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NAYARA ENERGY LIMITED
Presenters:Philip Bhaskar – Vice President Nitinkumar Chokshi - General ManagerPranav Bhatt – Deputy General Manager
1. Refinery Aerial View
PROCESS BLOCK FLOW DIAGRAM
HMU I/II
SRU, SRU1, SRU2
Blending
Blending
02-Production Data
Year 2017-18 2018-19 2019-20
Crude Throughput
20693 18897 20620
Products
MS 3325 3071 3631
Diesel 10435 9647 10253
Naphtha 1033 670 761
LPG 974 870 972
Kero 54 55 -
ATF 779 758 1088
VGO 110 268 212
Fuel Oil 0 354 47
Bitumen 373 144 101
Pet Coke 2340 2038 2342
Sulphur 339 280 384
All figures are in KT
2. Energy Consumption FY 19-20
Fuel Type Qty (MT) MTOE/Hr %
Coal 2060747.8 92 46.0
FG 369674.3 45 22.8
FCCU coke 178875.9 19 9.7
FO 140421.7 15 7.7
DCU Off Gas 114044.2 14 6.8
PSA off Gas 264294.5 11 5.5
VDU Off Gas 18322.3 2 1.1
NG 4697.0 1 0.3
Total 199 100
Refinery Power 144 MW
FO7.7% FG
22.8%
DCU Off Gas6.8%
VDU Off Gas1.1%
NG0.3%
PSA off Gas5.5%
FCCU coke9.7%
Coal46.0%
Fuel
3. Specific Energy Consumption of Nayara Energy Limited
Refinery’s SEC in terms of MBN (MBTU/BBL/NRGF)
63.84
62.77
58.69 58.87
59.62 59.7
57
62
2014-15 2015-16 2016-17 2017-18 2018-19 2019-20
MB
N
MBN (MBTU/BBL/NRGF )
• FY 2019-20 MBN slightly higher side as• Lower capacity
utilization at End of FY-2019-20 .
• Stabilization of new/revamped units commissioned post 2018 S/D.
Normalized
Target MBN- 60.35 Escerts eligible 18235
Data Source : Data published by BEE for PAT-cycle-II
4. Specific Energy Consumption of NAYARA -Comparison with other Indian Refineries
Specific Energy Consumption of Indian Refineries FY 2018-19
4b. Specific Energy Consumption of NAYARA-Global Benchmarking
95.9092.10
87.00
93.10
75.00
80.00
85.00
90.00
95.00
100.00
2103 2014 2016 2018
EII
Refinery’s SEC in terms of EII (Energy Intensity Index)
2013 is high due to Train 1 Expansion integration, CDU II Conversion from Visbreaker and CPP CFB Stabilisation.
2014 is end of run after four years of 2011 TA
2016 was low due to best performance after 2015 TA . VGO converted to VGOMHC.DHDT T’put increased after TA as one pair of feed /effluent exchanger taken online
2018 was TA year and was not normalized
ECEI World best Refinery
. ECEI is a very important metric in the Asia/Pacific region
because of high energy prices
The weighted-average Energy Cost Efficiency Index
(ECEI™) is 77 for the World Best Refineries in the 2018
Study.
The ECEI is 70 for Nayara Energy in the 2018 Study,
which is better than the World Best Refineries average.
5a. List of ENCON Projects in last 3 years
Year No of Proposals Investments in Million INR Savings in Million INR
2017-18 12 120.68 174.41
2018-19 10 264.84 165.16
2019-20 07 17.04 191.79
5a. List of ENCON Projects in last 3 years(2019-20)
Sl. No Project Details Investments Savings Payback
1 Installation of additional HKPA exchanger in crude PHT-2 circuit 14.8 57.6 0.26
2STG- 5 LPS extraction capacity increased which helped in reducing letdown by 20 TPH.
0.181 65.52 0.00
3Base Plant STG Condensate transfer to Train 1 Deaerator resulting one DM water transfer stoppage
2.0 9.83 0.20
4SRU2: LP condensate pump impeller trimming doneSavings : 15 KWh 0.05 0.49 0.11
5 DIH Column optimization resulted in 5 MT MP steam saving per Hr.. Nil 30.66 NA.
6RPM reduction of process pump driven by turbine based on CV out-put resulted in 1 MT HP steam saving per Hr.
