V.S.

Khare
Ch MS Manager, WR
Mktg Division
 Excecutive summary

1. As per DOE EERE study, possible practical energy consumption

is 50 MBTU/bbl for Crude distillation unit (Atm.) while IOC
refineries are consuming 56.3 MBN (MBTU/bbl/NRGF), which is
13% higher.

2. In absolute unit, Energy consumption in IOC refineries is 3172

MJ/tonne of crude processed. Benchmarked energy consumption
as given by International Finance Corporation {World Bank} is
2100-2900 MJ/tonne.

3. Energy efficiency in IOC refineries can improve by atleast 10%

4. Within India, we may benchmark “Essar Oil” as a standard to be

achieved with energy consumption level of 2567 MJ/Tonne of
crude processed. It may be noted that Essar in processing much
heavier and tougher crude with average API 27.

5. Total savings will be around 190 to 300 Million USD per annum.

Specific energy consumption in Indian Refineries GJ/MT

3.400 R IL
3.200
I O C L A ll r e f in e r ie s
3.000
2.800 CPCL
2.600
2.400 H P C L M u m b a i
B P C L K oc h i E S S AR
2.200
2.000
HPCL
1.800 V iz a g
B P C L Mum ba i
1.600
1.400
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
BPCL Mumbai BPCL Kochi HPCL Mumbai HPCL Vizag ESSAR Jamnagar IOCL ALL
RIL Jamnagar CPCL Chennai
IOC can do more for “Energy efficiency and Environmental protection”

Background:

Concern for global warming and Climate change brought the nations together
under UN umbrella to make concerted efforts for reduce pollution and “Carbon
footprint” to protect environment. High energy intensity sectors like transportation,
industries, housing etc are already in focus, for measurement, standardization and
monitoring. Methodology for measurement and allowances are in place for industry
specific CO2 emission, tax benefit schemes, use of renewable energy etc.

Petroleum refining is one major energy intensive operation world over. However,
benchmarking energy consumption in refineries is a cumbersome process. Factors
like type of processes, crude quality, operating conditions, product mix, demand
fluctuations etc, needs to be looked into as no two refineries are same. This has
resulted into broad comparison, assessing energy band width with scope for
improvement. As per various assessments available on net, scope still exists to
reduce Specific energy consumption in developed world by 10-15%, and in
developing countries by 25 to 30%. Energy efficiency in refinery is a key area as
energy cost amounts to 60-70% of operating cost in the refinery. It is also
necessary as heavier crude processing is more energy intensive, which means
more expensive as well as environmentally sensitive due to more CO2 emissions.

Objective of the paper:

Objective of study is to assess scope for improvement in energy use of IOC

refineries based on literature survey and IOCL data scrutiny.

Methodology used for the study:

1. Data Collection and analysis to assess bench mark consumption

2. IOC/OMCs and other refineries data collection and analysis

3. Comparison and benchmarking for IOC refineries for improvement.

Data search and analysis

IOC refineries data is taken from Refinery HQ data book 11-12, OMC’s data is
basically picked up from Annual reports of the companies and SD report.

Internet data search focused on US DOE-EIA1, International Finance Corporation

(World Bank), IBNL reports, DEFRA, UKPIA, & various research papers etc.

Limitation of the study:

1. At times crude assay data from various sources for same crude shows some
variation in the reported figures. Since this data is confidential in nature, and
with time there may be some change in quality of crude for same crude, it is
used as available with confidence level about 90%.

2. Energy content of fuel is assessed differently but in close range in various

countries. Energy efficiency is measured in countries in various units like
GJ/MT, or GJ/M3 or MBTU/barrel etc. This may have minuscule impact on
comparison of energy use in the refineries.

3. It is observed that TBP distillation Boiling Range (BR) varies with reporting
company and precise comparison is difficult as given below:
BR- India IIP, Derhadun KBC Profimatics Stat oil TOTSA* ENI

C1 to C4 gas Up to 20 0C C1 – C4

L Naphtha 40 – 80 C5 – 95 C5 – 90 15 – 80 C5 – 180

H Naphtha 80 – 140 IBP – 140 95 – 175 90 – 180 80 – 150

Motor Spirit IBP – 205 IBP – 210 C5 – 145 C5 -180

Kerosene 150 – 280 140 – 250 149 – 232 180 – 240 150 – 250 160/80 - 230

HSD//LGO 240 – 380 250 – 370 232 – 342 /369 240 – 320 175 – 375 230 – 370
HGO 320 – 375 400

VGO/FO/VD 370 – 530 369 – 509 375 - 525 375 – 575 370 – 530

Bit/Vac res 370 + 509 + 525+ 550+ 530

*Various combinations of BR in each category is mentioned

Observations from inter-net data search for bench marking

Data search reveals two basis approaches to energy consumption reported as “fuel

+ loss”, either as % of crude processed or in terms of energy unit as MJ/tonne of

