RAW IDEAS 1 2 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 1 1 1 2 3 4 5 6 7 8 9 Hydrotreater Route VGOHT off gases to FG Operate DHT at lower pressure FCC Utilise FCC fuel

gas at high pressure gainfully Utilise enriched O2 from N2 plant (To FCC?) Review calculation of Coke burnt in FCCU Low coke catalyst in FCCU Better cooling on FCCU overhead COKER Utilise Coker fuel gas at high pressure gainfully Recover Coker blow down gases Review petroleum Coke accounting procedure Better cooling on Coker overhead CRUDE Monitor and control ovaerflash in crude column VDU ejector off gases to furnace Reduce BS & W from desalted crude Minimise steam to diesel stripper Route CDU / VDU sour water in desalter Carry out optimisation of crude preheat exchanger train ATU Two stage stripping of Sour Water for effective removal of NH3 UTILITIES Recover spent caustic stripped gases COMPLEX WIDE Hot air from fin fan coolers to combustion air in furnaces? Use Fuel additives for better energy efficiency Use fire-side chemicals for improving efficiency Improvised FRP blades for CTs & fin fan coolers Utilise GT exhaust gases to furnaces? Glass / Ceramic-coated tubes in back end of APH Segregation of process, HRSG and AB BFW and utilise low temp. BFW for process ? Improve metallurgy and better sealing of isolation dampers to achieve higher air temperatures from APH Direct (1) blending to RRTF & MTF ( 2 ) Routing to MTF and RRTF

9 Steam trap monitoring program 10 Carry out site-wide insulation survey 11 Review reasons for running of standby pumps across the complex. Explore possibility of resizing the impellers to stop the standby pumps. 12 Recover HC from sampling drains 13 Optimise reflux ratio for all columns CPP 1 Offline / Real time optimiser for steam and power 1 MTF Improved on-line sampling of crude for improved monitoring ocean losses RTF 1 2 3 4 5 6 Minimise routing of VR to tank Direct routing of HSD from RTF to MTF, which will reduce inventory by 80 KT leading to savings of Rs 25.0 Cr/Yr Conversion of seal oil pumps to double seal type to reduce losses. Escape of oil through sour water/brine/boot water leg is to be minimised. Provision of condensate recovery in RTF is to be studied De emulsifier injection while unloading the crude tanker, for effective removal of water at MTF itself will reduce slop generation as well as hydrocarbon loss. Pumping out the hold up of large pumps to suction line instead of draining to OWS during maintenance will reduce slop generation as well as hydrocarbon loss. Close monitoring of product blending operations by effective use of hardware & software will lead to savings upto Rs 15 Cr/Yr 2 nos of independent suction & spillback in the VGOHT/FCC feed tanks. as any change in service from Sweet to Sour tank results in a loss of Rs 1 crore

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10 Interconnection of Aromatic tanks for savings in N2 requirement for blanketing 11 Mechanised cleaning/handling of tank bottom sludge will give recovery of oil from sludge. 12 Reducing the product rundown temperature to 35 deg C will reduce the emission loss from the tanks. 13 Provision of sight glass/automatic float type mechanical valve in the siphon drains of white oil products will reduce the hydrocarbon loss from water draining. 14 Changing of high & low levels of Storage tanks for reducing inventory will help in marginal reduction of Inventory 15 Hydrocarbon recovery system from ATF drains. 16 Isolation of steam coils of hot tanks and routing products (RFO & VGO) from unit at 90 deg C leading to savings in 10T/hr of LP Steam. 17 Implementation of LSWR reprocessing line from VGO/Crude TK-18 will lead to increase of the service factor of existing LSWR line by 3 times i.e. Cost of 11 km 10 electrically traced line equivalent to one time savings of Rs 10-15 Cr. Other gains are better VGO mgmt & avoiding loss in throughputs of VGOHT & FCCU. 18 Improving the propylene recovery from LPG in PRU (by about 2%) will lead to savings of Rs 45.0 Cr/Yr 19 Direct routing of PCN,SKO,ATF ,URG & PX to MTF will lead to savings upto Rs 20.0 to 25 Cr/Yr