Nil 6.13 NA
7Optimization of steam flow to VGO fin-fan provided to avoid congealing. 5 MT of LP steam saved per Hr.
Nil 21.55 NA
5a. List of ENCON Projects in last 3 years(2018-19)
Sl. No Project Details Investments Savings Payback
1 CCR Higher capacity Packinox replacement 196.60 121.89 1.6
2CPP CW Pump bowl assembly replaced to reduce CW flow rate to STG condensers to achieve design Delta T 9.00 8.82 1.0
3 Impeller trimming of raw crude booster pump .10-P-150 A/B/S 5.37 7.76 0.7
4Replacement of CCR heater convection coil from stud type to fin type for better heat transfer 42.0 5.59 7.51
5Exchanger Pass changed from 8 pass to 4 pass to reduce back pressure and increased PHT. 1.56 4.16 0.4
6 182P118 Cold condensate supply pump impeller trimming. 1.12 1.80 0.6
7Replacement of NHT heater convection coil from stud type to fin type for better heat transfer
9.00 1.24 7.2
8Optimizing distribution transformer voltage level by adjusting transformer tap setting Nil 3.96 NA
5a. List of ENCON Projects in last 3 years(2017-18)
Sl. No Project Details Investments Savings Payback
1 Base SRU – trap bypass & De superheated isolation passing valves replaced 1.0 32.7 0.03
2New exchanger train provided in reactor feed-effluent exchanger circuit in NHT.
90 25.9 3.5
3 Power saving in Sea water return pump by de staging. 2.3 22.9 0.1
4 Installation of energy efficient Fan blades in Cooling Tower 9.1 11.3 0.8
5 LED installation at different locations in refinery. 11.0 14.6 0.7
6LGO product Heat utilization in CDU-1 for increasing Desalter inlet temperature
6.6 12.5 0.5
7Desalination water Feed to CPU unit Pump - impeller trimming to min diameter
0.5 4.3 0.1
8Optimization of DHDS operating parameters. stripper & Drier inlet temp reduction.
Nil 34.0 NA
9Avoid sub-cooling of suspect condensate below 100°C.in ISOM unit through operational control
Nil 11.9 NA
6.1 Innovative Project 01 – Crude pre heat modification:
Trigger for the project
Action Taken
• Sustain required throughput level of 2300-2330 m3/hr• Maintain CDU Heaters Process Absorbed duty < 151 Gcal/Hr (Design)• Maintain VDU Heaters Process Absorbed duty < 65.4 Gcal/Hr (Design)
Augment Preheat train (PHT) with minimum modifications to achieve CDU heater CIT > 285 0C
PHT-2
Additional HK PA Vs Crude exchanger downstream of 10E155
Utilize spare 10E158 exchanger to recover additional duty from HK PA
Modifications comprises of additional exchangers & piping rerouting
14.8
57.6
3Months
InvestmentMillion Rs
ImprovementMillion Rs
Payback
Benefits achieved:
3 MMKcal/ hr reduction in heater fired duty.
Reduced hard firing in heaters
Sustain crude throughput at lower API
SAVINGS
6.1 Innovative Projects 01 – Crude pre heat modification continued.
TOP PA
LK
CRUDE TO
PREFLASH
LVGO HVGO
CRUDE FROM
DESALTER
VACUUM RESIDUE
HK PA
E-151A/B
E-152A-D
E-154
E-156E-157A-D
E-155B
E-155
163 ºC
159 ºC
142 ºC
Temperature Profile with Crude & HK PA Circuit Changes
6.2 Innovative Projects 02 – Avoiding HP to LP steam Let down
Limitation faced
Action Taken
Issue.
Higher pressure drop across LP extraction control valve
Average of 20 MT of HP to LP steam let down was required to meet refinery LP steam demand due to limitation in LP steam extraction capacity.
Control valve dropped and spool piece provided to achieve required extraction capacity based on header back
pressure
New Low pressure drop control valve procurement initiated.
0.18
65.5
Less than 1
day
InvestmentMillion Rs
ImprovementMillion Rs
Payback
Benefits achieved:
~20 MT of HP to LP Let down stopped.
