13/11/2009 slide number- 1 delivering excellence through people identifying potential - in offsites...

13/11/2009Slide Number- 1

Delivering excellence through people

IDENTIFYING POTENTIAL - IN OFFSITES AND UTILITIES INCLUDING STEAM & POWER

Dr S BANIKand

Mr A K VOHRA

ENGINEERS INDIA LTD

“WORKSHOP ON ENERGY MANAGEMENT & EFFICIENCY IMPROVEMENT IN OIL & GAS SECTOR”

13TH NOV., 2009, DELHI

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE

13/11/2009Slide Number - 2

Engineers India Ltd – Delivering excellence through people

REFINING CHALLENGESREFINING CHALLENGES UTILITIES & OFFSITE GROUP OF PLANTSUTILITIES & OFFSITE GROUP OF PLANTS STEAM SYSTEMSTEAM SYSTEM STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIESSTEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES POWER SYSTEMPOWER SYSTEM POWER SYSTEM ENERGY CONSERVATION OPPORTUNITIESPOWER SYSTEM ENERGY CONSERVATION OPPORTUNITIES COMBINED STEAM & POWER NETWORK OPTIMIZATIONCOMBINED STEAM & POWER NETWORK OPTIMIZATION

HEAT RECOVERY & CHPHEAT RECOVERY & CHP SMR & COGEN INTEGRATIONSMR & COGEN INTEGRATION

UTILITIES SAVING THROUGH REFINERY & PETROCHEMICAL UTILITIES SAVING THROUGH REFINERY & PETROCHEMICAL INTEGRATIONINTEGRATION

HYDROGEN SYSTEM & HYDROGEN CONSUMPTION HYDROGEN SYSTEM & HYDROGEN CONSUMPTION OPTIMIZATIONOPTIMIZATION

CONCLUSIONCONCLUSION

CONTENTSCONTENTS




REFINING CHALLENGES

Distillate Yield Improvements Fuel Quality Up-gradation Optimize Energy Performance Strict Environmental Norms Maximize Margins

Process High Sulfur Crudes Process High TAN/ Heavy Crudes

Synergy- Refinery and Petrochemical




Energy Performance Challenge

REFINERY CONSUMES ABOUT 7 – 8% OF THE CRUDE PROCESSED AS FUEL

REFINERIES ARE CONTINUOUSLY MAKING EFFORTS TO BRING REFINERIES ARE CONTINUOUSLY MAKING EFFORTS TO BRING DOWN THE ENERGY CONSUMPTIONS DOWN THE ENERGY CONSUMPTIONS

SPECIFIC FUEL CONSUMPTION HAS REDUCED BY ABOUT 20% -FROM 89.0 TO 71.0 MMBTU/BBL/NRGF , OVER THE LAST 8-10 YEARS

FUEL COST CONTRIBUTES 40-45%

TOWARDS THE COST OF REFINERY OPERATION 30-40% OF THE FUEL COST IS ATTRIBUTED TO GENERATION

OF UTILITIES LIKE STEAM / POWER FOCUS IS NOW ON ‘ UTILITIES’ CONSERVATION




UTILITIES & OFFSITE SYSTEMUTILITIES & OFFSITE SYSTEM

UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF:UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF: BOILERSBOILERS STEAM TURBINE GENERATORSSTEAM TURBINE GENERATORS GAS TURBINE GENERATORS / HEAT RECOVERY STEAM GAS TURBINE GENERATORS / HEAT RECOVERY STEAM

GENERATORSGENERATORS HYDROGEN GENERATION UNITHYDROGEN GENERATION UNIT NITROGEN GENERATION UNITNITROGEN GENERATION UNIT COOLING TOWERSCOOLING TOWERS INSTRUMENT AIR SYSTEMINSTRUMENT AIR SYSTEM WATER TREATMENT UNITSWATER TREATMENT UNITS

STEAM & POWER CONSUME BULK OF THE ENERGY IN STEAM & POWER CONSUME BULK OF THE ENERGY IN OFFSITE & UTILITIES SYSTEMOFFSITE & UTILITIES SYSTEM




REFINERY STEAM SYSTEMREFINERY STEAM SYSTEM

STEAM GENERATIONSTEAM GENERATION STAND ALONE BOILERSSTAND ALONE BOILERS HEAT RECOVERY STEAM GENERATORSHEAT RECOVERY STEAM GENERATORS PROCESS WASTE HEAT BOILERSPROCESS WASTE HEAT BOILERS WASTE HEAT FROM SMRWASTE HEAT FROM SMR

STEAM DISTRIBUTIONSTEAM DISTRIBUTION RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS & RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS &

TURBINE EXHAUSTTURBINE EXHAUST NORMALLY STEAM IS DISTRIBUTED AT 3 – 4 PRESSURE LEVELSNORMALLY STEAM IS DISTRIBUTED AT 3 – 4 PRESSURE LEVELS

