is a necessary molecule for upgradation of refinery streams and the cost
of hydrogen is generally considered as Rs. 1, 50,000 /MT based on yield and price
of feed to hydrogen generation unit. As a result, hydrogen unit as a standalone unit
& always emerges as unit with negative pay-back while treated as a utility block.
Net benefit from generating hydrogen is actually realized in hydrogen consumer
units like ISOM, DHDS, DHDT and OHCU, where the necessity of hydrogen is very
important and thus the return on capital is not a determining criteria.
The capacity of the recommended hydrogen recovery scheme for IOCL HR is 5.8
KTPA. New HGU unit of similar capacity range will be a very small unit to be
considered in the refinery. Therefore, capital cost for both units cannot be directly
compared. The Plant & Machinery cost of the recommended scheme is estimated
~ Rs. 105 Crores.
While, there is no revenue generation from HGU, from the recommended scheme,
net revenue generation from hydrogen recovery is about Rs. 87 Crores per annum,
Hence, the recommended hydrogen recovery scheme provides a significant return

on investment in the true sense can be taken up further for implementation
considering the scenario where the refinery is constrained with respect to hydrogen
BS up-gradation and which eventually jeopardize refinery operation.
Remark: IOCL HR has initiated action on the recommended EnCon scheme.
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IOCL – HALDIA REFINERY
5.7 ENERGY & PERFORMANCE IMPROVEMENT OF STEAM &

POWER NETWORK
In a Refinery, fuel cost constitutes considerable portion of the operating cost

and about 35-40% of these fuel costs can be attributed to generation of utilities
like steam and power. Steam is generated in boilers, waste heat boilers and
Heat Recovery Steam Generators. Steam is used in extraction / back pressure
turbines as electrical /mechanical power drive for power generation and running
of pumps, compressors and blowers and also as heating and stripping media.
Power is generated at site through Co-generation, bought from a local grid and
in some cases exported also. There are few mechanical types of equipment with
dual drives, which can be run with either a motor or a steam turbine.
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ENERGY SAVING SCHEMES
1. RECOVERY OF STEAM/CONDENSATE LOST IN REFINERY COMPLEX
a. Existing configuration :
In existing configuration, steam generated in the refinery is consumed in

reboilers, turbines, stripping columns, atomizing of liquid fuels, HGU as feed
stock, jacketing & tracing, soot blowing, flare etc. Steam is
returned/recovered as condensate to Deaerators, sour water to sour water
stripper and a portion of it is lost in the form of steam or condensate.
Detailed mass balance across the refinery, considering the variables such
as make up DM water to Deaerators, stripped water to ETP, steam to HGU,
blow down, atomizing steam and unrecovered steam/condensate etc.is
carried out. It has been observed that there is additional condensate
recovery potential available and it is recommended for recovering the same.
The condensate recovery potential is calculated based on Make-up DM

water for BFW generation in Deaerators. BFW is finally converted to Steam
in Boilers/WHB/HRSG. In normal scenario, steam is consumed in reboilers,
Turbines, atomizing, soot blowing, HGU reformer, stripping,
jacketing/tracing, PRDS, Back pressure/Extraction Turbines etc. The steam
consumed in reboilers and condensing turbines is recoverable Condensate.
The steam consumed in stripping, ejectors etc. is recovered as sour water
and is ultimately sent to ETP. Steam consumed in PRDS and
Extraction/Back pressure Turbines is let down to higher pressure to lower
pressure. The steam consumed as atomising steam, flare, as feed in HGU
cannot be recovered. The tracing and jacketing steam is also recovered in
ISBL and that of Off-sites is at times not recovered. A schematic of the above
description is as shown in the Figure 5.7.1 below.
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Figure 5.7.1: Overview of steam generation and consumption.
The total Make up DM water to various Deaerators in the entire refinery complex
is as shown in Table 5.7.1.
Table 5.7.1: Make-up DM water for various Deaerators

Unit DM water to De-
aerators (TPH)
TPS 88
DHDS, FCCU 45
GT-HRSGs 202
OHCU & HGU 93
Condensate return to 138
tank
Total (Net DM water 88+45+202+93-138=
Make up) 290
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Total steam generation in the refinery is 548 TPH. Break up of non-recoverable

steam consumption is shown in Table 5.7.2.
Table 5.7.2: Non Recoverable Steam Consumption
Steam Consumption Flow (TPH)

Atomising Steam 14
HGU 70
Soot Blowing 2
Blow Down 11
Flare 2
Deaerator Vent 1
Sour water to ETP 91
Total 191
Overall DM water balance for steam generation refinery is carried out and is as
shown in Figure 5.7.2. Steam consumed in stripping, Blow down, as feed in
hydrogen reformer, atomizing steam for fuel oil, soot blowing etc. cannot be
recovered and thus could not be returned to Deaerators. To account for this
loss, equivalent DM water has to be make-up in Deaerators which sums up to
~191 TPH. But actual DM water Make up to Deaerators is ~290 TPH. Thus an
additional ~99 TPH of DM water is to be Make-up because of loss in either
Steam or condensate form. Out of the total Condensate /steam lost,
approximately 20% of ~99 TPH could be live steam loss either through stream
traps/pin holes/ valves/flanges etc. and remaining 80 % could be in the form of
condensate and is as presented in Figure 5.7.3
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DM water makeup to
Deaerators:
290 TPH
Refinery Block
Steam generation Steam Loss (~20 TPH)
(548 TPH) Condensate Loss (~79 TPH)
191 TPH
 Stripped Sour water to

ETP
 Blow Down
 Atomising steam
 HGU steam consumed in
reformer
 Flare
Figure 5.7.2: Overall overview of Steam/Condensate Balance of IOCL HR.
Figure 5.7.3: Steam/Condensate Balance

c. Recommendation:
The steam generation and consumption is across the entire refinery complex
and is managed via steam Headers at various pressure levels. Thus the
Steam/condensate loss could be across the refinery. A complete survey of
steam system is to be carried out to find out physical losses and to be
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attending immediately. Using data reconciliation software tool can help to

arrive at proper steam balance across the entire refinery complex. Steam
trap management and proper condensate recovery system adds strength for
a better steam and condensate recovery as there is a huge potential. Also,
various commercially proven steam accessories to minimise steam losses
has to be adopted.
Refinery steam and power network is many times expanded in stages and
invariably results in a complex system of multiple steam and power
generators. These utilities generators may use different fuels and have
different thermal efficiency and hence different production costs. The
strategies which can be adopted for operating the total utilities system in an
optimum manner for a particular process load, product requirements and
within the existing hardware constraints are many and there exist opportunity
to optimize steam and power production for fuel / cost minimization. To
optimize such a complex system with large variables, linear programming
approach can be used as an effective tool.
d. Energy Savings:
Based on analysis, saving of steam and condensate recovery is envisaged.

Steam loss through leaks and vents can be reduced by ~20 TPH and savings
in the form of condensate is envisaged to be in the tune of 79 TPH.
Considering a conservative savings approach with 70% recovery, savings to
the tune of 11,000 MTOE/Yr. is primarily envisaged.
The Steam and condensate recovery starts from better steam trap
management. A proper Condensate recovery system adds strength for a
better steam and condensate recovery as there is a huge potential. Most
importantly, consumption of steam is to be optimized by adopting various
ENCON schemes as a holistic approach.
Various commercially proven steam accessories like Advanced Steam traps,
Pre- fold manifold, Pre-insulated tubing and flash steam recovery including
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thermo compressor, Condensate recovery with steam operated pumps

should be considered in implementation of this scheme.
It is a medium term scheme as it involves study of entire steam and

condensate network of the whole refinery complex.
This scheme involves a detailed study across the entire refinery. After steam
trap management and accessing actual steam generation and consumption
of various equipment’s by reliable instrumentation, an overall steam balance
has to be again carried out to bridge the gap between actual generation and
consumption. Accordingly condensate recovery system has to be designed
for recovering condensate back to Deaerators which then accounts for actual
order-of-magnitude cost.
Remark: IOCL HR has taken the action in FO and Bitumen area. Further,
scope exists.
2. Low End Heat Recovery From Exhaust Gas of GT-HRSGs

