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The Bharath Petroleum Corporation Limited (BPCL) Kochi Refinery, was commissioned in the year 1966 with a capacity of 50,000 barrels per day. Kochin Refinery was originally established as a joint venture in collaboration with Phillips Petroleum Corporation USA. The refinery serves as a front line entity as a unit of the Fortune 500 Oil and Gas Maharatna Bharat Petroleum Corporation Limited with a capacity of 3,10,000 barrels per day.

BPCL KR has decided to Revamp the efficiency of the following units

These heaters have high stack temperatures and BPCL intents to recover this heat energy. Therefore, to study the potential for efficiency improvement in these four existing furnace, BPCL assigned iFluids Engineering to conduct “Feasibility Study for efficiency improvement of process furnace”


The scope of work includes:


Codes & StandardsTitle
API 560Fired Heaters for General Refinery Service, Fifth Edition, February 2016.
API 530Calculation of heater tube thickness in Petroleum Refineries, 7th Edition, April 2015.
EDRExchanger Design and Rating
HTRIHeat Transfer Research Inc.
OISD118Layouts for Oil and Gas Installations, July 2008
TEMATubular Exchanger Manufacturers Association


  1. Data collection was carried out through drawings, documents and mails for details with regard to the furnace. The collected data was analyzed and the existing furnace efficiency was evaluated.
  2. Different options to improve efficiency identified. The thermal efficiency estimated and other key aspects such as instrumentation, civil and structural works, fuel savings, etc noted. The unit layout seen for additional space availability.
  3. Each option discussed as required with vendors for equipment sized to determine the total capital cost for each option
  4. Each option analyzed further including the operating cost based on its technical and commercial merits and identify the payback period to make the recommendation.


The project duration was 4 months.


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