Mathura Refinery

Friday, November 16, 2007

Mathura Refinery

MATHURA REFINERY - INDIAN OIL CORPORATION LIMITED
Mathura (Uttar Pradesh)
Unit Profile


Indian Oil Corporation Limited (IndianOil) is the largest commercial enterprise in India with a sales turnover of Rs.150, 677 crores and profit of Rs. 4, 891 crores for the fiscal year 2004.
Indian Oil is India’s number one company in Fortune’s prestigious listing of the world’s 500 largest corporations, ranked 170 based on fiscal 2004 performance. It is also the 18th largest petroleum company in the world and adjudged number one in petroleum trading among the 15 national oil companies in the Asia-Pacific region.

Indian Oil alone accounts for 56 % petroleum product market share among PSU companies, 42% National refining capacity and 68% downstream pipeline throughput capacity. Indian Oil group owns and operates 10 of India’s 18 refineries with a current combined rated capacity of 54.2 Million metric tonnes (MMTPA).

These include subsidiaries viz. Chennai Petroleum Corporation Ltd and Bongaigaon Refinery &
Petrochemicals Ltd. It owns and operates the country’s largest network of cross-country crude and product pipelines, with a combined length of 7,730 km with a combined capacity of 56.85 MMTPA. For the year 2004-05, IndianOil sold 50.1 million tonnes of petroleum products, including exports of 1.96 million tonnes.

IndianOil’s countrywide network of over 23,000 sales points is backed for supplies by its extensive, well spread out marketing infrastructure comprising 165 bulk storage terminals, installations and depots, 95 aviation fuelling stations and 87 LPG bottling plants. Its subsidiary, IBP Co. Ltd, is a stand-alone marketing company with a nationwide network of over 3,000 retail sales points.

Energy Consumption

Mathura Refinery consumes various types of fuels viz. Natural gas, R-LNG, refinery fuel gas and low Sulphur internal fuel oil (IFO) in furnaces / boilers. Natural gas, which is about 50% of total fuel consumed at MR is supplied by M/s GAIL whereas all others fuels are generated in the refinery itself. The IFO is fired as alternate fuel in old furnaces only.

The energy consumption in refinery is reported in terms of % Fuel & Loss on crude and MBTU/BBL/ NRGF (MBN), where the term MBTU refers to total heat value of fuel & loss in thousand BTU, BBL refers to barrel of crude processed and NRGF is a derived factor that depends upon actual intake in both primary and secondary processing units. The % fuel & loss, MBN and energy cost as % manufacturing cost for last three years is as given below:


It may be mentioned that % fuel & loss of refinery has gone up in last two years because of higher secondary unit throughputs in an effort to produce clean and higher value eco-friendly products. However,the specific energy consumption in terms of MBN (the real yard stick for energy performance) is slightly higher than previous year due to Annual Turn Around during June'04 & July'04.

Energy Conservation Commitment, Policy and Set-up l IndianOil is having strong Energy Conservation Commitment, which is also reflected in its Energy Management Policy. The policy consists of all points related to adopting & nurturing Energy Efficient and environment technologies. The policy is approved by the board of directors of the company and adopted by Mathura refinery.

Energy Conservation Achievements

Annual Energy savings to the tune of 26, 250 SRFT which is equivalent to Rs. 25.25 crores were
achieved with the implementation of major energy conservation schemes.

Some of the major steps taken by Mathura Refinery for energy conservation are as given under:

  • Installation of Air pre-heater (APH) in furnaces.
  • Provision of high efficiency burners.
  • Use of low-pressure gas in AVU /VBU furnaces which otherwise was being flared.
    Soaker technology in Visbreaker Unit.
  • Process optimization using advance process control.
  • Steam turbine for Boiler feed pump and use of turbine exhaust in de-aerator
  • Installation of Gas Turbines along with Heat Recovery Steam Generation.
  • Use of LP steam in VDU for stripping purpose and for re-boiling in PRU etc.
  • Replacement of Metallic Fans with FRP blades in process units.
  • Heat integration between different process units.
  • Change of service in crude pre-heat circuit from SR to LVGO for pre-heat improvement
    De-bottlenecking of main column 19-C-1 & Debutanizer 20-C-4 overhead circuits of FCC for recovery of gas and reduction of flare in summer months.
  • Provision of secondary seal in one crude & 3 MS/ Naphtha tanks.
  • Tank wagon gantry automation.
  • Generation of MP steam in place of HP steam in CRU steam generator.
  • Chemical treatment of CW system, thereby improving exchanger's fouling factor.
    VBU preheat exchanger-cleaning management.
  • Comprehensive survey of burners components and re-assembling during annual turn around in2004-05 by external agency M/s Camvid, Bangalore.
  • Additional condensate recovery at Propylene unit.
  • Yield and energy revamp of crude distillation unit in Aug-Sep' 04.
  • New overhead Air coolers for crude distillation unit.

Optimization of pre-heat train in AVU, FCCU & NSU with addition of new heat exchangers.
In addition, the benefits of energy conservation measure implemented earlier were sustained during the year 2004-05 also. Refinery has used extensively Physical Acoustic Leak detector for detecting gas loss to flare by regular survey of safety valves and control valves connected to flare. Encon audit of furnaces,steam leak, heat exchanger, crude oil receipt, Natural gas receipt, custody transfer operation etc were carried out by Internal Energy Audit group.

Energy Conservation Plans and Targets

Mathura Refinery is committed to further reduce energy consumption by finding out new avenues on continuous basis. Refinery has planned for VBU revamp, APH in VBU, Flare gas recovery system,Introduction of specialty amine for Amine treatment, Retrofitting existing Hydro-mechanical governor with electronic governor, H2 recovery from CCRU cat reduction gas and step less control for high power consuming make up compressor in OHCU etc at an estimated cost of ~ Rs. 23 crores which will bring a saving of ~ 14,000 SRFT/year.

Environment and Safety

Environment Mathura Refinery, being located on National Highway No.2 connecting the capital city Delhi with the historic city Agra and in the sensitive Taj Trapezium Zone (TTZ), is the first industry in India for which an expert committee carried out a scientific Environmental Impact Assessment (EIA) study. Implementation of the recommendations of the EIA study even before commissioning of the refinery, laid a strong foundation of the Environmental Management System right since inception and it is an ever-continuing mission.

A full-fledged Environment Protection (EP) Cell having qualified engineers exists to deal with all
environmental issues. A well-equipped Pollution Control Lab has also been established to Monitor environmental performance on day-to-day basis. The lab is approved by the Ministry of Environment & Forests (MoE&F) and accredited by the National Accreditation Board for Testing and Calibration Laboratories (NABL). In addition, A full-fledged Occupational Health Center (OHC) is functional at the refinery for monitoring of work-related hazards namely toxic gas hazards, noise hazards, etc. and health monitoring of employees.

Safety

Safety being an integral part of refinery operation, best practices on safety are in place at Mathura Refinery. The safety is accorded the highest priority. To make the refinery a safe place for its employees,environment and nearby community, the high standard of safety is maintained. Latest equipments on safety are introduced time to time. Safety system is continuously monitored and upgraded through monthly shop floor safety meetings, Management Review and through Internal/ External safety audits.

Certificate of Merit Refinery
RELIANCE INDUSTRIES LIMITED
Refinery Division, Jamnagar (Gujarat)


Unit Profile

Reliance, Jamnagar is the largest grass root refinery set up with annual capacity of 27 million tons and the 3rd largest refinery in the world at any single location.

The refinery and Petrochemical Complex comprises of Crude Unit (2 parallel trains), Diesel Hydrotreator (2 trains), VGO Hydrotreator (2 trains), Sulfur (3 trains), Hydrogen (2 trains), Coker, Fluid Catalytic Cracker,Propylene Recovery Unit, Amine treating Unit, Desalination Units, Naphtha Hydrotreating, Catalytic Reforming, Paraxylene Extractions trains (3 nos), Tatoray Unit, Xylene extraction, Polypropylene Unit (3 trains), Captive Power Plant and a Effluent treatment plant.