crude processed. Some of the major references used are briefly narrated below:

a) Paper on energy band width in oil refineries, (Industrial technology program

of DOE, EERE) – approached the issue by studying 5 major processes in
the refinery i.e. CDU/VDU, FCC, Catalytic hydro-treating, catalytic reforming
and Alkylation. These processes consumed ~ 70% of total energy in refinery
operations. They have mapped theoretical minimum energy (TMP), practical
minimum energy (PME) and current average energy (CAE) required for
these processes. Difference between CAE and PME is termed as energy
band-width and based on this, saving potential is assessed. It is also
observed that, of total energy consumed in US refinery operations, about
62% energy is required for Gasoline production, while 23% energy is used
for Kerosene and HSD manufacturing. As such, energy consumption in US
refineries is much more as Gasoline make up 53% of total demand, while
HSD/Kero/Jet fuel accounts for ~ 34%.

b) In the study on energy management and optimization in Industry in 2000,

benchmark energy consumption for various products as given below for EU
refineries with energy consumption is considered as 6.5% of crude
processed:
Best practice SECs based on a typical refinery
Consuming 6.5% of throughput
Refinery product SEC GJ/Tonne
Gases (LPG, Refinery gas) 1.3
Gasoline 3.8
Kerosene 1.6
Gas oil including Naphtha 3.2
Fuel oil 1.8
Others 1.8
 c) In European Union, Solomon Energy intensity index (EII) is more widely
used. It has come out with a methodology of CO2 emission allowance and
emissions trading scheme where in CO2 emission of each process (CWT)3 is
mapped with Atmospheric distillation reckoned as 1, and based on refineries
energy consumptions performance index, CO2 emission allowances is
decided. It has now benchmarked energy consumption as 0.0295 ton/tonne
of CWT.

It is also observed that, actual specific energy consumption in petroleum refining

has increased in the beginning of the decade due to upgradation of fuel quality and
heavier crude, but now it is showing decreasing trends due to various measures
and technology improvement.

Details collected from various papers are tabulated below for quick reference to
know the reported trends and benchmark for in energy consumption in refineries:
Reference IFC report CEEDAC Energy Richmond4 Av’ge Research UKPIA European2
2007 2011 mgmt environmen- Russia paper South commission
report Study- Eu tal review Africa Dr Ozren
(Canada) refineries presentation Ocic
Energy 2100-2900 2650-3000 2400-2900 3300-5600 2830 348 - 580 5 to 6% 4-8 % of
consumption MJ/tonne of MJ/M3 MJ/tonne MJ/M3 MJ per MJ/ bbl of crude crude t’put
crude oil tonne 2500-4200 t’put
Electricity 25-48
consumption KWH/t....
Fresh Water 0.07-0.14 M3
make up
1

1 1. ITP paper on energy band width in Refinery processes

2 As per presentation by Prof Dr Ozren Ocic, made on sustainable energy, (European commission), in oil refineries,
share of energy equivalent of crude oil used for own energy consumption is in the range of 3-4% for simple refinery
and 4% to 8%, for complex refinery, which depends on range of products and number of so called secondary
processing units in use. It has also pointed out in the presentation that oil refinery of mid level complexity, and 5
million tonnes/y capacity, has decreased own energy consumption from 10% to 7%. Similar assessment in UKPIA
2013 report has indicated that energy consumption in UK refineries is between 5-6% of crude equivalent for per
tonne of crude processed.
3 Constructing benchmark – presentation by Allan Reid at CONCAWE joint ICAP/NA2050 workshop at New York,
24 Sep 2012.

4 Richmond presentation came out very specifically on energy intensity and crude quality w.r.t. density and sulfur
content.
Indian Scenario:
Energy efficiency was a concern area for refining sector and MOP&NG carried out
various studies as given below:

EIL report: As per study conducted in 1995-96 for energy consumption in various
processes and utilities in Indian Refineries, it was then assessed that large
potential exists in improving overall energy efficiency in Indian Refineries by about
20% in processes and from 14-41% in utilities. Based on this report, energy
conservation program (ENCON) was launched and progress was made in
improving energy efficiency. Today PSUs are reporting energy consumption as
energy factor {MBN (MMBTU/bbl per NRGF)}, which was reworked in 03-04 by EIL.

The energy factor is defined as given below:

Energy factor = Energy consumption+loss in MBTU

Crude intake in bbls * Refinery NRGF
Refinery NRGF (energy factor) is worked out in two steps:

Step I – Unit NRGF = Energy consumption of the process unit

Energy consumption of crude distillation unit

Step II - Refinery NRGF = Σ(unit NRGF*unit intake in bbl)/ crude thruput.

Thus energy factor assesses actual energy consumption in refinery in terms of

distillation unit consumption as a single unit (EDC – equivalent distillation column).

