units, such as the crude and vacuum gas oil hydrotreater, vacuum residue, and crude unit. • Maximising hot stream in the downstream process unit to minimise double energy penalties, reducing the need for cooling through fin fan coolers and heating again via steam heaters or process fuel heaters. • An air preheater for the furnace to preheat the combustion air with hot flue gases exiting the furnace stack. • Scale is crucial, as ensuring a design margin in the size of equipment allows for extended capacity with minimal energy consumption. • Zero effluent discharge at the complex maximises the recycling and reuse of water, especially treated water make-up in cooling towers and cooling tower blowdown recovery. • Condensate recovery system captures high-level steam condensate and flashes it to produce low-level steam. This creates a closed-loop system, where the blowdown and condensate are finally recovered to minimise heat and condensate losses. • High-efficiency trays are installed in many distillation columns to improve mass transfer efficiency and reduce reboiler and condenser duty. Role of ISO 50001 energy management system (EnMS) • Implementation of ISO 50001 across the Jamnagar site. • Energy management policy signed off by top management. • Following the standard and procedure with respect to the energy management system. • Rigorous monitoring of significant energy users. • Deployment of internal and external audits for continuous improvement.
• Dovetailing ISO 50001 from top to bottom with timely review and objective and target fixation. • Plant-wide EnMS coordinator for effective deployment. Implementation of best practices Energy monitoring system • Energy key performance indicators (KPI) monitoring through automated digital dashboards (see Figure 1 ) and management information systems (MIIS) gives a competitive advantage by enabling continuous tracking of energy KPIs. This facilitates proactive and corrective actions to reduce fuel costs effectively. • Furnace efficiency, polytropic efficiency monitoring of turbines and compressors, and flare loss monitoring. • Norms versus actual performance monitoring of steam, power, and fuel variance, along with root cause and corrective action. • Hot and cold streams monitoring of intermediate streams to reduce the double energy penalty for cooling and reheating. • Captive Power Plant (CPP) heat rate and cogeneration efficiency monitoring ensure a lower fuel bill. • Energy real-time optimiser (ERTO) for hourly fuel bill optimisation. Fuel mix and power mix usage, along with renewable power intake, are used to reduce the fuel bill. • Establishing annual energy targets through effective software and thorough preparation for all energy utilities. This includes analysing best- in-class and benchmarked performance to set ambitious targets aimed at reducing operating costs. • Monitoring and tracking fuel usage and losses at each site to proactively take corrective and preventive actions. Salient best practices for monitoring include • Establishing fuel and loss (F&L) targets in the annual operating plan (AOP). • Monitoring and predicting heat exchanger fouling, as well as tracking flow and velocity. • Manufacturing Executive Council review of F&L. • Performing reviews at the cluster president and site president levels.
Figure 1 Energy dashboard
Refining India
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