In Existing configuration, 3 Gas Turbines namely GT-1, GT-2 & GT-3 can
generate around 20 MW of power. Naphtha is fired in these machines.
The average stack temperature for all these GT-HRSGs are ~165oC.
The heat lost to the atmosphere is high. Since it is proposed to go for

natural gas firing in GTs, stack temperature can go much below than
current level. So a Heat recovery system can be installed to recover this
heat content to bring down the low end temperature to a lower value as
shown in Figure 5.7.4. Gas Turbines are a compact and package
machines and additional pressure drop in the inlet or outlet of HRSG has
impact on its performance. So it has been envisaged that low end
recovery can bring down the flue gas temperature to around 110oC with
a maximum pressure drop of 25mmwc. A detailed analysis of HRSG duct
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may help to bring it down further by adjusting the existing tubes with a
low pressure drop design. Heat Recovery envisaged from all the GTs is
~16.6 MMkcal/hr. The values are as represented in Figure 5.7.5.
Figure 5.7.4: Heat recovery unit at back end of HRSG
Heat Recovery (MMkcal/h)
5.9 4.8 5.9
GT-1 GT-2 GT-3
Figure 5.7.5: Heat Recovery for GT-HRSGs
c. Recommendation:
By the analysis of data, it is observed that there is a huge potential of

back end heat recovery from GT-HRSGs. This heat can be recovered
and can be used to generate heat required to heating cold DM water
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which is earlier being heated with other process streams or any other
fluid that can ultimately run a Vapour Absorption Machine (VAM).
The heat recovered can be utilised in generating power in ORC, but the
efficiency of power generation may not justify the implementation of this
scheme.
d. Energy Savings:
The actual total energy recovery potential at the back end of HRSG is to
the tune of 16.6 MMkcal/h. However based on efficiency of VAM only
10.82 MMkcal/h is the potential by recovering entire heat in to DM water.
The VAM machine is envisaged to generate around 3575 TR which is
approximated to ~8652 MTOE/yr. This Chilling load can help in reduction
of power required in chillers for AHUs if this chilled water generated is
used in place of existing chillers or augmenting power in Gas Turbines if
it is used to cool the inlet air of Gas Turbines.
The energy saving potential is as shown in Table 5.7.3 below.
Table 5.7.3: Energy saving potential

Heat Available in Flue gas 16.64 MMkcal/h
Heat Delivered in VAM 10.82 MMkcal/h
Chiller load available 3575 TR
8652 MTOE/Yr
Auxiliary Power required ~175 KW
254 MTOE
Power consumed (DM water pumps) ~80 KW
113 MTOE/Yr
Cooling water required 3576 m3/h
565 MTOE/Yr
Energy Potential (VAM) 7720 MTOE/Yr
Thus, energy saving to the tune of ~7500 MTOE/Yr. is envisaged. Also it

can be noted that the energy saving potential increases if in case hot DM
water is directly consumed in Deaerators, which needs a detailed study.
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The scheme involves creating two new facilities mainly the Extra heat
surface area at the back end of HRSG and an altogether new Vapour
Absorption Machine (VAM) module if envisaged. In a detailed study,
existing heat transfer are in HRSG shell may be replaced with low
pressure drop high heat transfer finned tubes to act upon reduction of
additional pressure drop created by installing heat recovery system at
back end.
VAM is generally modular in nature and can be easily accommodated in
the CPP area. Extra space could be created by replacing existing CPP
cooling tower with the fan less cooling tower which is proposed as a
separate scheme.
This is a medium term scheme as it involves handling critical equipment
like Gas Turbines as additional surface has to be created in Back end.
The VAM is a modular one and so can be installed easily but needs
creating additional space near the CPP area.

The order of magnitude cost for
 Creating additional surface area = ~ INR 6 Crore/ HRSG
 Creating Additional Surface for all 3 GTs = ~ INR 18 Crore
 Vapour Absorption Machine(VAM) = ~ INR 28 Crore
Total Cost = ~ INR 46 Crore
 Energy savings (~7500 MTOES/Yr.) = ~18 Crore
Straight line pay back comes to be around 2 Year 6 months.
3. Heat Recovery from Boiler’s & HRSG’s blow-down

Presently ~ 100 TPH of HP steam is generated from Boilers and 250 TPH
of MP steam is generated from HRSGs. ~ 3 TPH of hot Blow down from
boilers and 7.5 TPH of hot blow down from HRSGs are lost to atmosphere
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The energy in the hot blow down is wasted without recovering the heat
content in it.
To recover Flash LP steam from this hot Blow-down, Flash vessels can
be installed for all Boilers & HRSGs separately to generate LP steam of
3 Kg/cm2g and 2.5 Kg/cm2g respectively for direct consumption in
Deaerators as shown in Figure 5.7.6
Figure 5.7.6 Recovery of Flash steam from Blow-down
d. Energy Savings:
By installing flash vessel, ~ 0.67 TPH of LP steam from boiler blow down
and 0.7 TPH of LP steam from HRSG blow down is generated. Also the
remaining heat in the blow down can be extracted by placing an
exchanger as shown in the figure 5.7.6. The total savings which is
equivalent to 1,200 MTOE /Yr.
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To recover Flash LP steam and additional heat recovery to DM water
from this hot Blow-down, Flash vessels followed by exchangers can be
installed for all Boilers & HRSGs separately.
It is a short term scheme to install flash vessel and an exchanger.
f. Order-of-magnitude Cost & Straight-line Payback:

Based on the flash vessel size and piping for collection of all blow downs
order of magnitude cost has estimated.
 Estimated cost : INR 250 Lakhs
 Energy saved : 1300 MTOE/Yr
 Savings : INR 314 Lakhs
The Straight-line payback comes to be around 8 months
4. Replacing PRDS with Turbo generator for generation of Power
Presently, around 65 TPH of MP steam that is required in the refinery is
generated via PRDS from HP steam.

There is potential to generate power by installing a Turbo Generator to
produce power instead of direct killing of this high pressure energy.
A Turbo generator can be installed to generate power from high pressure
HP steam that is presently being killed to MP steam in a PRDS. This
requires a parallel arrangement of Turbo generator to the existing PRDS
to meet the plant MP steam loads uninterruptedly as shown in Figure
5.7.7.
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Figure 5.7.7 Installation of TG for Power Generation
d. Energy Savings:
By installing Turbo generator, in present scenario, 65 TPH of HP steam

is killed to MP steam.
 Steam through PRDS : 65 TPH

 Power generation possible : 4.08 MW
 Energy savings : 5946 MTOE/Yr
Thus ~5800 MTOE is saved by installing a Turbo Generator between HP

to MP levels
Turbo Generator has to be installed in parallel to existing PRDS as shown

in figure 5.7.7 above. Installation can be done at any suitable location is
the refinery where both these steam headers are available and suitable
electrical system to handle generated power.
It is a medium term scheme to install a Turbo generator.
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The Order-of-magnitude cost for installation of Turbo generator is

estimated as below:
 Estimated cost : INR 900Lakhs
 Energy saved : 5887 MTOE/Yr
 Savings : INR 1413 Lakhs
The Straight-line payback comes to be around 6 months
Remark: IOCL HR has initiated action for installation of back-pressure turbine.
5. Rationalisation of Boiler operations

Presently there are 3 Boilers in the refinery out of which one is in
continuous operation and other 2 Boilers are intermittent in operation
based on steam and power requirement. The average steam generation
is to the tune of 90 TPH, 60 TPH 130 TPH in Boiler-1, Boiler-3 & Boiler-
4 respectively.