LBNL report: Under world-bank's Asia sustainable and alternate energy program
(ASTAE), supported through DOE, Ernest Orlando Lawrence Berkeley National
Laboratory, analysed and reported following assessment about Energy
consumption in Indian refineries:

1. Indian Refineries are simple with secondary to primary ratio <30% except for
Jamanagar (59%), Barauni and Panipat (40%).

2. During 03-04 to 12-13, distillate yield increased from ~72% to ~78%.

3. Energy consumption increased from 2.44 PJ/MT in 98-99 to 3.0 PJ/MT in

2002-03 owing to increase in secondary processes for product quality
 improvement (PQI). It is expected to increase upto 3.44 PJ/MT by 2012 as
product quality improvement continues (640PJ).

Shell global Solutions: The analysis carried out by shell global solutions in 03-04,
performance of all PSU’s refineries is compared with Asian and Global standards
and specific action recommended for each refinery in various areas based on
following parameters.

Preliminary assessment of IOC Refineries energy efficiency:

Though IOC reported better energy efficiency amongst PSUs refineries, on MBN
(MBTU/bbl NRGF), following observations are made:

1. PSUs are reporting energy consumption in MBTU/bbl/NRGF while Private

players like Essar has reported the same as crude % as fuel+loss.

2. Energy consumption in refinery is MBN/bbl/NRGF is the actual fuel+loss in

refinery, but benchmark consumption keeping in view throughput of units is
not available to compare it. This is clear from the fact that every year
performance is improving but we don’t know excess consumption as on date.

3. It is therefore proposed to assess actual energy consumption in refineries in

terms of fuel+loss as % of crude thruput and MJ/MT of crude thruput. Same is
then compared with peers and benchmark is decided for improvement.

A ) Energy consumption in the refineries:

Energy consumption in the refinery is a function of type of crude processed, %

distillate yield (conversion), and other operating parameters including size of
refinery, on line availability, unplanned shutdown, maintenance etc. In view of
above, detailed analysis is carried out as given below:
 A1) Detailed Analysis: Type of crude processed in Indian Refineries:

IOC's crude basket expanded in last 10-12 years: IOC refineries are now
processing more light sweet crude procured from West African and Asian countries
as seen from available assay of crudes. These crudes have favorable yield
compared to our demand pattern except Gas, and gives better yield on distillates,
needs less conversion of bottom residue, comparatively low sulfur removal and
upgradation and hence lower energy consumption. Crude assay for crudes used in
IOC refineries on regular basis now and their yield (%Wt) is as indicated below:

MAYA
ORIENT
SIRRI
LAVAN BLEND
ISTUMATH (1)
UMM SHF
RATAWI
GIRRSOL
CEIBA
AMENAM
HUNGO
KISSANJE
AZER LT
U ZKM
ZAFFIRO
BONGA
FORCADOS
KIKEH
ESCVOS
Q IOBE
BONNY LT
NIM (NEMBA)
ERHA (exxon a'pprox vol %
YOHO Exxon V/V
MIRI LT
BRASS LT
LABUAN
EA
OKONO
SER LT
ARAB HY
ARB MD (3)
SUZ MX Gulf of Suez
KWT (MINA?)
DUBAI
ARB MX
BSR LT (2)
IRAN MX (LT)
MURBAN
Mangala
North Gujarat
Assam Mix
Ravva
Bombay High
Panna
A'kleswar+Gandhar 40:60

0 10 20 30 40 50 60 70 80 90 100

>509 369-509 232-369 149-232 C 5 -149 C1-C4 Gas

 From above graph, it is clear that crudes now used regularly have better yield of
distillates, & Atm distillation unit residue (LR) is quite low compared to middle-east
crudes or even with Indian crudes. In other words, our distillate yield improvement
is on account of sweet crude oils now refined without using severe processing.

Many other types of crude tried in IOC refineries were found similar to Middle East
crudes when compared on Atm distillation unit residue (LR). Generally, CDU
products are straight run and blended with other streams to give final products.

DJ E NO
R AB I LT
CAB ND
AL S AIN
PLUTOn io yield v/ v% from B P
M AS ILA
KOLE
M E S LA
E S IDE R
PALNCA
B R E NT
S AXI
S OYO
ODU
TAPIS
AGB AM I

0 10 20 30 40 50 60 70 80 90 100
>509 369-509 232-369 149-232 C 5 -149 C1-C4 Gas

Detailed assay of various crudes used in IOC refineries is attached in Annexure

A2) As regards HPCL, it is observed that they have claimed a crude basket of 108
crudes, but from the AR it is assessed that, they are still using Middle-East and
Indian crudes. However with commissioning of HEML, which have higher
complexity (NCI), use of high sulfur heavier crude will increase in HPCL refineries.
From the reports of BPCL, it is observed that they are still using light sweet crude
including Middle -East crude.