2 MW of additional power could be generated
SAVINGS
6.2 Innovative Projects 02 – Avoiding HP to LP steam Let down benefits.
7. Utilization of Renewable Energy Source
• Solar photovoltaic cell in security watch
tower in remote location.
• Small windmill installed to provide lights to
security cabin
• Solar Operated Traffic Flasher Lights
installed near Refinery Main gate &
Township gate.
• Solar Heater provided at Oil Club.
• Emission free- electrically powered Golf
Carts and Fuel Free- Bicycles are used in the
Refinery.
• Bio gas plant based on canteen food waste.
• Day light harvesting in warehouse.
Oily Sludge reprocessing at Delayed Coker Unit
Reusing 100% Spent Carbon in Captive Power Plant Boilers
Co-processing of Oily Sludge, Oily Cotton Rags, Spent Resin
and Heater Deposits at Cement Industry as Alternate Fuel
Name of the Fuel
2018-19 2019 -20
Quantity of waste Fuel
used(MT/ year)
Energy Saved in terms of Heat Value
(million kcal/year)
Quantity of waste Fuel
used(MT/ year)
Energy Saved in terms of Heat Value
(million kcal/year)
Spent carbon 169 1014Oily Sludge 4503 15760 2489 8711
8.Utilization of waste material as fuel
0 2000 4000 6000 8000 10000 12000 14000 16000
2018-19
2019-20
169
1014
4503
15760.52489.12
8711.92
Energy saved by using waste
Oily Sludge Spent carbon
MKCal/Year.
MT/Year
MKCal/Year.
MT/Year
CO2e (MT) Emissions
KG CO2 / MT of crude processed.
2019-20
308
2018-19
322
2017-18
301
9. GHG Inventorisation
GHG increased in FY 18-19 due to Refinery Turn Around so resulting lower crude T’put
10. Green Belt at NAYARA
Horticulture at Refinery (1064 Acres)
Description Total No.
Green Belt(873.1 Acres)
Mango trees 1,07,137
Pomegranate trees 1,960
Forest Species 1,99,369
Total Plants 3,08,466
Landscape(126.7 Acres)
Refinery Landscape area(m2)
3,77,565
Township ,Meera hostel ,Airport (m2)
1,35,124
Total Landscape 5,12,689
11. Team work, Employee Involvement & Monitoring
Head Technical
Head EnCON
Lead EnCON
EnCON Engineers
ENMS Coordinators
Unit wise
Daily monitoring system • Daily energy performance report.• Performance tracking of Energy intensive equipment.• Online information through dash-board application.
Review meeting chaired by Director and Head of Refinery• Monthly performance review meeting (MPR • Quarterly system review meeting (MRM)
Employee Involvement:• Unit wise members for energy management system co-
ordination on rotating basis.• On line portal for submission of improvement ideas.• Training and encouragement programmes .
Energy efficiency / awareness training program
• Quarterly ENMS 50001:2011 training.
• Brain storming session unit wise and with ENMS co-
ordinator.
12. Implementation of ISO 50001:2011-EnMS
• First certified in 2014• Recertified in 2017• Activities started to migrate to ISO
50001:2018
Refinery Performance Monitoring System (RPMS)
Provide Data Analytics for analysis & troubleshooting of operations
Real-time visibility with Role-based Dashboards with drill-down & detail views
Developed Refinery KPIs for monitoring in real-time
Automation of Excel based all Process Reports
Event driven notifications (SMS/Email) for deviations with escalations
Mobile Apps with self-service data access for refinery performance monitoring
13. Other Innovative technologies implemented
Data Analytics Dashboards KPIs Reports Applications Mobile Apps
Resource Conservation Measures- Within Nayara Premises
2018-2019 – Approximately 1800 Nos. of trees planted in 3 Acre Land
2019-2020 – Approximately 9097 Nos. of trees planted in 8 Acre Land
175 Ha of Mangroves Plantation done in the Marine area.
26
5 Rain-water Harvesting Ponds
Rainwater harvesting in
Sea Water Supply & Return
Reservoirs
Drip Irrigation
Water Conservation Measures- Within Nayara Premises
CSR Focus Areas
Reach and Impact
Focus Area Reach and Impact
Health and Sanitation
Community Health Programme reaching out to more than 60,000 people annually. Project Tushti addressing the problem of malnutrition in Devbhumi Dwarka, bringing the number near zero by 2022. Collection and disposal of garbage in 5 villages, reaching out to more than 20,000 beneficiaries and resulting in visibly
cleaner and healthier surroundings.