As per the Fuel oil flow and steam generation for individual Boilers, it can
be observed that the efficiency of all the Boilers is less. The Boiler-1,
Boiler-3 are very old and are not having APH. Though there is APH in
Boiler-4, it is also not working to its best based on the data provided. So
there is a huge energy saving potential by replacing them with higher
efficiency one.
The old inefficient Boilers i.e. boilers 1 & 3 can be replaced with New
highly energy efficiency state-of-the-art units. In case of Boiler-4,
replacing the APH may also be considered based on the detailed study.
Also, as the refinery is planning for replacing existing fuel from fuel oil to
Natural gas to all the Boilers, accordingly higher area in Air Pre-Heater in
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in new Boilers is recommended. If Boiler-4 is not replaced with a new one

then, additional APH surface is thus recommended.
d. Energy Savings:
The Energy saved by replacing the Boilers is as shown in the Table 5.7.4
below.
Table 5.7.4: Savings from Rationalisation of Boiler
Parameters Units Boiler1 Boiler3 Boiler-4

Steam Flow TPH 90.0 60.0 130.0
Fuel Flow TPH 7.4 4.9 10.0
Calorific value 10000.0 10000.0 10000.0
Efficiency % 79.8 80.7 85.1
Best Efficiency % 93.0 93.0 93.0
New Fuel Flow 6.4 4.2 9.2
Fuel Savings TPH 1.1 0.6 0.9
Hrs/Year Hrs 8000.0 8000.0 8000.0
Annual Savings MTOE 8454 5169 6828
Thus ~20,000 MTOE is saved by replacing the old boilers with brand new
highly efficient state-of-the-art Boilers. It has been mentioned that the
Boiler-1 and Boiler-3 are in operation for approximately 3-4 months in the
whole year. So savings are prorated and approximated to ~10,000 MTOE
The scheme involves replacing the old boilers with newer ones. It
requires detailed study of the available Boilers and then replacing them
with new ones. Some part of the old Boilers may be utilized in the new
one.
It is a medium term scheme to install a new Boilers.
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The Order-of-magnitude cost for installation of new Boilers is estimated

as below:
 Estimated cost : INR 107 Crore
 Energy saved : 10,233 MTOE/Yr
 Savings : INR 24.56 Crore
The Straight-line payback comes to be around 4 years and 4 months.
Remarks: However IOCL HR is anticipating increased demand of steam,

requiring all Boilers to be in operation. In that scenario, the energy savings
are to the tune of 20,000 MTOE and pay-back will come down to 2 years & 2
months.
5.7.1 OPTIMISATION OF STEAM AND POWER NETWORK POST

IMPLEMENTATION OF SCHEMES
In existing configuration, due to various schemes recommended, pattern of

steam and power consumption varied significantly as shown in Table 5.7.5.
Table 5.7.5: Impact of Steam and power due to various schemes
Sl. Unit ENCON Scheme Addition of Steam Power

No to Header (TPH)
HP MP LP KW
1 DHDS Installation of hot separator in DHDS to produce 5
MP steam (5 tons/hr.) from stripper bottom & thus
reduction in Reactor Effluent air cooler duty.
2 OHCU Installation of hot separator in OHCU to produce 16
M.P. Steam from Reactor Effluent after exchanger
(91-E-02) & also reduction in reactor effluent air
cooler duty
3 H2 Mgt. Recovery of Hydrogen from Refinery Off gases -2200
4 FCC Replacement of Full condensing Turbine of MAB 25 -3200
to motor in FCC unit
5 FCC Replacement of Full condensing Turbine of WGC 11.5 -1500
to motor in FCC unit
6 SWSU Increase of inlet temperature of sour water feed to 4.3
sour water strippers of 29 & 94 units.
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7 ARU Increasing the inlet temperature of Rich amine 3.8

feed to Amine regeneration units of 26 & 93 (old &
new ARU’s).
8 TGTU Use of Low Temperature Co-Mo Catalyst in TGTU 2.8 -0.9
to reduce MHP superheated steam consumption in
Hydrogenation reactor preheater
9 CDU-I Stoppage of Stripping steam to LGO & HGO 0.76
strippers
10 CDU-II Stoppage of Stripping steam to LGO & HGO 0.68
strippers, optimization of Stripping steam to crude
column
11 Refinery Application of Electrical tracing in offsite piping and 25 20 -8627
tank farm in place of steam tracing
12 Refinery Replacing existing cooling towers with new fan 2118
13 CPP Low End Heat Recovery From Exhaust Gas of GT- 643
HRSGs
14 Refinery Heat Recovery from Boiler’s & HRSG’s blow-down 1.37

15 CPP generation of Power 4080
16 Refinery Installation of Turbo generator in Natural gas 2480

header at OSBL to recover pressure energy
17 Refinery Flare Gas Recovery -110
18 Refinery Rationalization of Air Compressors 562
Total 3 84 29 -5754
As per the Table 5.7.5, it can be noted that there is additional availability of 3
TPH, 84 TPH and 29 TPH of HP steam, MP steam and LP steam respectively
post implementation of these schemes. Through electrical balance, there is net
power requirement to the tune of 5.75 MW.
IOCL Haldia informed that due to implementation of various projects, the steam
as well as power demand is going to go up and thus proper steam balance has
to be carried out before going for installation of new steam/power generation
equipment.
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An Overall steam Power optimisation be taken altogether for running the GT,
Boiler and STG in an energy efficient manner through software tools like
EngCHP developed by EIL.
However, a complete steam balance has been done for a hypothetical scenario
in which all the energy schemes accepted by the Refinery are assumed as
implemented and is as shown in Table 5.7.6. The refinery Steam is balanced in
all the headers by balancing each header with best possible options.
Table 5.7.6: Overall Steam Balance
HP MP LP
Sl.No Cases 60 kg/cm2g, 14 kg/cm2g, 2.5 kg/cm2g,
450oC 300oC 220oC
Base Case- Inputs
1 Steam Generation from UB 157.00
2 Steam generation from HRSGs 183.00
3 STG
4 Supply of Steam from HP to MP -148 96.00
5 PRDS
6 Supply of Steam from HP to MP -60 60.00
7 Turbines
Supply of Steam from MP to LP by Turbines
8 (BFW, CT & IFO pumps) -109.00 109.00
Calculations
Excess steam available in header wrt. Base case
9 due to Various schemes adopted 2.80 83.95 28.57
10 Options to balance steam headers
11 LP steam balance
Converting OHCU CT & DM water turbine driven
12 pump to motor (requires power of ~ 1.5 MW) 28.57 -28.57
13 Excess steam available in header 2.80 112.52 0.00
14 MP steam balance
15 Reducing steam from HP-MP PRDS 60.00 -60.00
Reducing steam from STG (Power generation
16 reduces by 3.3 MW) 52.51 -52.51
18 HP steam balance
Reducing HP Steam generation from Utility
19 Boiler -115.31
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Rev. 1
Through overall steam balance, excess LP steam can be balance by converting

Turbines to motor which requires power to the tune of ~ 1.5 MW. The excess
MP steam can be reduced from PRDS and remaining from STG (Power
generation to the tune of ~ 3.3 MW comes down). Thus the steam to the tune of
~115 TPH accumulates in HP steam header which can be reduced from Utility
boilers. Thus net power demand increases by 4.8 MW and overall power
demand increases by 10.55 MW. This additional demand can be met through
installing GT inlet air cooling or to be imported from grid.
**********
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5.8 ENERGY & PERFORMANCE ANALYSIS OF UTILITIES &

OFFSITES
Refinery consists of many utilities other than Steam and Power like IFO, Fuel
gas, Boiler feed water, DM water, cooling water, service water, drinking water,
Fire water, Plant/ Instrument air system, Nitrogen, Flare, Blow down, Flushing
oil and slop system etc. There is a provision to import LNG in IOCL Haldia is
being explored.
There are around 90 steam traced offsite tanks which are for storing feed and
products from various units and to maintain the temperature as heat is lost to
the atmosphere. The product lines that carry these hot products to and fro
between the units and tanks are also steam traced
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Energy Saving Schemes
1. Application of Electrical Tracing in Offsite Piping and Tank Farm in

Place of Steam Tracing
In existing configuration, ~25 TPH of MP steam and 20 TPH of LP

steam is consumed in offsite area which includes the steam traced
process lines and tanks.
It is observed that steam going to off sites is substantial. As per the

analysis, it is observed that actual steam required to compensate the
heat loss is less compared to the steam that is provided. Also, the offsite
area is vast and a proper steam trap maintenance is a herculean task
and thus leads to many trap failures and loss of steam accordingly. The
condensate that is formed is also at times of suspect condensate
category and thus is generally not recovered though it contains good
heat content. Steam and condensate system in off sites is thus an area
of concern and is of less cleaner operation. Also there are cases of tube
rupture due to steam ignited corrosion and thus loss of steam as well as
product and additionally down time to replace those lines.
As discussed above, the steam system brings in inefficiency of

operation and adds to the maintenance vows. So it is recommended to
replace the existing steam system for Tanks and Pipeline tracing with
altogether new and advanced electrical tracer. This will substantially
reduce the operating cost and also is a clean mode of operation
involving less manual interventions. The facility to connect the new
electrical tracing system to existing DCS and incorporating advance
technologies like IIOT can make the system more robust and reliable.
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d. Energy Savings:
The recommendation is to replace entire steam that is going to offsite

area to both tanks and steam traced process lines with electrical tracing.
This will decrease the burden on steam generation and increase
electrical load. The Energy savings are calculated as shown below
 Steam consumed in Offsite (MP+LP) = 25+20 TPH