A3) Essar oil in recent report/presentation compared crude API gravity processed,
and Nelson Complexity Index (NCI) for various refineries, an indicator of refineries
ability to process various difficult crudes is given as below:
 API Gravity of Crude processed in different Indian Refineries – Essar presentation
Refinery Nelson CF 2008-09 2009-10 Q2 CY10 Q3 CY 10 Q4 CY 10
IOC Panipat 11.6 31.6 32 32.1 31.9 31.7
IOC Mathura 7.3 32.1 32.1 32.3 31.9 32.3
EOL Vadinar 6.1/11.8 32.8 31.8 32.3 32.5 32.5
IOC Koyali 5.5 33.2 32.9 32.9 32.5 32.6
CPCL Manali 7.2 33 33.4 33.5 33.4 33.3
HPCL Vizag 5.5 35.6 35.9 34.9 35.1 34.3
HPCL Mum 7.0 34.3 34.9 32.9 35.2 35.5
MRPL 4.6 35.6 35.7 36.1 36.3 36.4
BPCL Mum 5.9 34.8 35.9 37.1 38.6 37.9
BPCL Kochi 3.5 36.6 38.1 37.6 38.8 39.3

Above table indicates that most of the refineries in India have moderate NCI, and
hence “fuel consumption+loss” should be in close range for all refineries.

A4) Type of crude imported by PSUs and that of Essar oil has been assessed from
crude cost as given in AR, which is given in table below:

Crude oil price

45000.0
43000.0
41000.0
39000.0
37000.0
35000.0
Rs/MT

33000.0
31000.0
29000.0
27000.0
25000.0
23000.0
2008-09 2009-10 2010-11 2011-12 2012-13
Year

IOC Rs/MT BPC Rs/MT HPC Rs/MT Essar imported crude price Rs/MT

It is observed that, Essar oil price (CIF basis) is much lower compared to IOC crude
price (FOB), which is due to heavier crude in use by Essar Oil. At the same time
BPC/HPC are using similar or light sweet crude than IOC. IOC/BPC has clearly
mentioned the price as FOB but HPC price is not clear.
 B) Increase in % yield of distillate (light and middle distillate)

Almost in all refineries, distillate yield has increased in last decade. It is observed
that, there is increase in energy consumption which is related to product quality and
sulfur removal rather than more severe processing. Yield improvement in IOC and
other Indian refineries is as under:
Refinery 01-02 02-03 03-04 04-05 05-06 06-05 07-08 08-09 09-10 10-11 11-12 12-13
Guwahati 82.5 78.5 78.1 80.6 80.8 81.2 81.2 82.4 84 83.4 82.9 79.7
Digboi 68.7 67 67.2 70.2 73.5 71.8 73 72.7 72.3 70.8 70.94 73.67
Barauni 84.9 84.6 85.6 85.5 86.3 86.1 85.4 85.7 86.8 86.1 85.22 86.16
Koyali 70.3 70.7 70 65.4 68.9 71.7 71.3 71.4 70.5 70.6 77.9 78.09
Panipat 76.7 76.6 76.2 76.1 75.2 72.2 78.1 80.7 81.2 80.9 82.29 82.5
Hadia 57.7 62.7 62.9 62.3 61.4 62.5 61.4 63 60.2 64.4 66.47 66.86
Mathura 73.3 74.5 74.8 73.4 70.6 71.5 70.8 71.1 71.7 73.2 73.8 73.27
B’gaon 86 85.3 82.3 81.80 82.3
IOC tot 72.1 72.8 73.2 71.5 72.1 72.5 73.7 74.8 75.3 75.4 77.8 78.1
CPCL 68.3 69.2 69.03 70.28 69
HPC-M* 67.8 68.3 68.96 71.35 70.87 71.10 69.9 71.8 72.4 72.3 73.5
HPC-V* 77.2 73.9 75.3 76.71 76.78 79.18 73.6 73.5 71.5 74.0 72.6
MRPL 72.8 72.57 72.66
BPC# 75.94 77.04 74.54 73.52 73.55 73.21 75.99 75.39 77.76 80.49 79.18 79.79
Essar 74 72 72 79*

C) Product quality and Technology available:

In India as per Auto fuel up-gradation policy, Bharat-II norms since Apr 2005, and
Bharat-III norms since Apr 2010 were made applicable on all India basis. Also,
Bharat-IV norms were made applicable since Apr 2010 in 13 cities, extended now
to 50 cities and likely to be applicable by 2015 on all India basis. To upgrade fuel
quality to meet BS III and BS IV norms and to increase distillate yield, all refineries
added secondary processes/increased the capacity of already existing units. These
processes are hydrogen unit, DHDS, hydro-treating, CCRU, Sulfur recovery unit,
hydro cracker, delayed coker, etc. It may be noted that a few standard processes
patented by a few companies world over are used in the refineries. As such, energy
consumption of the processes supplied by various vendors does not vary
significantly in the refineries.
 Assessment :

