Kochi Refinery’s commitment to energy conservation has always been at the forefront. Energy management system was recertified in line with ISO 50001:2018 and fully integrated. Energy conservation at Kochi Refinery receives continuous focus both in terms of improvement in operations / maintenance as well as development of new projects. Also, BPCL Kochi Refinery has invested in bringing best in class energy efficiency systems for new projects.

Some of the best measures and practices being adapted for energy reduction are listed below:

• Flare loss reduction Measures:
  • 1. Implementing Advance Process control strategies to the extent possible to avoid flaring
  • 2. Implemented flare gas recovery system for IREP units.
  • 3. Optimum usage and balance of fuel gas in heaters and boilers in Refinery to minimise fuel gas flaring.
  • 4. Conducting Comprehensive PSV/PCV leaks surveys across all units.
  • 5. Minimising flaring during startups and shutdowns by adopting best control strategies and procedures.
  • 6. Daily Monitoring and accounting flare losses.
• Fuel & Loss Reduction measures:
  • 1. Adoption of new technologies / digital interventions
    • Using AI for real time monitoring of Critical equipment’s in Kochi Refinery which provides predictive failure alerts to avert major failure of equipments.
    • Advanced Process Control implementation in all process and petrochemical units.
    • Advanced Process Control implementation in Hydrogen & Fuel Gas management.
  • 2. Adoption of Energy Efficiency Improvements measures at Design Stage
    • Implementation of Power Recovery Expander in the regenerator flue gas system of PFCCU unit.
    • Implementation of hot oil system instead of steam, maximisation of electrical drives in place of steam drives in MSBP unit
  • 3. Steam Reduction:
    • Heating and tracing steam loads reduction through implementation of electrical heat tracing, reducing connected steam header size and rationalization of tank operations.
    • Installation of plate type high efficiency heat exchangers in sour water and amine circuits of SRU-3 for steam reduction.
  • 4. Furnace Efficiency improvement:
    • Efficiency improvement of DHDT Charge heater IGH-101 with extra convection coils and plate type air preheater thereby converting it from forced draft to balance draft.
• Best Practices followed in KR:
  • Maximization of Hot Feed to Process Units
  • Upgrading old systems with energy-saving models (like conventional lighting with LEDs)
  • Improve steam system management to reduce leaks, optimize pressure, monitoring condensate recovery systems
  • Conduct regular energy audits to identify areas for improvement.
  • Carrying out various surveys (Steam, Insulation, PSV/PCV, Air, Nitrogen and Heater efficiency Surveys) for loss reduction
  • Implement a culture of energy awareness among employees with training programs and creation of Energy champions for all units along with monthly follow-up and discussions.
  • Develop and track key performance indicators (KPIs) for energy consumption
  • Regularly benchmark your refinery's energy performance against industry leaders.
  • Comprehensive steam trap management and third-party survey for performance assurance.
• Steps taken for utilizing alternate sources of energy

  Following Solar Power plants were installed.

  • 3.37 MWp Solar plant at Rainwater Harvesting Pond.
  • 6.0 MWp Solar plant at CISF Colony