“Carbon Foot Prints in Refineries”

14.12.2013

By Supriya Sapre,

Bharat Petroleum Corporation Limited

Mumbai Refinery (MR)

Agenda

• BPCL MR an overview

• Classification of GHG Emission sources

• Carbon Footprint Baseline-line at BPCL MR

• Learnings

• Path Forward

3.8

0

1

2

3

4

5

6

7

8

9

10

11

12

13

1976

1.0

78-83

1.1

83-88

1.0

88-93

0.6

93-98

1.3

98-03

1.5

’05-06

1.7

’06-07

1.0

13.1

‘07-13

12.0mmta

BPCL Mumbai Refinery overview

BPCL Mumbai Refinery overview

1955-76

Crude unit

Cracking unit

Bitumen unit

Vacuum unit -I

Platformer unit

3 No. Boilers

Solvent unit

7 units

2006 onwardsCrude unit

Cracking unit –I revamped

Bitumen unit-revamped

Vacuum unit-I

Reformer unit-revamped

3 No. Boilers-revamped

New solvent unit

Cracking unit – II -revamped

High Vacuum unit-revamped

Aromatics unit -revamped

Amine treating unit – I & II

New Sulfur recovery unit - I & II

MTBE

Crude unit – II & III

Vacuum unit - III

DHDS unit - revamped

Hydrocracker - revamped

NHDS

Captive Power Plant - (3)

HGU – I & II

LOBS

CCG Splitter

25 units

Capacity expansions

Technology up gradation

Value added products

Product quality / environment

Capacity expansions

Technology up gradation

Value added products

Product quality / environment

1990

Crude unit-revamped

Cracking unit

Bitumen Unit

Vacuum unit-I revamped

Aromatics unit-revamped

3 No. Boilers

Crude Unit II

New solvent unit

Cracking unit – II

High Vacuum unit

Amine treating unit - I

Sulfur recovery unit

12 units

BPCL Mumbai Refinery overview

ISO 90011996 Quality Management

ISRS Level 81997

ISO 140011998

ISO 170252003

OHSAS 180012007

Shell benchmarking2004

Six Sigma2006

World Class Safety

Focusing on Environment

Laboratory competency

ProcessManagement

IdentifyingImprovement opportunities

Occupationalhealth & Safety

RBNQA 2007-12

Solomon benchmarking2010

Shell RPIP/ BPMAI 2011-12

What is the connection between Energy and

Carbon Dioxide?

=Energy Use

HFCs, PFCs &SF6

N2O

CH4

CO2

Burning of fossil fuels

Carbon footprint (FP): is “the total set of GHG

(greenhouse gas) emissions caused directly and

indirectly by an individual, organization, event

or product”

Global Warming

GHG by type of Gas

Total GHG=1771.6 mmtpa

CO2 70.8%

CH4 22.54%

N2O 5.1%

HFCs 1.5%

GHG Sectoral Distribution

Total GHG= 1771.6 mmtpa

Energy

71%

Agriculture

19%

Industry

7%

Waste 3%

India GHG Emission 2007

Agenda

• BPCL MR an overview

• Classification of GHG Emission sources

• Carbon Footprint Baseline-line at BPCL MR

• Learnings

• Path Forward

Classification of GHG Emission Sources

• Petroleum Refineries with varying

complexities consume 6 to 10% of their

crude thruput as fuel, and generate 20 to

30 % CO2

Classification of GHG Emission Sources

• Emissions may be classified as:

– Scope-1 Direct Emissions from sources

that are owned or controlled by the refinery

– Scope-2 Emissions from off site

generation of electricity, steam for on-site

requirement of power, utilities

– Scope-3 Indirect Emissions includes

emissions from sources not owned or directly

controlled, but are related to the activities of the

refinery

Classification of GHG Emission Sources

Category Scope-1 Example of Sources

Combustion Devices

Stationary Sources Boilers , Heaters, Furnaces, Power and Utilities, flares,

Incinerators, thermal/catalytic oxidizers, consumption of

LPG, Biogas plant in canteen

Mobile Sources Company Vehicles

Vented Sources

Process Vents Reactors, distillation columns, absorbers, strippers , mixing

tanks

Other Venting Storage tanks, gas-driven pneumatic devices, loading

racks, loading operations

Maintenance/

turnarounds

Vessel Depressurizing, Equipment Cleaning

Activities Non-

routine

Discharges from Pressure relief Valves and other

emergency shut-down devices

Fugitive Sources Leaks from valves, flanges, pumps, compressor seals

Other Non-point sources Wastewater treatment, waste handling operations

Classification of GHG Emission Sources

Category Scope-2 Example of Sources

Indirect Emissions Import of power and utilities

Category Scope-3 Example of Sources

Mobile Sources Import of raw material, ie crude oil via ships/vessels,

Transportation of finished product via rail, road and

coastally, receipt of other essential materials, travel of

workmen to workplace, business travel etc.