From the details mentioned above, it is assessed that Indian refineries are
processing similar crudes, have similar distillate yield, maintain 100 + % capacity
utilization, and meet same quality norms. As such difference in energy consumption
should be in very close range unless poor efficiency. At the same time, in Annual
report of Essar oil 2012-13, it is indicated that average API gravity of crude
processed has dropped to 27 compared to 32 earlier and refinery is also in a
position to make Euro V quality MS/Gas oil, thus making it more energy consuming
refinery due to intense processing/ quality up-gradation of heavier crude. This is
also clear from the lower price and higher GRM of Essar oil.
In view of above, energy consumption in PSU refineries and that of private
refineries is compared based on available data from IOC refinery intranet data, and
annual reports of the companies. Data is mainly compared for fuel+loss as % of
crude processed and also based on the energy consumption per MT of crude as
per details available in Director’s report. Details are as given below:

I) Fuel + loss as % of crude processed:

Refinery 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13
Guwahati 10.2 17.8 14.6 13.2 15.6 14.5 14.2 12.6 11.3 10.9 12.15 12.16
Digboi 8.8 9.1 12.8 11.8 12.1 12.4 12.9 11.9 10.6 10.6 10.3 10.12
Barauni 7.0 11.4 11.2 10.2 10.1 10.3 10 9.0 8.5 8.6 9.23 9.2
Haldia 10.1 10.0 10.0 8.9 9.4 9.2 8.9 9.1 9.1 10.0 9.41 9.41
Koyali 6.8 6.8 6.5 7.4 7.5 7.6 6.7 7.0 6.6 7.8 9.8 9.7
Panipat 8.6 8.6 8.3 8.5 10.8 14.6 9.8 9.6 8.7 9.6 10.53 10.5
Mathura 6.4 6.6 6.6 7.2 9.1 8.8 8.8 8.7 9.0 8.3 8.8 8.41
B’gaon 5.2 6.6 6.9 9.53 10.51
IOC tot 7.5 8.0 8.1 8.4 9.3 10.1 8.8 8.5 8.2 8.6 7.56? 7.25?
CPCL NA NA NA 9.11 9.1 9.11 8.93 8.94 9.27 9.60 9.6 9.5
HPC- M* 7.11 6.88 6.55 6.57 6.76 6.34 6.85 6.64 7.64 7.60 7.9 7.5
HPC- V* 6.10 5.95 6.13 6.13 5.98 5.80 5.58 5.69 6.77 7.30 7.4 7.6
MRPL$ 6.58 6.44 6.54 6.71 6.43 6.20 6.51 6.79 7.0
BPC+ # 5.3 5.74 5.71 5.90 6.73 6.62 6.59 6.62 5.93 5.64 6.06 5.9
Essar 6.45 6.02 6.2 6.3 NA
# Calculated from Annual report on crude processed and production figures For BPC mum+KRL $ Based on Annual report
either given in performance or in note 19 and 20. * Encon report/AR
Energy consumption, distillate yield and quality of crude processed are closely
related and product quality is not varying much, with Essar oil at focal point, which
is processing much heavier and tough crude (API 27), energy consumption in
refineries and distillate yield is studied from the below given graph.

As seen from the graph, BPC Mumbai is quadrant 1 which indicates better energy
efficiency and distillate yield than Essar, probably due to higher use of R-LNG . It
may be noted that BPC Mumbai is now manufacturing Lubes which is energy
intensive process and its energy efficiency and distillate yield is far better than its
peers like HPC Mumbai and CPCL/Haldia. Barring these three refineries in
quadrant 3, all other refineries are required to improve their distillate yield and
energy efficiency. Refineries in quadrant 4, i.e. Bongaigaon, Barauni, and Panipat
must improve their energy efficiency while maintaining their yield pattern.

II) Energy consumption in Indian refineries MJ/Tonne

From ENCON data available in Annexure to Director’s report, energy consumption
in refineries in GJ/MT of crude processed is also calculated which is given below:
Energy consumption in GJ/MT of crude processed:
02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13
BPCL Mumbai 1.806 1.812 1.849 2.084 2.259 2.303 2.296 2.172 2.155 2.069 2.156
BPCL Kochi 2.218 2.487 2.460 2.261 2.387 2.380 2.559 2.799 2.504
HPCL Mumbai 2.680 2.569 2.505 2.498 2.390 2.999 2.328 1.947 2.734 2.783 2.674
HPCL Vizag 2.121 2.014 2.171 2.194 2.076 2.000 2.034 2.481 2.697 2.736 2.811
ESSAR V’nar 2.706 2.613 2.412 2.244 2.494 2.567
IOCL ALL 2.550 2.744 2.996 3.036 2.896 2.968 2.886 3.245 3.160 3.172
RIL Jamnagar 1.436 1.523 1.710 1.714 1.872 3.260 3.119 3.086 2.987
CPCL
Chennai 2.876 2.991 2.732 2.672 2.676 2.686 2.488 2.493 2.548 2.737 2.494
For calculating energy consumption is GJ/MT, following assumptions about heat
content of various fuels used in refineries are made:
Fuel Calorific value MJ/Kg

