Bharat Petroleum: Mumbai Refinery Energy Conservation

The following energy conservation and loss controlmeasures have resulted in significant fuel savings at the BPCL Mumbai Refinery:

Maximisation of Crude throughput in modern highly energy efficient integrated Crude & Vacuum Unit
Anti-Foulant chemical injection in all Crude & Vacuum units
Injection of fire side chemical additive in HVU heater
Regular cleaning of preheat exchangers of process units
High emissivity ceramic coating was applied in process tubes and refractory walls of CRU Inter 1 & 2 furnaces resulting in 3% fuel savings
Reduction of slops generation by tighter operational control
Reduction of Hydrogen loss to flare from Make Up Gas Compressor (MUG) section of Hydrocracker Unit by resetting of set point of control valve
RGC seal gas drain pot vent modification from flare to RGC suction in Hydrocracker resulting in reduction of 2 T/D of H2 to flare
Provision of still well sleeve assembly for 15 MS & Naphtha tanks to reduce evaporation losses
Continuous monitoring & control of all parameters of furnaces & boilers
Continuous monitoring & control of flare
Regular steam insulation & steam leak surveys and repairs
Replacement of leaky steam traps & regular attending to steam leaks

A comprehensive "Steam Generation and Distribution Study" was carried out by M/s. Tata Consulting Engineers. Phase wise replacement of steam headers insulation has commenced.
Phased implementation of recommendations of the Slops system study in the refinery conducted by M/s. Engineers India Ltd., to minimize slops generation is under progress.
A comprehensive survey on "Instrument Air Supply System" was carried out to identify instrument air leaks and the recommendations are being implemented.
Further efforts to maximize crude throughput of the highly energy efficient CDU/VDU complex including revamp of the unit is being studied.
Installation of Step-less control for MUG compressor of Hydrocracker unit is under implementation.
Feasibility of Flare Gas Recovery System is being evaluated.