 Equivalent steam MTOE = 25,714
 Offsite steam traced pipe length =~25 kM
 Electrical Power required to process lines =1875 KWH
 Electrical Power required for tanks =6752 KWH
 Total power required =8627 KWH
 Equivalent Power MTOE = 12,548
 Net Savings = 13,166
Thus ~ 13,000 MTOE can be saved by replacing existing steam tracing

in tanks & process lines with electrical tracing. The energy requirement
comparison between the steam tracing and electrical tracing is as
shown in Figure 5.8.1.
25714
12548
STEAM TRACING ELECTRICAL TRACING
Figure 5.8.1: Comparision between Steam and Eletrical Tracing
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The scheme involves replacing the existing steam tracing with electrical
tracing for both steam traced pipes and tanks. The tracing for Tanks and
pipes is different and thus requires different implementation philosophy.
Implementation Philosophy for Steam Traced Pipes:
Existing Steam traced pipes have steam tracer coil/s running along and
is insulated. Sometimes tracers are aided by heat transfer compounds
for better heat transfer between steam tracer and process pipe. For
implementing electrical tracing, the insulation over this pipes has to be
removed first and then electrical tracer Tape can be installed in a close
vicinity of pipe and bundled. The steam tracer is intact and need not be
removed as it can be used at times there is issue with electrical system.
Thus this gives flexibility to the refiner to operate both the systems as per
their convenience. But care is to be taken that both the systems should
not operate at the same time as it may damage the electrical system. The
insulation may be again utilized based on its condition or can be replaced
with a new and improved one to minimize heat loss.
Implementation Philosophy for Steam traced Tanks:
Existing Steam traced Tanks have steam tracer coil/s running in to the
tanks just above the bottom of the tank providing the required heat and
the outer surface is well insulated to minimise the heat loss. For
implementing electrical tracing, the insulation over the Tanks has to be
removed first and then electrical tracer Tape can be installed in a close
vicinity of the tank. The steam tracer is intact and need not be removed
as it can be used at times there is issue with electrical system. Thus this
gives flexibility to the refiner to operate both the systems as per their
convenience. But care is to be taken that both the systems should not
operate at the same time as it may damage the electrical system. The
insulation may be again utilized based on its condition or can be replaced
with a new and improved vertical double-locking standing steam
insulation panel system to minimize heat loss and ease of installation.
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The power modules, thermostats, controller and panel stations etc. are
to be connected to existing power network of the refinery. The DCS
connectivity is of similar nature of data logging as already adopted in
refinery.
This scheme is a short term scheme as hot work can be done without
disturbing the running plant and it doesn’t warrant any down time of units
or offsite area. The scheme is easy to implement at site.
f. Order-of-magnitude Cost & straight-line Payback

The order of magnitude cost for replacing steam tracing system with
electrical tracing in offsite area is as evaluated as below:
Electrical Tracing Installation cost
 For steam traced pipes = ~ INR 32 Crore
 For steam traced Tanks =~ INR 117 Crore
Total Installation cost = ~ INR 149 Crore
Total MTOE savings per annum = 13,166
Energy savings = ~INR 31.6 Crore
It has to be noted that the above cost figures includes complete

replacing of existing steam tracers and then installing electrical tracing
though it is recommended to keep both the tracers. The payback period
comes to be around 4 Years and 6 months
2. Replacing existing cooling towers with new fan less cooling tower
technology
Presently, Refinery is having 5 in number of cooling towers catering to

various groups of units. All these cooling towers which are primarily induced
type consume Power to run the cooling tower fans.
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Cooler water network is a heat rejection system in which already low grade
heat is wasted. Additional power is consumed by cooling tower fans in the
process of cooling the hot cooling water to desired temperature in cooling
towers which is again a waste of energy. As per the analysis of data of
existing cooling towers, they can be converted to fan-less cooling towers
without any impact on degree of cooling desired.
By replacing all the cooling towers in the refinery with this novel jet type fan-
less cooling towers in a phased manner, refinery can save power consumed
in the cooling tower fans. Details of cooling towers with their approximate fan
power consumption is tabulated in Table 5.8.1 below.
Table 5.8.1: Cooling Towers with power consumption

Operating Power
Sl.No Cooling Tower Circulation rate consumption
(m3/hr) (KW)
1 TPS 4000 260
2 PCT 9000 550
3 DHDS 12000 758
4 OHCU 9000 420
GT 2000 130
Total flow 36000 2118
c. Recommendation:
It is recommended to replace existing cooling towers with jet induced fan
less cooling towers. This will help in reduction of power consumption in fans.
Also interconnection of cooling towers helps in reduction of power consumed
in Pumps as running many smaller pumps is less efficient to that of larger
ones. Interconnection between various cooling towers thus reduces
pumping loads during low temperature seasons when the cooling load
requirement comes down as pumps can operate at full loads instead of many
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pumps running at part load. The actual installed Fan-less cooling tower is as
shown in Figure 5.8.2.
Figure 5.8.2: Schematic of Fan-less Cooling Tower

The Fan-less cooling towers have various additional advantages like easy
installation because of modular arrangement, water saving because of
minimum drift losses, less maintenance because of no moving parts. Also
investing in spare parts is minimal. The technology involves no Filling etc.
inside the cooling towers thus reducing weight of the structure and increases
reliability and safety of cooling towers. Incorporating it in the new design can
help controllability of cooling water network thus increasing the productivity
as well.
d. Energy Savings:
By replacing above mentioned cooling towers with a Fan-less cooling
towers, the power requirement to the tune of ~ 2.1 MW can be reduced. Thus
~ 3000 MTOE can be saved per annum which can be further increased
considering power savings by consolidation and rationalization of small
cooling towers with larger one meeting combined capacity requirements.
The implementation of this scheme involves replacing existing cooling
towers with new jet type fan-less cooling tower. Consolidation and
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rationalization of small cooling towers with larger ones required additional

piping work and related accessories and larger pumps in place of earlier
smaller one. Inter connection of cooling towers need some extra piping and
control philosophy to save on operating expenses.
The fan-less cooling towers can be easily installed at site due to its modular
in nature. It can occupy the same foot print of existing cooling towers but
consume some extra elevation as it needs more volume compared to
traditional cooling towers.
It is a Short term scheme to replace existing cooling towers with new one
but overall cooling tower integration is a long term scheme as it needs
complete study of cooling water network.

Based on the capacity of the cooling towers, cost estimation has been
carried out and estimated the order of magnitude cost.
 Energy savings : 3081 MTOE/Yr
 Cost Savings : Rs. 739 Lakhs
Thus, estimated Straight-line payback comes to be around 1 year.
3. Rationalization of Air compressors

In the Refinery complex, presently there are around 6 Air compressors under
continuous operation generating instrument air, plant air etc. Also there are
additional air compressors in the Nitrogen plant specifically to generate
Nitrogen required by the refinery. The total list of Air compressors that are
studied are as shown in Table 5.8.4. Also there are other compressors which
are in standby operation mode.
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Table 5.8.4: Details of Air compressors
Location Name Type of Design Operating Drive

Compressor Capacity Capacity Power
Nm3/hr Nm3/hr KW
TPS 57-km-03 Centrifugal 4800 3720 466
TPS 57-km-02 Centrifugal 6400 4070 635
DHDS 73-k-01 Centrifugal 4834 3600 455
DHDS 74-K-101 Centrifugal 3100 1800 350