Agenda

• BPCL MR an overview

• Classification of GHG Emission sources

• Carbon Footprint Baseline-line at BPCL MR

• Learnings

• Path Forward

GHG Emission Estimation methods

• API Compendium of Greenhouse gasemissions methodologies for the oil and gasindustry -2009

• ISO 14064 -1

• Central Pollution Control Board (CPCB) reporton vehicular emissions factors

• Central Electricity Authority: CO2 Baselinedatabase

• GHG protocol and IPCC guidelines

GHG Emission Estimation methods

BPCL MR GHG emission estimation using

• Laboratory analysis

• Fossil fuel consumption data

• IPCC emission factors

• Central Pollution Control Board (CPCB) report

on vehicular emissions factors

• Central Electricity Authority: CO2 Baseline

database

• WRI factors

Sample Calculation of GHG

Scope-1, Stationary combustion

• IPCC guidelines for tier-1 used

• Steady optimal conditions assumed

• Oxidation factor for carbon assumed to be unity

• Calculating GHG emission for 259.5 TMT of Fuel oil consumed

tCO2 825061 99.7%

tCH4 equivalent to tCO2 672 0.08%

tN2O equivalent to tCO2 1860 0.22%

tCO2e 827593 100%

Sample Calculation of GHG

Scope-1, Stationary combustion

Year 2011-12 BASIS VALUES

Fuel Type LSHS

X10 6 Kgs A 259.5 Metered

NCV

Kcal/Kgs

B 9817.6 Tested at BPCL MR laboratory

CO2 Kg/TJ C 77400 IPCC Guidelines table 2.2

CH4 Kg/TJ D 3 IPCC Guidelines table 2.2

N2O Kg/TJ E 0.6 IPCC Guidelines table 2.2

tCO2 F A*B*4.184/1E9*C/1

000

Calculated 825061

tCH4 G A*B*4.184/1E9*D/1

000

Calculated 32

tN2O H A*B*4.184/1E9*E/10

00

Calculated 6

tCO2e F+21*G+310*H GWP100 of CH4 and N2O as

compared to CO2

827716

Sample Calculation of GHG

Scope-3, Transportation of crude oil

• Freight transport factor as per WRI table 13

used.

A Amount of material

transportedShort Ton

Miles55660836750

BEmission factor of this

transportation

kgCO2/Short

Ton Miles0.048

Emission reported tCO2 A*B/1000

2671720.164

Summary of Emissions

Category Particulars tCO2

Scope-1Direct Fuel Consumption (Thermal &

Electrical)2057096

Gas Flaring 3279.2

Biogas generation from waste treatment 52.88

LPG consumption in Canteen 252.74

COMPANY TRANSPORT 1235.1

Total refill value in "CO2 fire extinguishers" 1.794

In-plant vehicular movement 0.006

Scope-1 Total 2061918

Scope -1 emissions from BPCL MR: 2.0 million tCO2

Summary of Emissions

Category Particulars tCO2

Scope-2 Electricity Purchased 19486.8

Scope-3 OWN TRANSPORT 795.2

Employee Business Travel 734.85

Inbound Logistics - Ship 2671720.1

Outbound Logistics - Road 23476.9

Outbound Logistics - Ship 2135.5

Scope-3 Total 2698862.5

Scope -3 emissions from BPCL MR: 2.7 million tCO2

Summary of Emissions

BPCL MR 2011-12

Scope-1 Direct Emissions (TMT CO2e) 2061.92

Scope-2 Emissions thru imported power

(TMT CO2e)