Refinery coke 27.2

Fuel Oil 41.03

HSD/Kerosene 41.87

Natural gas/Refinery flue gas 36

Electricity 3.6

Benchmarking

It is therefore clear that IOC refineries have lot of scope to improve energy
efficiency. Comparing energy consumption benchmark proposed by IFC 2100 to
2900 GJ/MT, and knowing that Essar oil is well within this band width while
processing much heavier crude that what IOC is processing, we may consider
Essar Oil energy efficiency level as benchmark to be achieved as our 1st goal.

Saving potential

The difference between energy consumption in IOC refineries and that of Essar oil
is 605 MJ/Tonne. This is equivalent to additional 14.4 kg of liquid fuel consumption
per MT of Crude oil processed in IOC's refineries. Even if we could manage to save
35% of the above amount i.e. 5 kg/MT, total savings at the rate of 700 USD /MT of
crude price will be 191 Million USD. If entire 14 kg Per MT of additional
consumption, we will be able to save 535 Million USD per annum.

IOC thruput Fuel saved kg/MT Total fuel saved Mts Rate/MT Total savings
54650 5 273250 700 191275000
54650 14 765100 700 535570000

Considering 1 tonne of oil contains 860 kg of carbon, and 44 gms of CO2 contains
12 grams of Carbon, if 100% conversion to C02 is considered, it will amounts to
reducing CO2 emission to the extent of 0.8 to 3.0 million tonnes.
Where to focus:

As Per carbon foot print map prepared by Advanced manufacturing office by

energetics incorporated, major energy losses occurred in US refineries are in
following areas

 US refineries total energy consumption 3231 TBTU

 Losses in process heating 422 TBTU

 On site steam generation losses 205 TBTU

 On site Steam distribution losses 145 TBTU

 Machine drive 96 TBTU

 Machine driven systems like pumps compressors 104 TBTU

Subject energy mapping in US refineries indicate that total energy losses is 30% of
total energy used in the refineries. IOC may take a view and prepare such
document to map energy losses for each refinery so as to chalk out a plan for
improving energy efficiency.

We may have to assess critically following factors in our refineries.

1. Energy wastage in terms of steam leakages

2. Gas flaring

3. Energy efficiency of the units like boilers, power plants.

4. Poor insulation losses in steam lines and losses in process units.

5. Energy efficiency of mechanical units.

6. Use of alternate energy sources like Solar or wind power

7. Heat exchangers efficiency, tube fowling, thereby reducing overall heat

transfer coefficient

This will help us in saving foreign outgo minimum 200 million USD per annum,
decrease carbon foot print and use public money efficiently.
 Annexure A
Evaluation of Crude oils used in Indian Oil Refineries

