Annual Report 2008-2009 - Bharat Petroleum

(b) Has Technology been fully absorbed?
Yes.
(c) If not fully absorbed, areas where this has not taken place, reasons therefore and future plans of
action:
Not applicable.
B) KOCHI REFINERY
1. Efforts, in brief, made towards technology absorption, adaptation and innovation
The Refinery has implemented the following projects to obtain the benefits of the latest technological developments
and advances during 2008-09:
a) Naphtha Stabilizer reboiler:
The Naphtha Stabilizer reboiler in CDU-1 was converted to a steam type reboiler (more efficient than the
current fired heater type reboiler) during December 2008. The reboiler was designed by M/s EIL.
b) Coke Catcher in Vis-Breaker Unit:
A coke catcher was installed in VBU during November/December 2008 to reduce the deposition of coke in
the Vis-breaker fractionator. Modification carried out in-house with technology support from M/s. Shell Global
Solutions.
c) Treatment of overhead gases from the Crude column and KHDS product separator:
Facilities for treating Crude Unit overhead gases and KHDS product separator gases by scrubbing with
Di Ethanol Amine for removing H 2
S, was commissioned in March 2009.
d) Introduction of Auxiliary Firing in CO boiler:
Due to operation of FCCU in full combustion mode after revamp, CO boiler steam output had come down
from 80 TPH to about 40 TPH. By introducing/increasing auxiliary firing in waste heat boilers, almost 100%
additional energy spent can be recovered as useful output. With auxiliary firing, stack losses remain more
or less constant and overall efficiency of the system improved considerably. As fuel gas was not adequately
available, the CO boiler fuel oil firing system was revamped with new fuel oil heater and replacement of two
burners. Steam output from the CO boiler was increased from 40 TPH to 60 TPH.
e) Swapping of stripping steam in CDU-1 and FCCU from MP to LP steam
Stripping steam in crude column and product strippers in CDU-1 and FCCU have been changed over to
LP steam from MP steam, by laying a dedicated LP steam header from LP steam extraction line of Steam
Turbine Generator (STG). Dedicated LP steam header ensures required super heat for the steam admitted to
strippers.
2) Benefits derived as a result of the above efforts, e.g. product improvement, cost reduction, product
development, import substitution, etc.
a) Naphtha Stabilizer reboiler:
Replacement of fired heater with new steam Naphtha reboiler in CDU-1 reduces the fuel cost due to better
efficiency of boilers than the existing heater.
b) Coke Catcher in Vis-Breaker Unit:
A coke catcher was installed in the bottom portion of the vis-breaker fractionator. This has resulted in the
reduction of plugging of heavy materials in the heat exchangers, which are installed in the fractionator bottom
circuit exchanging with crude. The project was commissioned during November/December 2008.
c) Treatment of overhead gases from the Crude column and KHDS product separator:
Amine absorbers were installed in the Crude column overhead gas accumulator overhead circuit and KHDS
product separator off gases to utilize the gases as fuel gas directly in the fired heaters. This reduces the load
in the main Amine Absorption Unit (AAU), thereby increasing its efficiency.
44 Bharat Petroleum Corporation Limited