It has been observed from the data that the air compressors in Refinery are
running below their rated flow. This leads to higher power consumption to
the tune of ~ 560 KWH. This can be reduced by going for a lower capacity
air compressor along with other two running at higher capacity to meet the
requirements or installing a VFD.
c. Recommendation
As per the analysis, it has been observed that the Air compressors across
the Refinery in both TPS and DHDS units are running at part load and are
not performing well as they are running at lower capacities. So, it is thus
recommended to install a compressor of lower capacity and running others
at higher capacity at their best Efficiency point to meet the requirements or
to install VFD in the existing compressors.
The compressors 57-KM-02 and 74-K-101 are having more specific energy
consumption. So by replacing them with a low capacity one may help running
of other compressors at their best efficiency point. This may require installing
a new small air compressor of ~1200 nm3/h
Also it is recommended to go for Air leak survey before going for any actual
investment as the efficiency of the air network generally improves reducing
the compressor duty accordingly. How, ever IOCL HR mentioned that they
recently gone for Air leak survey.
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The data is only of air compressors for plant air and instrument air. Extending
the study considering Nitrogen compressors also can help in taking further
better decision as a common air network for service air and nitrogen plant
can help running a few compressors to meet the requirement at best
efficiency point and keeping others in standby mode.
d. Energy Saved:
By implementing this scheme of rationalization of air compressors, the power
consumption to the tune of ~ 0.56 MW can be reduced. Thus ~ 800 MTOE
is saved per annum which may be further increased by considering power
saved in compressors that are presently in service in nitrogen units and
taking up recommendation of air leak survey.
The implementation of this scheme involves rationalization of air

compressors across the refinery by installing VFD or installing new one with
lower capacity. As it is proposed to go for a new air compressor of ~1200
nm3/h operating flow capacity.
f. Order of magnitude cost/straight line pay back:
The total order of magnitude cost for implementing the scheme is based on
procuring a new compressor as below
 New Centrifugal Air compressor with VFD: ~30 Lakhs
 Energy Savings: ~196 Lakhs
The Payback come to be less than 6 months.
4. Flare gas recovery

In the Refinery complex, presently there are two Flare gas recovery units of
liquid ring compressor type. The refinery still has flaring to the tune of ~4000
Tons per annum.
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It has been observed from the data that there is still a potential to recover
this additional flare gas adopting similar technology as existing ie. Liquid ring
compressor are a new technology which is much adaptable based on ejector
system. Thus ~ 4000 Tons of flare gas can be recovered on annual basis.
This leads to power consumption to the tune of ~ 108 KWH. As flare is
intermittent in nature, this flow and corresponding power consumption will
vary accordingly.
c. Recommendation
It is recommended to install a new Flare gas recovery unit for additional flare
gas recovery along with existing ones. It is recommended to go for ejector
based flare gas recovery system with liquid water as motive fluid rising the
flare gas pressure to fuel gas header pressure as shown in figure 5.9.4.
Adding amine to water in proportion required can help bring any slipped H2S
content in the flare gas to the levels needed to add this flow to fuel gas
header. Else additional capacity is to be provided for cleaning the
compressed flare gas before sending it to fuel gas header.
The ejector technology in place of liquid ring compressor technology is

suggested as the moving part in this case is pump and ejector is a static
equipment thus minimising cost and maintenance issues. Also other benefits
of efficiency and turn down capacity adds up to this choice.
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Figure 5.8.4: Schematic of Flare gas recovery unit
d. Energy Saved:
By implementing this scheme of flare gas recovery, ~ 0.5 TPH of flare gas is
recovered. The energy saving potential is as shown below.
 Flare gas recovered = 0.5 TPH (4000 TPA )

 Calorific vale = 10,000 Kcal/kg
 SRFT of Flare gas recovery = 4000 MTOE/yr
 Power consumed = 108 KW
 SRFT of power = 167 MTOE/yr
 Net savings = 3833 MTOE/yr
Thus, ~ 3800 SRFT /yr is saved by implementing flare gas recover scheme.
However, it should be noted that the Hydrogen content is the flare is high,
so recovered flare gas can add up to Hydrogen recover scheme.
The implementation of this scheme involves installing a new flare gas

recovery unit along-side of existing ones. This requires a modular ejector,
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pump, KOD setup along with a deep liquid seal setup as shown in figure
below. Also, any available pumps at the liquid flow of ~ 40 m3/h with a
discharge pressure of 80 barg can be used.
f. Order of magnitude cost/straight line pay back:
The total order of magnitude cost for implementing the scheme is based on
procuring a new flare gas recovery unit of the ejector type.
 New Flare gas recovery unit: ~19 Crore
 Energy Savings: ~9.22 Crore
The Payback come to be ~ 2 years and 2 months
Remarks: It has to be noted that refinery-wide study may minimize the flare
generation. As the refinery has 2 flare gas recovery units but flaring is still observed,
a detailed study is required to utilise the existing flare gas recovery compressors
before going for new ejector based system.
5. Low End Heat Recovery From Exhaust Gas of CIDW and DHDS furnace
In Existing configuration, there are three natural draft furnaces in CIDW
unit and one in DHDS unit of 2.85, 2.77, 5.2, 7.56 MMkcal/h fired duty
each respectively. The average stack temperature for these heaters are
590 oC, 450 oC, 280 oC, 405 oC respectively. Huge heat s lost through
there heaters to atmosphere.
The heat lost to the atmosphere is high. Since it is proposed to go for

natural gas firing in these natural draft furnaces, stack temperature can
go much below than current level. So a Heat recovery system can be
installed to recover this heat content to bring down the low end
temperature to a lower value as shown in Figure 5.9.5. So it has been
envisaged that low end recovery can bring down the flue gas temperature
to around 250oC with a maximum pressure drop of 25mmwc to maintain
adequate draft in the existing stack. A detailed analysis of duct may help
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to bring it down further. Heat Recovery envisaged from all the furnaces
is ~1.11MMkcal/hr. The values are as shown in Table 5.8.5
Table 5.8.5 Low end heat recovery from furnace
Unit Heater fired duty, FG Operating Desired Duty TR
No MMKcal/h formed, stack temp, temp ex- recovered,
kg/h oC APH, oC MMkcal/h
CIDW 84-F-01 2.85 5703 590 250 0.38 125
CIDW 84-F-02 2.77 5533 450 250 0.22 71
CIDW 84-F-03 5.2 10400 280 250 0.06 20
DHDS 25-F-01 7.56 15120 405 250 0.46 151
Figure 5.8.5: Heat recovery unit at back end of Furnace
c. Recommendation:
By the analysis of data, it is observed that there is a huge potential of

back end heat recovery from furnace. This heat can be recovered and
can be used to generate heat required to heating cold DM water which is
earlier being heated with other process streams or any other fluid that
can ultimately run a Vapour Absorption Machine (VAM). Generating
chilled water to meet the refrigeration unit requirements in control room,
satellite stations etc. The heat recovered can be utilised in generating
power in ORC, but the efficiency of power generation may not justify the
implementation of this scheme.
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d. Energy Savings:
The actual total energy recovery potential at the back end of furnaces is
to the tune of 1.53 MMkcal/h. However based on efficiency of VAM only
1.11 MMkcal/h can be recovered. This can be used to heat the DM water.
However the VAM machine is envisaged to generate around 366 TR
which is approximated to ~886 MTOE. This Chilling load can help in
reduction of power required in chillers for AHUs if this chilled water
generated is used in place of existing chillers.
Energy Savings are approximated to 800 MTOE/Yr.
The scheme involves creating two new facilities mainly the Extra heat
surface area at the back end of furnaces and an altogether new Vapour
Absorption Machine (VAM) module if envisaged
VAM is generally modular in nature and can be easily accommodated in
nearby area.
This is a medium term scheme as it involves handling critical equipment
like furnaces as additional surface has to be created in Back end. The
VAM is a modular one and so can be installed easily but needs creating
additional space near the CPP area.

The order of magnitude cost for
 Creating Additional Surface for all furnaces = ~ INR 1.48 Crore
 Vapour Absorption Machine (VAM) = ~ INR 2.93 Crore
 Total Cost = ~ INR 4.41 Crore
Energy savings = ~INR 2.12 Crore
Straight line pay back comes to be around 2 Years and 2 months.
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6. Thermal efficiency improvement of the fired heaters by designing /

modifying APH system and / or converting from dual firing to 100% fuel
gas / RLNG firing
a) Existing Configuration:
Most of the high firing duty process heaters are dual fired and consumption
of total fuel Oil is around 96,000 Ton per annum.
b) Observations & Analysis

 Since fuel contains around 0.5 to 1.5 wt. % sulphur, there is a limiting
temperature for APH system design and corresponding thermal
efficiency achieved. For a dual fired system, efficiency on gas firing will
also be lower (similar to FO firing)
 FO firing is also associated with a significant quantity of steam required
for atomisation.
 FO firing also leads to soot deposition on extended surfaces in
convection section and APH resulting in lower heat transfer rate which
tends to lower the efficiency of the heaters. This is partly avoided by use
of soot blowing steam.
 At times, dripping of the oil near burner/ coke formation in burner tip need
frequent attention for safe operation.
c) Recommended Scheme
In today’s scenario, gas firing is an attractive option for higher thermal
efficiency and stringent environmental requirement. Therefore, most of the
fired heaters are recommended for converting from dual firing to FG / NG.
Further, APH system can be designed / modified for 100% gas firing
corresponding to lower flue gas temperature (125 – 130 °C)
Switch over from F.O/dual firing to FG / NG firing will have following benefits:
 Higher waste heat recovery from flue gas due to lower dew point.
 Saving of steam used for FO atomization, Soot blowing
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 Other energy savings associated with FO circuit / network

