ITC PSPD (Bhadrachalam) is one of the biggest and renowned paperboard manufacturers in India. The unit has 7 paper and board manufacturing machines powered by its own thermal power plant of total capacity 125 MW with a network of 7 turbines and a battery of 9s boilers, which include 3 no’s Soda recovery boilers and 6 no’s Atmospheric Fluidized bed combustion type coal-fired boilers. The Soda recovery plant is operated with 2 Rotary kilns of 200 and 300 TPH respectively with a lime purity of 79 ± 2.5 as a prime requirement with a firing system of fuel combination 60:40 ratio of producer gas and furnace oil. The producer gas plant is operated with 8 No’s of gasifiers with a capacity of 1400 M3/Hr and coal as an input material. During the process, Coal tar is the byproduct of the producer gas. The outline of the project is to design a heat exchanger to reduce the Tar(Fuel) Viscosity so that it matches the physical properties of conventional fuel (Furnace Oil). This will be helpful in reducing the Furnace oil consumption by 40 percent after substituting furnace oil with Tar. Hence the cost of production is optimized.