STAT oil data C1-C4 Gas C5 – 180 180-240 240-375 375-525 >525
ENI C1-C4 Gas C 5 -180 180-230 230- 370 370 – 530 >530
Total fina TOSTA
C1-C4 Gas 15 – 150 150-230 230 – 375 375 -550 >550
range
Marphy oil co kikeh C1-C4 Gas C5-155 155-230 230-340 340-446 >446
Ratawi C1-C4 Gas 10 – 150 150-260 260-340 340-450 >450
IIP Dehradun Upto 20 IBP – 140 140-250 250 – 370 370 – 530 >530
Crude name Country API % S Wt TBN C1-C4 Gas C 5 -149 149-232 232-369 369-509 >509
A'kleswar+Gandhar
India 46.9 0.041 3.8 24.9 22.3 23.9 18.8 6.3
40:60
Panna india 39.4 0.11 1.1 17.6 20.6 28.1 26.7 5.9
Bombay High India 39.35 0.17 0.05 1.9 18.6 20 24 28.4 6.2
Ravva India 35.9 0.08 0.5 12.4 21.4 27.8 37.9
Assam Mix india 29.85 0.24 1.2 15 17.6 27.1 27.2 11.9
North Gujarat india 26.83 0.17 0.4 4.4 10.1 19.2 31.2 34.7
Mangala India 29.1 0.08 0.25 0.01 1.23 6.327 17.37 44.14 30.91
MURBAN Abu Dhabi 39.3 0.8 0.06 1.23 19.19 17.35 26.75 20.04 15.23
IRAN MX (LT) Iran 32.6 1.5 0.08 1.29 16.52 12.92 23.2 19.54 26.06
BSR LT (2) Iraq 30.8 2.67 0.1 0.99 15.06 12.48 21.75 19.45 30.01
ARB MX Saudi arabia 30.77 2.37 <0.2 1.98 12.27 19 18.51 26.15 22.06
DUBAI Dubai 30.4 2.13 0.05 1.09 14.45 12.98 24.5 20.99 25.69
KWT (MINA?) Kuwait 30.4 2.59 0.11 1.13 13.71 12.1 21.4 19.49 31.9
SUZ MX Gulf of Suez Egypt 29.9 1.64 0.05 0.86 13.89 11.51 22.09 20.49 30.86
ARB MD (3) Saudi arabia 28.9 2.73 0.05 0.79 12.52 12.02 22.25 20.29 31.97
ARAB HY Saudi arabia 27.8 2.81 0.22 1.05 11.86 11.05 20.4 18.79 36.45
SER LT Brunei 40.2 0.05 0.16 1.11 24.95 21.22 35.82 13.95 1.74
OKONO Nigeria 40.6 0.07 0.2 1.42 31.33 12.41 35.08 16.58 3.19
EA Nigeria 35.1 0.09 0.21 1.69 15.41 17.29 44.8 17.76 2.97
LABUAN Malaysia 31.6 0.08 0.014 0.25 15.37 17.47 43.53 19.59 3.68
BRASS LT Nigeria 41.9 0.08 0.12 2.24 26.17 17.73 30.25 17.3 5.81
MIRI LT Malaysia 32.4 0.08 0.16 0.64 16.2 17.28 40.7 19.73 5.23
YOHO Exxon V/V Nigeria 40.1 0.095 0.26 1.89 30.21 20.51 21.54 23.12 4.72
ERHA (exxon vol %) Nigeria 34.8 0.16 0.354 1 19 20 30 25 5
NIM (NEMBA) Angola 39.79 0.22 0.1 1.68 24.01 15 26.67 18.35 13.7
BONNY LT Nigeria 34.5 0.14 0.011 1.07 16.02 15.2 35.81 21.65 9.87
Q IOBE Nigeria 35.7 0.12 0.062 1.02 19.27 15.33 31.7 22.08 10.33
ESCVOS Nigeria 35.1 0.15 0.018 0.8 17.99 17.1 31.17 20.82 11.86
KIKEH Malaysia 34.9 0.105 0.08 0.85 17.14 13.14 35.33 25.63 7.9
FORCADOS Nigeria 29.7 0.19 0.013 0.49 11.16 13.6 39.13 24.32 11.13
BONGA Nigeria 30.19 0.25 0.55 0.69 13.66 14.9 33.79 29.88 7.15
ZAFFIRO E Guinea 29.6 0.27 0.68 0.91 13.41 13.71 28.5 22.89 20.34
U ZKM Abu Dhabi 33.2 1.89 0.05 1.46 14.91 13.79 23.65 20.24 25.51
 Annexure A contd
Evaluation of Crude oils used in Indian Oil Refineries