 Reduction in other maintenance requirements associated with oil and
steam circuit.
d) Energy Savings
Total savings have been worked out as 5000 MTOE/Yr considering lower
stack temperature, less combustion air requirement, saving of atomization
steam and soot blowing steam.
This excludes savings from FO tanks heating / FO lines tracings/FO
pumping/ Maintenance cost of soot blower/F.O pumps/F.O tanks and lines
insulation.
Remark: IOCL HR has initiated action on this recommended scheme.
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SECTION 6.0
SUMMARY OF RECOMMENDATIONS
129
6.0 SUMMARY OF RECOMMENDATIONS
The recommended schemes under energy study can be summarized under

various energy study areas which are unique and not fully exploited so far. This
section gives a comprehensive understanding of the contributions of these
energy study areas in terms of vast potential in energy savings.
6.1 HEAT INTEGRATION
This is an energy study area in which the potential of inter unit and intra unit
heat integration is explored. Under inter unit heat integration, it is observed that
most of the heat potential in the streams is lost through the air-coolers/ trim
coolers during their routing to storage or due to the existing configuration /
operating philosophy. So, wherever possible, emphasis is given to increase the
preheat temperature of feed to the unit / equipment. Under this category, various
schemes like feed preheat improvement in CDU, NHT CRU, KHDS and heat
recovery from product rundown of VDU-I are studied and recommended.
Under intra unit heat integration, emphasis is given to identify areas in which
heat potential in streams / system is not utilized due to the inherent unit
configuration. The potential schemes recommended in this area include
installation of hot separator for heat recovery from stripper bottoms in OHCU
6.2 LOW LEVEL HEAT RECOVERY
This energy study area mainly focuses on the effective utilization of low level
heat available with different streams in the refinery viz. unit rundowns, flue
gases from boilers/heaters and boiler blow-downs. It is observed that these
streams have significant heat potential which is currently disposed off to
atmosphere directly (in case of flue gases) or lost through air coolers / trim
coolers.
The schemes recommended under this category are heat recovery from boiler’s
& HRSG’s blow down and Low End Heat Recovery from Exhaust Gas of GT-
HRSGs & flue gas of furnaces.
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6.3 INTERVENTION OF NEW TECHNOLOGIES
This is an important area of energy saving explored during the study. Under this,
thrust is given to implement the new technologies and also to replace the
existing inefficient system with a new and efficient systems. Refinery is losing
substantial energy through hydrogen rich fuel gas to flare, loss due to
condensation of steam and inefficient condensate recovery systems.
As a part of this, new energy saving schemes like use of electrical tracing /
heating in place of steam tracing / heating, plate type heat exchangers in
SWS/ARU, flare gas recovery, and fan less cooling towers in place of
conventional induced draft cooling towers are also recommended.
6.4 RATIONALIZATION & UPGRADATION OF FACILITIES
In the category of Rationalization & up gradation of facilities, importance is given

to reduce specific energy consumption to produce unit quantity of product. It is
observed that in the refinery, old systems / configurations are being used with
inherently lower efficiencies and use of drives linked to operating philosophies.
Refinery is also losing substantial energy through hydrogen rich fuel gas to fuel
gas systems
The schemes that are recommended, as part of this area of energy study are
recovery of hydrogen from refinery off gases, change of condensing turbine /
back pressure drives to motor drives in FCC, reduction of VDU-I column top
pressure, rationalization of air compressors.
The total Energy Savings (excluding option-2) = 98, 400 MTOE/Yr.
6.5 STEAM AND POWER NETWORK OPTIMIZATION
131
Any energy saving scheme, if implemented in the refinery will most of the time
affect the steam network and / or power network. Therefore, these facilities need
to be optimized. In the current scenario, a complete steam and power network
balance has been carried out for the scenario in which all the energy schemes
accepted by IOCL-HR are assumed as implemented. The energy saving
measures identified in this area are
 Recovery of steam/condensate loss in refinery complex

 Replacing PRDS with turbo generator for generation of power.
6.6 FIRED HEATERS’ EFFICIENCY IMPROVEMENT
Fired heaters contributes considerable part of the energy consumption in a

refinery. A comprehensive study and optimization of fired heaters will greatly
reduce the specific energy consumption of a refinery. The areas which are
evaluated under this category are excess air optimization by incorporating
reliable O2 analysers, thermal Efficiency improvement by augmenting APH
system based on predominant gas firing, changing worn-out burner components
for improved combustion performance and replacement of critical dampers.
6.7 OPTIMIZATION OF OPERATING PARAMETERS
Optimizing the operating parameters is expected to contribute greatly for the

reduction in energy consumption without significant impact on product pattern
and with no investment. The recommended scheme is stoppage of stripping
steam to LGO & HGO strippers, optimization of stripping steam to crude
column
The total Energy Savings = 915 MTOE/Yr.
The comprehensive findings under this section are summarised in Figure 6.1
132
120000
98400
100000
80000
60000
40000
19200
20000 11000
10000 9500 7750
915
0
Figure 6.1: Salient areas of Energy Savings
6.8 WALK-THROUGH PERFORMANCE AUDIT OBSERVATIONS
As a part of EEI study, walk through performance audit has been carried out by
expert team constituted by CHT. The committee comprises of representatives
from various refineries, CHT and EIL. The major findings are summarised below
along with energy savings. Further, the list of audit findings is enclosed.
a. Feed Preheat improvement in FCC

It is observed that the feed preheat temperature in FCC is around 123 °C
against the design value of 188 °C due to the bypass of Slurry / feed
exchanger (E-17) as there is some limitation in the heat recovery from slurry
circuit (choke).
It is recommended to utilize the heat available in slurry PA is used to preheat
Feed from 123 °C to 215 °C in Feed/Slurry exchanger (existing). Therefore the
duty requirement in heater is reduced from 4.97 MMkcal/h to 1.25 MMkcal/h.
133
The energy savings are worked out to be around 2900 MTOE/Yr

corresponding to fuel saving in heater.
b. Tuning of Anti-surge controller / Review of critical speed for Main Air

Blower (MAB) in FCC
Presently, it is observed that 20, 000 Nm3/hr air is being vented in MAB. The
blower is driven by condensing turbine, which consumes 32.5 TPH of MP
steam. It is recommended to review the tuning of Anti-surge controller and
critical speed of turbine / compressor to optimize the blower operation.
It consumes approximately 6 MW (rated power) at 100 % load leading to

substantial loss of energy due to anti-surge opening / venting.
Savings for MAB
 Venting of air, % = 25
 Energy Loss, KW = 1500
 MTOE Savings = 2100
Thus, Net fuel savings corresponding to savings is approximately 2100

MTOE/Yr.
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SECTION 7.0
GENERAL RECOMMENDATIONS
&
BEST PRACTICES

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A981-0000-03-41-SR-011
7.0 GENERAL RECOMMENDATIONS & BEST PRACTICES
At the heart of a refinery lies the equipment and they consume considerable
utilities for their operation. Efficient utilisation of these equipment’s and utilities
reduces the energy consumption. The Refineries have adopted many best
practices for efficient energy use by developing regular maintenance schedules
which also improves the reliability and thus profitability due to less down time
and higher availability.
This chapter is intended to provide general recommendations and best practices

which have already been taken care of by some refineries. It is to be noted that
these cross cutting energy efficiency measures discussed below are generally
quick wins and most of them are low cost/no cost recommendations. These help
to sustain the benefits of implementation along with other recommended energy
efficiency schemes.
7.1 Recommendations and Best Practices for Columns
Refinery consists of various columns performing the function of generation of

products with certain specification from the crude oil. Distillation, Stripping and
absorption columns thus has to be energy efficient in operation.
a) Recommendations that can be Implemented at Site:
 Maintaining optimum column parameters like pressure, reflux ratio etc.
 Adapting dead-band facility in control valve to minimise flare loss
 Optimising stripping steam based on product quality instead of a constant

flow or through a malfunctioning flow meter.
 Minimising heat loss by maintaining insulation properly
b) Recommendations that may Require Licensors/Vendor Interactions:
 Adopting enhanced distillation controls, IIOT that reduce reboiler duty

and also caters to seasonal operating pressure adjustments
 Upgrading column internals based on pressure drop etc.