Highlights:
  • Largest Grass Root Refinery.
  • World's Largest FCCU - 10.05 MMTPA (200 KBPSD).
  • World's Largest Coker - 8.3 MMTPA (155 KBPSD).
  • World's Largest Aromatics Complex - 2.1 MMTPA (PX + OX) capacity in one site.
  • World's largest PP in one site - 750,000 MTPA India's largest Sulfur Recovery Complex - 1350 TPD Large size Captive Power Plant 360 MW Capacity (Power) and 1500 MT/Hr (HHP Stem) India's largest Petroleum Terminal, Oil movement and Storage area.
Energy Consumption

Year Sp Power Cons. Kwhr/MT of intake Thermal Consumption Mkcal/MT of Intake
2002-03 73.87 0.668
2003-04 73.49 0.661
2004-05 73.1 0.662

In the Refinery Energy monitoring, the practice of evaluation of Energy Index is prevailing. An Energy Index is the ratio of actual energy consumed and the standard or theoretical energy consumed. Lower the Energy Index better is the Energy Efficiency.

In Energy Indices evaluation, the feedstocks of all the processing units are considered and the energy Index arrived at by International Systems such as either Shell or Solomon Benchmarking normalizes all the specific energy consumption and the reduction in the Index Indicates true reduction in the energy consumption. Following are the Energy Indices for Reliance Jamnagar.

Shell Benchmarking Solomon Benchmarking

Year CEL* Year EII*
2001 94.3 2000 69.2
2002 88.7 2002 64.2
2003 87.6 2004 62.3
2004 86.9

Reliance Jamnagar is topping the list of Shell Benchmarked Refineries in the world and also topping the list of Large Complex Refineries in Solomon Benchmarking in the Asia Pacific Region for last five years.

Energy Conservation Commitment, Policy and Organizational Set up Reliance has a comprehensive policy on energy conservation. Innovative energy conservation practices
are practiced all throughout the site. Better operating practices, improved operating efficiencies, optimum utilization of resources increased automation, introduction of advanced control systems, new techniques and technologies, higher capacity utilization are the various methods used which aim at the corporate goal or commitment to conserve / optimize energy consumption .

Energy Management Set-up

At Reliance Jamnagar on a continuous basis, a detailed review is made at sector chief levels fortnightly with complete focus on Energy Consumption. A rigorous plan is generated by Central Technical Services for implementation of the various projects which are being implemented or are planned in future. Top, middle, junior management and workmen of all level are committed and involved to meet the same corporate goal.

The Energy conservation team structure which work out together for implementation of the projects.

Mathura Refinery, commissioned in 1982, current rated capacity of 8.0 MMTPA crude processing, is meeting the product demand of Northwest region of the country including the National Capital Delhi. The Refinery processes low sulphur crude from Bombay High, imported low sulphur crude from Nigeria, and high sulphur crude from Middle East Countries. In the original refinery configuration, there was one primary Atmospheric Vacuum unit coupled with Vis-breaker Unit, Fluidised Catalytic cracking Unit, Bitumen Unit and Sulphur Recovery unit as secondary units.

Subsequently, in order to meet the stringent product specification arising out of environmental considerations secondary units viz. Catalytic Reforming Unit (CRU), Diesel hydro de-sulphurisation Unit (DHDS), Once Through Hydro-cracker unit (OHCU), new Sulphur Recovery unit (SRU), MS quality upgradation, DHDT etc were incorporated in the refinery configuration. The process configuration of the Refinery employs state-of-the-art technologies with minimal impact on the environment. Mathura Refinery has taken many initiatives to produce more and more clean fuels in stages in the interest of environment,public health and preservation of national monuments around Mathura region. As a result Mathura refinery has been able to supply highly eco-friendly petrol and diesel to NCT, NCR and Agra region in phase manner.

Since, April 2005, Mathura Refinery is the first refinery in India, which is capable of producing
100% auto fuels meeting Euro - III norms.