STAT oil data C1-C4 Gas C5 – 180 180-240 240-375 375-525 >525
ENI C1-C4 Gas C 5 -180 180-230 230- 370 370 – 530 >530
Total fina TOSTA range C1-C4 Gas 15 – 150 150-230 230 – 375 375 -550 >550
Marphy oil co kikeh C1-C4 Gas C5-155 155-230 230-340 340-446 >446
Ratawi C1-C4 Gas 10 – 150 150-260 260-340 340-450 >450
IIP Dehradun Upto 20 IBP – 140 140-250 250 – 370 370 – 530 >530
Crude name Country API % S Wt TBN C1-C4 Gas C 5 -149 149-232 232-369 369-509 >509
AZER LT Azerbaijan 34.6 0.15 0.3 0.59 11.93 12.58 30.3 24.7 19.65
KISSANJE Angola 30.8 0.37 0.49 0.8 16.8 10.3 23.7 23.8 24.6
HUNGO Angola 28.3 0.64 0.47 0.8 18.6 9.6 22.8 24.2 23.6
AMENAM Lybia 36.8 0.14 0.019 0.69 13.7 11.56 24.61 21.69 27.58
CEIBA E Guinea 31.2 0.51 0.386 1.1 13.98 11.07 23.45 21.87 28.14
GIRRSOL Angola 31.1 0.36 0.3 0.82 11.01 11.34 26.31 24.06 26.09
Saudi Iraq
RATAWI 24.2 4.1 0.14 0.72 10.6 14.1 11.7 15.5 47.4
NZ
UMM SHF Abu Dhabi 37.2 1.31 0.05 1.33 19.01 15.68 26.1 19.98 17.72
ISTUMATH (1) Mexico 32.4 1.35 0.05 0.84 15.49 14.2 24.09 19.84 25.22
LAVAN BLEND IRAN 33.7 1.83 0.06 1.64 15.61 14.3 24.35 19.93 23.66
SIRRI IRAN 32.1 1.85 0.05 1.16 16.13 12.82 25.24 21.23 23.08
ORIENT Equidor 28.1 1.01 0.09 0.75 11.74 11.55 23.89 21.48 30.34
MAYA Mexico 21.1 3.38 0.1 0.41 9.81 9.08 18.2 17.8 44.56
ENFIELD Australia 21.7 0.12 0.39 36.3 3.4
NKOSSA Congo 48.3 0.06 0.01 2.17 32.79 16.51 22.72 15 7.49
AGBAMI Nigeria 47.2 0.044 0.05 2.4 35.5 15.9 31.9 11.1 3.2
TAPIS Malaysia 44.8 0.03 0.08 0.73 18.64 25.34 39.76 11.62 2.74
ODU Nigeria 32.9 0.15 0.55 0.82 16.24 15.39 32.71 22.59 8.88
SOYO Angola 38.6 0.13 0.05 1.05 15.94 14.86 28.09 22.67 12.55
SAXI Angola 33.9 0.26 0.69 1.3 21 11.1 26.5 22.7 17.4
BRENT North Sea 38 0.44 0.006 1.62 21.73 13.52 24.55 20.22 13.58
PALNCA Angola 37.2 0.18 0.05 1.29 16.71 15.41 27.31 22.39 11.76
E SIDER Libiya 36.6 0.4 0.01 1.33 16.64 14.06 25.26 21.26 16.69
MESLA Libiya 36.6 0.16 0.017 0.37 14.64 14.85 27.8 23.61 14.14
KOLE Cameroon 31.8 0.34 0.48 0.7 15.5 14.16 26.8 21.3 17.18
MASILA Yemen 31.1 0.54 0.013 0.33 11.45 13.71 25.99 22.96 20.48
PLUTOnio yield v/v%
Angola 33.2 0.36 0.15 1 20.4 8.9 23.7 25.6 18.2
from BP
AL SAIN Qatar 29 2.2 0.09 0.63 9.73 12.24 26.46 23.09 22.38
CABND Angola 32.7 0.13 0.12 0.96 11.54 10.56 22.16 23.81 25.07
RABI LT Gabon 35.8 0.111 0.05 0.32 11.63 10.98 24.67 26.65 25.76
DJENO Congo 27.3 0.42 0.77 0.76 7.22 9.3 23.56 27.13 30.07
ABU SF
HOUT 31.8 1.82 0.06 24.6 21.2
FURIAL Venezuela 30 1.06
 Annexure B

Energy consumption in refining processes as mapped by ITP and LBNL study.

IT P P e tro lu e m s tu d y L B N L s tu d y in s e le c te d in d ia n
b a n d w id th in d u s trie s
P roc e s s T ME P MD CEA B e n c h Ma rk A c tu a l
0 0 0 B T U /b b l of fe e d 0 0 0 B T U p e r b a rre l
A tm d is tilla tion 22 50 109 7 3 .6 to 7 8 .6 5 7 4 .6 to 1 2 3 .9

V a c u u m D is tilla tion 46 54 89 6 5 .3 8 6 .2 to 1 9 8 .4

C ru d e V a c u u m in te g ra te d u n ti N ot a v ia la b le 8 8 .0 to 1 0 9 1 0 4 .9 to 1 5 5 .7

F lu id C a ta ly tic c ra c k in g 40 132 183 2 5 0 .4 2 5 6 .6 7 5 to 5 0 5 .0

D e la y e d c ok e r N ot A v ia la b le 3 1 6 .7 1 3 7 0 .1 to 4 2 1 .1 4
O n c e th ru h y d roc ra c k e r N ot A v ia la b le 2 6 2 .3 2 4 3 3 .3

C a ta ly tic H y d rotre a tin g 30 55 81

C a ta ly tic R e form in g 79 203 264

A lk y la tion -5 8 156 250

H2 S O4
HF -5 8 152 245

N a p th a S p litte r N ot A v ia la b le

A rom a tic R e c ov e ry N ot A v ia la b le 5 0 5 .8 4 6 5 4 .1 7 5

H y d rog e n 6 6 .9 3 8 7 .3 8 7 to 1 1 0 .8 5 0

T O T A L e n e rg y c on s u m p tion in re fin e ry

P rop a n e D e a s p h a ltin g 2 6 1 .6 4 4 5 4 .3 8 to 5 7 3 .2 5 5
T ME : T h e ore tic a l m in im u m e n e rg y
P ME : p ra c tic a l m in im u m e n e rg y
 Annexure C

Source : Energy efficiency in south African crude oil refinery industry- MS study paper by Caitlin Bergh.
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