19.48

Total GHG inventory (TMT CO2e) 2081.4

Total GHG inventory in MMT CO2e 2.081

Refinery Thruput for 2011-12 in MMT 13.355

GHG Footprint in MT CO2e/MT of Crude

processed

0.158

GHG Footprint in MT CO2e/Barrel of Crude

processed

0.0214

GHG Footprint in MT CO2e/MT of Crude/NRGF 0.0252

Carbon Footprint Management

Existing strategies

• Cleaner Fuels

• Efficient technologies

• Facilities for furnaces

• Flare management

• VOC Control from storage tanks

• LDAR

• Benzene Vapour recovery Unit

• Product transportation via pipelines

RLNG SKID

Innovative Energy Conservation Initiatives

• GT-3 Uprate

• Steam trap management

• Steam management in Hydrogen Generation Unit

• Vacuum Unit ejector sequencing for steam optimization

• Injection of crude antifoulant

• Reflux optimization in vacuum column

• Monitoring of energy parameters in BPMAI

Saving of 4906 MT of Fuel in 2011-12,

& 3626 MT in 2012-13

Agenda

• BPCL MR an overview

• Classification of GHG Emission sources

• Carbon Footprint Baseline-line at BPCL MR

• Learnings

• Path Forward

Learnings

• Transportation of raw material, ie crude oil at

BPCL MR contributes to GHG emissions

equivalent to entire scope-1&2 for refinery

processing

2.06

0.02

2.70

Million tCO2e

Scope-1

Scope-2

Part Scope-3

Learnings

8%

21%

22%15%

34%

Breakup of Direct Emissions

Steam

Power

Hydrogen Generation

Coke

Others

• Power and Steam generation constitute

almost one third of the total emissions

from refinery direct fuel consumption

Learnings

43%

2%

12%

1%

23%

15%

4%Emission from individual fuels

LSHS(Residual fuel oil)

BHGO (Gas oil)

FUEL GAS (Refinery Gas)

BHAG (NG from Uran)

RLNG

COKE

PSA OFF GAS

• Fuel oil consumption contributes 43% of emissions from refinery direct fuel consumption

• Emissions from different fuels depend on its composition(molecular wt, calorific value)

Learnings

• GHG emission can be used to compare

performance of refineries wrt

– Absolute value of emission/MT of crude

processed

– Absolute value of emission/bbl of crude processed

– Emissions based of complexicity of configuration

– Solomons CEI

Learnings

• Refinery fuels can be compared for tons of emissions per ton of fuel consumed.

• Emission factors are dependent on composition affecting accuracy of estimation.

Fuel tCO2/MT % Reduction in tCO2 over FO(Base)

Refinery Fuel oil 3.19 0.0%

Refinery Fuel Gas 2.72 14.7%

LNG 2.70 15.4%

H2 Rich refinery gas 0.67 79.0%

Path Forward

• Carbon management thru innovative, energy efficient technical improvements

• Supply chain strategies for low emissions

• Include climate change reduction targets as part of Sustainability, and Business plan

– Flare gas recovery

– Renewable solar energy at MR

– Steam trap management

– GT Uprate

• Efforts for increasing of green belt, which acts as GHG sink

Rank Country Year Total[1]Hydroelectrici

ty[2]

Wind

Powe

r[3]

Biomass

and

Waste[4]

Solar[5]

Geothe

rmal[6]

1 China 2011 797.4 687.1 73.2 34 3

European

Union[7]2010 699.3 397.7 149.1 123.3 23.1 5.6

2United

States2011 520.1 325.1 119.7 56.7 1.81 17.0

3 Brazil 2011 459.2 424.3 2.71 32.2 0.0002

4 Canada 2011 399.1 372.6 19.7 6.4 0.43

5 Russia 2010 166.6 163.3 0.004 2.8 0 0.47

6 India 2011 162 131 26 4 1

7 Germany 2012 136.1 21.2 45.3 40.9 28.0 0.03

8 Norway 2011 121.4 119.6 1.29 0.48 0.02

9 Japan 2011 116.4 82.5 4.35 23.1 3.80 2.89

10 Italy 2012 89.759 43.25613.33

3

9.281

(2010)[8]18.637 5.252

World top 10 renewable electricity producers[edit]Measurements are in TW·h/year (terawatt-hours per year), equal to 1 billion Kilowatt-hours per year.

thousanf of

tons % of worlds

Rank World 29,888,121 100%

1 China (ex.Macau, Hong

Kong,) 7,031,916 23.50%

2 United States 5,461,014 18.27%

3 European Union (27) 4,177,817 13.98%

4 India 1,742,698 5.83%

5 Russia 1,708,653 5.72%

6Japan 1,208,163 4.04%

7 Germany 786,660 2.63%

8 Canada 544,091 1.82%

9 Iran 538,404 1.80%