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7.2 Recommendations and Best Practices for Fired equipment
Refinery has various fired equipments like Furnaces, Reformers, Boilers etc.
consuming large amount of energy. Regular monitoring of the equipment is
essential to control the energy loss.
 Optimisation of quantity and quality of atomizing steam to maintain

proper combustion
 Controlling air to fuel ratio by adjusting the draft and burner air registers
based on varying loads
 Installation of glass-window type peepholes to minimize the air leakages
 Monitoring excess air, stack temperature and fuel consumption in the

furnaces & reporting regularly to control the furnace operation & Carrying
out Stack oxygen survey with portable analysers regularly
 Replacing Dripping / malfunctioning burners/components immediately
 Installation & regular calibration of Fuel oil and fuel gas flow meters
 Monitoring furnace shell temperature and repairing the refractory lining

on regular basis to minimise heat loss
 Monitoring and reporting of detailed furnace efficiency and fuel loss

should at regular intervals by adopting software tools
b) Recommendations that may require Licensors/Vendor Interactions:
 Installation & regular calibration of Analysers for measuring Oxygen,

Carbon monoxide to have better combustion control
 Rationalisation of units based on proximity and load requirements

thereby reducing dependence on Natural draft designs
 Replacing Fuel oil with clean fuels like Natural gas for improved back end
recovery and lesser steam load etc.
 Considering higher heat containment and heat recovery to process fluid

in the initial design itself.
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 Conducting Computational Fluid dynamics (CFD) study for

malfunctioning equipment for better air and fuel gas flow distribution.
7.3 Recommendations and Best Practices for Steam and Power network
Steam and power are the major utilities that are consumed in the refinery
complex, constituting ~ 50 % of total energy needs. Thus optimum generation
and consumption of these utilities helps in efficient energy usage.
 Minimising Steam losses through faulty steam traps, damaged insulation

and leaks etc. by regular steam trap maintenance and steam leak survey
programs
 Maximising Condensate recovery and flash steam generation
 Optimising steam consumption in Deaerators for BFW generation
 Recovering heat from blow down for DM water heating or flash steam
generation
 Reducing standby and turn down operation losses
 Improving distribution system insulation
 Improving efficiency at seam and power end use
 Maintaining proper power factor of electrical system and Reducing
electrical distribution & transformer losses
 Reducing voltage unbalance and utilisation of variable voltage controls
 Optimisation of steam and power network to operate Boiler, Gas

Turbines and STG etc. efficiently using software tools like EngCHP
developed by EIL.
 Adopting new technologies like inlet air cooling which helps in generating
more power from existing gas turbine assets, Thermo compressors,
Advanced Steam traps, Pre- forged manifold, Pre-insulated tubing etc.

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7.4 Recommendations and Best Practices for Motors and Turbines
Motors and Turbines are drivers which consume power and steam, respectively
to drive the equipments like pumps, compressors, blowers etc. Operating these
equipments at optimum conditions thus reduces utility consumption.
 Properly choosing the right equipment size and type based on

sustainable usage & which helps to operate them at its best efficiency
 Maintaining proper steam conditions like pressure and temperature at the

inlet of turbine
 Maintaining proper vacuum inside the condenser of condensing turbine

by optimum steam to the ejector and cooling water temperature.
 Maintaining proper insulation to reduce energy losses from turbines.
 Selecting motors to condensing turbines, thereby reducing specific

energy consumption
 Replacing old & inefficient motors/turbines with latest state-of-the-art

ones
7.5 Recommendations and Best Practices for Pumps, Compressors,

Fans/Blowers
A Refinery consists of many pumps & compressors in operations for proper

flow and pressure requirements of liquid & gaseous feeds/products. Energy
efficient operation of these equipments helps in steam and power
requirement in connecting equipments like Turbines and motors
respectively.
 Using proper size equipments based on application helps in lowering

power requirements.

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 Trimming of impeller or application of VFD for variable flow to reduce flow

& to minimise MCF in continuous operation
 Maintaining these equipments properly and curtailing leakage through

clearance reduction and improved seals etc.
 Maintaining the belt drives and other accessories immediately as and

when required
 In case of compressors, maintaining proper pressure drop in air filter, gas

intake temperature, inter and after coolers through proper cooling water
flow & temperature, proper non leaking air traps etc reduces utility
requirement
 Utilising lower capacity equipments instead of running larger ones at

lower loads like using hand held Air-Entraining Air Nozzles for cleaning
or drying helps in reducing air compressor load.
 Replacing old and inefficient rotating equipment’s with state-of-the-art

one.
 Using advanced monitoring, controls and IIOT, thus handling the

demands accordingly
 Sizing the downstream pipes properly thus reducing the pumping

requirements to a minimum.
 Placing compressor at proper location and elevation
7.6 Recommendations and Best Practices for Heating, Cooling & Process
Integration
Heating, cooling and process integration plays a crucial role in the overall
refinery processes. Energy efficient integration of these in the process can help
reduced consumption of utilities like steam and power.
 Monitoring Heat exchanger fouling closely.

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 Cleaning of the exchangers on regular basis as per schedule for better

heat recovery.
 Carrying out overall pinch analysis of a particular unit and total site pinch
analysis for optimum utility use
 Recovering low level heat through technologies like DM water heating,

low pressure steam generation, Organic-Rankine-Cycle (ORC), Hot
water belt and Vapour absorption machines (VAM) etc.
7.7 Recommendations and Best Practices for Utilities and Offsites
Refinery consumes many utilities other than steam and power like cooling water,
instrument air, nitrogen etc. Steam/ power is consumed in generation of these
utilities and thus optimum utilisation of these improves energy efficiency of the
refinery.
 Adopting various surveys like air leak survey, control valve survey, flare loss
survey and insulation survey etc.
 Reducing flare losses by properly monitoring and reporting by installation
and regular calibration of flow meter
 Maintaining Cooling water temperature / pressure / flow by maintaining
condensers to regulate off-gas loss.
 Reducing steam to offsite in steam traced pipes and tanks by adopting

energy efficient electrical tracing
 Adopting new technologies like fan-less cooling tower, generation of power
from Natural gas pressure, flare gas recovery etc. helps.

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7.8 Computational Fluid Dynamics (CFD) analysis for trouble shooting

Refinery operations
Computational Fluid Dynamics (CFD) is an innovative and powerful design

analysis and prediction tool. It is a potent tool for flow simulation & visualization
of the specific rheology of the fluid and the complex geometries in complex
refinery applications. Heat transfer, chemical reaction, multi component flow,
effect of additional body forces such as electromagnetic or centrifugal, Vibration
due to Fluid-Structure-Interaction, flow induced noise etc. can be effectively
modeled with CFD.
Modelling and testing a design before implementation helps to save time and
money, and allows testing of various ideas for troubleshooting the problems.
Also, doing preventive analysis much before it becomes a big problem, for e.g.
Combustion air duct analysis for age old heaters for change in feed pattern or
fuel pattern etc. helps the refiners in a big way.
The applications of CFD can be as shown below
 Steady & transient flow simulation
 Environmental Impact/Safety studies
 High speed compressible flow
 Conjugate heat transfer
 Heating ventilation & air conditioning
 Multiphase flow simulation
 Cavitation study
 Combustion study
The Figure 7.1 is a schematic of capabilities of CFD with some examples

embedded in it.

