Energy conservation measures taken and additional investment/proposals for conservation of energy:

Being in the business of supplying clean energy to the nation, BPCL is very conscious of its energy conservation activities. Energy conservation has a direct impact on environmental emissions.

Energy conservation efforts receive continuous focus and is one of the key focus areas of BPCL Mumbai Refinery, both in terms of improvement in operations / maintenance as well as development of new projects. Continuous monitoring of energy consumption and hydrocarbon loss is undertaken using sophisticated instruments, periodical audits, global bench marking and data acquisition system. Elaborate and systematic energy accounting and Management information systems are the hallmark of Refinery Operations.

Despite increase in the complexity of operations, Mumbai refinery has achieved significant reduction in fuel and loss in the last few years by incorporation of various energy conservation measures, constant monitoring / tighter control of plant operations & good housekeeping. Energy conservation efforts received continuous focus both in terms of improvement in operation / maintenance as well as development of new projects.

Relentless efforts towards energy conservation on a sustained basis have resulted in significant saving of energy and natural resources. BPCL Mumbai Refinery has a very robust and effective Energy Management System (EnMS) accredited with ISO 50001:2011 certification since 2014 and is one of the first refineries to achieve this landmark certification in India. Now, Mumbai refinery is undergoing recertification & up-gradation of Energy Management System (EnMS) as per new standard i.e. ISO 50001:2018.

The following energy conservation and loss control measures have been implemented which have resulted in significant fuel savings.

• Provision of Divided Wall Column (DWC) in ISOM Unit for steam saving.
• Implementation of Advanced Process Control (APC) in various units of Mumbai Refinery.
• Implementation of Steam leak & Steam traps management in CDU3 /NHGU /HCU /LOBS /DHDS /CCR & FCCU, Utility, Offsite area, CCU, MTBE, RMP SRU, BBU and DHT including associated pipe racks.
• Replacement of 100% Non-flameproof light fittings in Mumbai Refinery with LED fittings for power saving of 2.2 MW.
• Development of renewable energy (Solar) capacity of 1 MW till date and another 0.5 MW generation capacity is planned in near future.
• Implementation of Condensate Recovery System (CRS) in various units of Mumbai Refinery.
• Supply of Hot Lean Amine from RMP Amine Regeneration Unit (ARU) to Hydrocracker Unit (HCU) and Stoppage of Existing Lean Amine LP steam Preheater in Hydrocracker Unit for steam saving.
• Replacement of low efficiency pumps with new low life cycle cost (LLC) pumps for power saving.
• Development of R&D chemical for Furnace tubes cleaning in Crude Distillation Units.
• Recirculation of hot sour water from the Crude Distillation Unit column hot reflux drum as wash water in the overhead exchangers for steam saving.
• Provision of Welded Plate type heat exchanger in Diesel Hydrodesulphurization Unit (DHDS) Amine Recovery Unit (ARU) for steam saving.
• Mumbai Refinery is carrying out Refinery Performance Improvement Program (RPIP) through M/s Boston Consultancy Group (BCG) for implementation of new energy saving measures.
• BPCL Mumbai Refinery has become pioneer in implementation of Electrical Heat Tracing (EHT) in place of steam tracing.
• Comprehensive study on “Nitrogen & air leak survey” to identify leaks.
• Launched Energy champion initiative in the year 2017-18 so as to establish an “Ownership” approach towards energy conservation to have seamless implementation strategy right from “conception” to “completion”.

Digitalization efforts to reduce energy consumption

Model development for online monitoring of Energy parameters/Specific energy Consumption (MBN) using regression modelling

To meet the energy reduction targets, the need is to develop a predictive analytics (i.e. use of regression modeling) based solution that would accurately forecast future energy consumption pattern and help in taking proactive & corrective measures to control energy consumption.

The Key features are:

1. Sensitivity analysis: This unique feature allows user to analyze impact of change in operating parameters with respect to energy consumption
2. Monitor: Provides near real time monitoring of actual energy v/s predicted
3. Benchmarking: Provides comparison against benchmarks based on actual v/s Predicted v/s baseline v/s Design
4. Forecasting: Predicts daily, weekly, monthly and annual energy requirements for better planning
5. Optimize: Enable optimization of process parameters considering process constrains to get desired outputs for decision support.