Environment and Energy

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

Energy conservation efforts received continuous focus and is one of the key focus areas of BPCL 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.

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 ISO50001:2011 certification and is one of the first refineries to achieve this landmark certification in India.

  1. Sustained operation of heat integrated, energy efficient, state of the art CDU 4 unit throughout the year.
  2. Chemical decontamination technique has been adopted during refinery turnarounds. This resulted in reduction of turnaround duration and also improved heat exchanger cleaning. 
  3. Excellent Hydrogen Management was achieved by processing of hydrogen rich off gas ex CCR, in Hydro-cracker -  PSA and Hydrogen Unit to recover valuable hydrogen from the off gases.
  4. On-line chemical cleaning of furnaces to clean off fouling and deposits on the radiation tubes leading to better heat absorption in radiation section
  5. Use of energy saving LED lamps
  6. Continuous monitoring & control of all parameters of Furnaces, Gas Turbines & Boilers
  7. Continuous recovery of flare gas with the help of FGRS and strict monitoring of process conditions to control flare loss.
  8. Survey of PSV/PCV to identify passing valves and rectification to reduce flare loss. Periodical Survey of Compressed air and Nitrogen leaks and rectification. 
  9. Superior insulation was provided on steam headers to reduce surface heat loss
  10. Availability of a robust “Energy Portal” for on-line monitoring of refinery process Performance and energy consumption, including monitoring of “significant Energy uses”. 
  11. Implementation of Advance Process Control (APC) schemes in proces units. 
  12. Implementation of Advance Process Control (APC) in High Efficiency Boilers (HEB) and “Online Utility Planner and Optimizer”, a first of its kind in the country. 
  13. Implementation of “Steam Trap & Leak Management” project to achieve zero steam leaks in RMP Complex.
  14. Replacement of conventional steam ejector in VDU3 by LRVP arrangement
  15. Installation of Condensate recovery in process plants.
  16. Double Wall Column (DWC) has been commissioned, as part of ISOM unit, to achieve significant reduction in energy consumption.