reserved
142
A981-0000-03-41-SR-011
Figure 7.1: Schematic representation of capabilities of CFD

reserved
143
COMPREHENSIVE STUDY FOR Annexure-I
ENERGY & PERFORMANCE IMPROVEMENT Page 1 of 2
HALDIA REFINERY Rev. 1
ANNEXURE – I
OBSERVATIONS OF
PERFORMANCE AUDIT TEAM
HALDIA REFINERY Rev. 0
Major implementable improvement measures identified during Walk

through Performance Audit
As a part of study, Walk-through Performance Audit has been carried out during
site visit dated 3rd - 4th Nov ’17 by expert team constituted by CHT. The committee
comprises of representatives from various refineries, CHT and EIL. The major
findings are summarised below along with energy savings.
S.No. Unit Selected Performance audit Observations EIL’s

observations and
findings
1 CDU-II Main Fractionator delta P at 0.45 Kg/cm2 ---
against design of o.40 Kg/cm2. Delta P
further increases while processing some of
the Nigerian crudes. Additional exchangers
required in CR-2 service. Feasibility of
change in modern design internals in MF
may be explored.
2 CDU-II Because of the limitation in MF column, lower ---
pressure operation is prohibited.
3 KHDS Reactor delta P observed to be 2.65 Kg/cm2 ---
(g) against design of 1.0 Kg/cm2
4 FCC Feed preheat found to be only 123 oC Included in section
against design of 188 oC. Heat recovery from 6.0
slurry circuit is limiting (chockage), HCO vs.
feed Heat exchanger bypassed
5 FCC Venting of air @ 20,000 Nm3 / hr Included in section
6.0
6 FCC Orifice chamber DDSV problem (stuck-up) to ---
be resolved as quickly as possible
7 OHCU Presently MDEA strength only 20 % against ---
&ARU design 28 %. It is recommended to increase
strength to 28-30 % to reduce amine
circulation rates thereby reducing energy
consumption.
8 Off-site Auto mode Tank wagon loading system to be ---
made functional
9 Off-site Redundant lines and unused lines to be ---
dismantled.
10 LOBS In CIDW, H2S leak is predominant near ---
furnace area-suggested to arrest the leak on
priority
COMPREHENSIVE STUDY FOR Annexure-II
ANNEXURE – II
MANDATORY ENERGY AUDIT SUMMARY

BY PCRA
I. Summary of Recommendations by PCRA

PCRA conducted the Mandatory Energy Audit (MEA) for IOCL HR in Jan 2017. Primarily, scope included was on electrical
systems, Power & utilities. The energy saving potential areas identified and recommended by PCRA are given in Table. A
Table. A Details of Energy Saving Measures recommended by PCRA

Sr. Location Location Energy Conservation Measures Annual MTO Annual Investment Payback
No. Saving Kwh/ E Saving Rs. Lakhs Period years
Yr. Lakh
Rs/Yr.
1 Refinery Switching off Transformer by shifting load 4,81,800 41 27 - Immediate
to standby to eliminate no load loss
2 Refinery Saving from improvement of power factor 58 38 - Immediate
to .995 from equivalent monetary savings
3 Refinery Saving for improvement in Load Factor 58 38 - Immediate
from equivalent monetary savings
4 All Area Replacement of LT motor with energy 26,81,035 231 150 560 3.73
efficient motors
5 All Area Replacement of HT motor with energy 27,10,451 233 152 1,009 6.65
efficient motors
6 Boiler ID and FD Fan Power reduction by arrest 1,30,900 11 7 3 0.41
House of air leakages in APH

7 Boiler Control of throttling losses in condensate 34,992 3 2 2 1.12
House extraction pump
8 TPS Install Temperature based ON/OFF 11,14,093 96 62 2 0.03
control system for CT Fans in TPS,
DHDS, OHCU and Process CT
9 HVAC Operational controls of HVAC system in 1,71,803 15 10 - Immediate
SYSTEM various locations
10 LOB Install VFD for chilled water Pump-1 6,220 1 0 0 1.15
11 LOB Install VFD for chilled water Pump-2 5,443 1 0 0 1.31
12 LOB Install VFD for Air Handling Units AHU 12,363 1 1 1 0.87
Motors
13 GT Install VFD to AHU Motors-1 13,646 1 1 1 0.92
14 GT Install VFD to AHU Motors-2 13,219 1 1 1 0.95
15 MSQ Install VFD for Process Pump 1,54,224 13 9 10 1.16

(Isomerisation Feed Pump)
16 MSQ Install VFD for Process Pump 86PM-08B 82,944 7 5 6 1.29
(Deisohexaniser Reflux Pump)

17 MSQ Install VFD for 87PM-01B-shu feed pump 81,648 7 5 6 1.31
18 Refinery Elimination of distribution loss 55,258 5 3 8 2.42
19 All Areas Replace lights with energy efficient LED 60,01,939 516 336 394 1.17
lights
20 CPP Improvement in Boiler Efficiency 61,80,153 531 346 Nil Immediate
21 CPP Steam Turbine operation at optimized 83,48,721 718 468 Nil Immediate
extraction to improve heat rate
22 CPP GT-1+2+3 operating at Optimum heat 5,38,41,180 4,630 3,015 Average 0.68
rate Rs. 650
Lakh per
GT
Compressor
23 Refinery Saving by voltage optimization in lighting 1,93,632 17 11 Nil Immediate
transformers
24 TPS Saving through insulation survey in TOS 14,77,325 127 83 10 0.12
unit-4
25 Saving by Heat Recovery by arresting Air 15,70,050 135 88
leakage in APH
Total savings 8,53,63,039 7,456 4,856 3,962

Eeis - Final Report (Rev.1) - Iocl HR

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FINAL REPORT

IOCL- HALDIA REFINERY

IOCL- HALDIA REFINERY

EIL JOB No: A981

CLIENTS COMMENTS INCORPORATED & FINAL

2.0 OBJECTIVE OF THE STUDY…………………………………………….24

3.0 BASIS OF THE STUDY……………………………………………………27

4.0 METHODOLOGY ADOPTED…………………………………………......30

5.0 ENERGY & PERFORMANCE ANALYSIS -

5.1 PRIMARY PROCESSING UNITS …...…………………….……………..37

5.2 MS BLOCK………………………. ………………….……………………..60

5.3 SECONDARY PROCESSING UNITS ……..……………………….…....66

5.4 TREATING UNITS…………………………………………….……………77

5.5 SULPHUR BLOCK…………………………………………………….…...80

5.6 HYDROGEN GENERATION UNIT…………………………………….....85

5.7 STEAM & POWER NETWORK…………………………………………...93

5.8 UTILITY & OFFSITES.........................................................................112

6.0 SUMMARY OF RECOMMENDATIONS………………………………..129

7.0 GENERAL RECOMMENDATIONS & BEST PRACTICES…………...135

ANNEXURE-I: OBSERVATIONS OF PERFORMANCE AUDIT TEAM

ANNEXURE-II: MANDATORY ENERGY AUDIT SUMMARY BY PCRA

IOCL-Haldia Refinery which operates at 7.5 MMTPA refinery was given an

Accordingly, IOCL-HR entrusted EIL for carrying out “Comprehensive study on

II. EIL’s Execution Methodology:

III. Summary of Study and Analysis

a. Primary Processing Units

 Replacement / Up-gradation of existing CDU-1&2, VDU- 1&2 with new,

In MS Block, energy losses are mainly due to cold feed processing by

c. Secondary Processing Units

 Installation of hot separator in OHCU to produce MP steam.

 Maximising preheat temperature by considering hot feed in KHDS unit

Hydrogen network runs throughout the refinery complex to cater to the

g. Steam and Power Network

 Recovery of steam/condensate loss in refinery complex.

h. Utility and off-sites:

 Rationalization of Air Compressors

Table 1: Savings of Energy Schemes- Refinery Section-wise

Block Wise Energy Savings (% Contribution)

16.8% 37.1% Secondary Processing Units (16.7)

Figure 1: Energy Savings Contribution-Refinery Block-wise

IV. Summary of Recommendations

The recommended schemes under energy study can be summarized under

The total Energy Savings (excluding option-2) = 10,000 MTOE/Yr.

b. Low Level Heat Recovery

The total Energy Savings (excluding option-2) = 9,500 MTOE/Yr.

c. Intervention of New Technologies

The total Energy Savings = 19,200 MTOE/Yr.

d. Rationalization & Up-gradation of facilities

In the category of Rationalization & up gradation of facilities, importance is given

The total Energy Savings (excluding option-2) = 98,400 MTOE/Yr.

e. Steam and Power Network Optimization

 Recovery of steam/condensate loss in refinery complex

The total Energy Savings = 11,000 MTOE/Yr.

f. Fired Heaters’ Efficiency Improvement

Fired heaters contributes considerable part of the energy consumption in a

The total Energy Savings (excluding option-2) = 7,750 MTOE/Yr.

g. Optimization of Operating Parameters

Optimizing the operating parameters is expected to contribute greatly for the

Area-wise Energy Savings (% contribution)

Figure 2: Energy Contribution- Energy Category-wise

V. Summary of Recommendations by Performance Audit Team

VI. Summary of Recommendations by PCRA

 Power saving by replacing existing motors with energy efficient motors