Education and Skill
Development
Touching more than 4000 students and 100 teachers through diverse programmes on education, catering to the age group of 6-35 years. The interventions have also resulted in 11 out of 18 schools being brought up to the A grade (as per Gunotsav ratings).
Education Innovation Project reaching out to 2000 teachers across schools in 33 districts of Gujarat. More than 300 Students being trained on soft skills annually in iLabss (Integrated Lab for Soft Skills Development in ITI
Khambhaliya, Devbhumi Dwarka)
Environment Sustainability
Water conservation projects & water distribution programs reaching out to more than 5000 direct and indirect beneficiaries.
Additional water storage capacity of 7.80 MCM created in last 6 years. Water consumption has also been reduced by 2.50 MCM by promoting Micro Irrigation Technique and Soil Moisture Conservation
Sustainable Livelihood
Farm & Non Farm based Livelihood program–Agriculture Development, and Animal Husbandry reaching out to more than 10,000 beneficiaries annually, improving cattle health, breed, and increasing productivity and income among others.
Close to 500 women linked to trainings, financial literacy and skill development through self-help groups, stitching centre.
CSR activity
Source:
Glimpses
Other information- Awards Received in FY 2019-20
SR NO Award Description Organized By Received On
1Nayara Energy Ltd. received Winner trophy in 19thAnnual Greentech Environment Award 2019 from Greentech foundation.
Greentech Foundation 12th Jul 2019
2 Silver Award in allied concept Presentation on Enhance Reliability & Energy Saving in Sea water return pump in QCFI 30th Annual convention
QCFI Vadodara Chapter 07th Sept 2019
3Silver Award in allied concept Presentation on Trouble shooting: High-Pressure Drop in Crude Column in QCFI 30th Annual convention
QCFI Vadodara Chapter 07th Sept 2019
4Silver Award in allied concept Presentation on Slop Optimization at Oil Terminal in QCFI 30th Annual convention
QCFI Vadodara Chapter 07th Sept 2019
5Nayara Energy Ltd. received Certificate for “Noteworthy Project In Water Management Beyond The Fence” Category At National Awards For Excellence In Water Management from CII.
Confederation of Indian Industry (CII)
19th Sept 2019
6Nayara Energy Limited, Vadinar has received prestigious award “Excellent Energy Efficient Unit” for the best performance in 2018-19 at National Energy Efficiency Summit held by CII Hyderabad.
Confederation of Indian Industry (CII)
18th Sept 2019
7Nayara Energy Limited Won “ National Energy Leader ” Award for getting the Excellency award consecutively for the past three years at National Energy Efficiency Summit held by CII Hyderabad.
Confederation of Indian Industry (CII)
18th Sept 2019
Best Practices Implemented on Energy Front
• Involvement of Top Management by putting forward ”Energy” as one of the elements contributing
towards achieving “World Class refinery” tag.
• APC module implemented to optimize the operation in various unit.
• Indirect losses on slop processing, yield loss and product quality giveaway minimized by diligent
Operation.
• Distillation temp, pressure adjustments with changing feed rates /qualities
• Close monitoring of high energy intensive equipment performance, e.g. Furnaces & Boilers, rotating
equipments distillation columns.
• Carrying out a comprehensive Hydrocarbon Loss Audit.
• Online monitoring of all Flare valves to minimize flare loss (Flare Flow transmitters provided last
year) .
• Prepared Energy mapping of each unit.
• Outsourcing steam traps management to minimize steam losses.
Best Practices Implemented on Energy Front
Encouragement/ Information
Idea Generation –MOC Portal
GRM/Energy/
HSEF
ENCON Team
RLT
Thank YouNitinkumar ChokshiGeneral Manager Lead EnCON(M) [email protected]
Bhaskar PhilipVice President -Technical Services, (M) +91 [email protected]
Pranav BhattDGM EnCON(M) [email protected]