END USEEND USE PROCESS STREAM HEATINGPROCESS STREAM HEATING AS A SOURCE OF WATER ( HYDROGEN GENERATION )AS A SOURCE OF WATER ( HYDROGEN GENERATION ) COMPONENT SEPARATIONCOMPONENT SEPARATION SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. )SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. )

RECOVERYRECOVERY CONDENSATE RECOVERYCONDENSATE RECOVERY




STEAM GENERATIONSTEAM GENERATION AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF

RELIABILTY OF STEAM SUPPLY)RELIABILTY OF STEAM SUPPLY) LEADS TO GENERATION OF EXTRA STEAM WHICH IS FINALLY LEADS TO GENERATION OF EXTRA STEAM WHICH IS FINALLY

CONDENSED IN COOLRS AND CONDENSATE IS RECYCLEDCONDENSED IN COOLRS AND CONDENSATE IS RECYCLED PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN

EFFICIENCY OF ~ 85 – 86%.EFFICIENCY OF ~ 85 – 86%. EFFICIENCY CAN BE IMPROVED TO +90%EFFICIENCY CAN BE IMPROVED TO +90% AVAILABILTY OF SPACE COULD BE A LIMITATIONAVAILABILTY OF SPACE COULD BE A LIMITATION

LOW EXCESS AIR BURNERSLOW EXCESS AIR BURNERS WILL REDUCE STACK LOSS AND FUEL WILL REDUCE STACK LOSS AND FUEL

USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE RUN ON PART LOAD FOR RELIABILTYRUN ON PART LOAD FOR RELIABILTY

BOILER FEED-WATER PUMPSBOILER FEED-WATER PUMPS BLOWERSBLOWERS

REFINERY STEAM SYSTEM – ENERGY REFINERY STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIESCONSERVATION OPPORTUNITIES




IMPROVE WATER TREATMENT TO MINIMIZE IMPROVE WATER TREATMENT TO MINIMIZE BOILER BLOW DOWNBOILER BLOW DOWN

RECOVER ENERGY FROM BOILER BLOW DOWNRECOVER ENERGY FROM BOILER BLOW DOWN

OPTIMIZE DEAERATOR VENT RATE TO MINIMIZE OPTIMIZE DEAERATOR VENT RATE TO MINIMIZE AVOIDABLE LOSSAVOIDABLE LOSS

MAINTAIN REFRACTORY IN GOOD CONDITION TO MAINTAIN REFRACTORY IN GOOD CONDITION TO REDUCE SURFACE LOSSREDUCE SURFACE LOSS

STEAM SYSTEM – ENERGY CONSERVATION STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIESOPPORTUNITIES




IMPROVE STEAM DISTRIBUTION SYSTEMIMPROVE STEAM DISTRIBUTION SYSTEM AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATIONAVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION

IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & MAINTENANCE PROGRAMMAINTENANCE PROGRAM

LEAKING TRAPS SHOULD NOT EXCEED 5% OF THE TRAPS LEAKING TRAPS SHOULD NOT EXCEED 5% OF THE TRAPS FAULTY TRAP WITH 1/8 INCH ORIFICE INSTALLED ON 6.5 KG/CMFAULTY TRAP WITH 1/8 INCH ORIFICE INSTALLED ON 6.5 KG/CM22G LINE G LINE

MAY CAUSE STEAM LOSS OF 300 TPAMAY CAUSE STEAM LOSS OF 300 TPA RECOMMENDED STEAM TRAP SURVEY RECOMMENDED STEAM TRAP SURVEY

UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVsUTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs


STEAM LINE PRESSURE, KG/CM2G TRAP TESTING FREQ.

10.0 KG/CM2G AND ABOVE WEEKLY TO MONTHLY

2.0 TO 10.0 KG/CM2G MONTHLY TO QUARTERLY

< 2.0 KG/CM2G ANNUALLY




END USE IMPROVEMENTSEND USE IMPROVEMENTS REQUIRES CASE BY CASE ASSESSMENTREQUIRES CASE BY CASE ASSESSMENT

RUNNING SINGLE TURBINE DRIVEN PUMP / BLOWERRUNNING SINGLE TURBINE DRIVEN PUMP / BLOWER TWO TURBINE DRIVEN 495 KW AIR BLOWERS WERE RUN TWO TURBINE DRIVEN 495 KW AIR BLOWERS WERE RUN

IN SRU UNIT INSTEAD OF ONE AT PART LOAD OF 250 KW .IN SRU UNIT INSTEAD OF ONE AT PART LOAD OF 250 KW .

OPTIMIZATION OF STRIPPING STEAMOPTIMIZATION OF STRIPPING STEAM MINIMIZE DEAERATOR VENT STEAMMINIMIZE DEAERATOR VENT STEAM CONDENSATE RECOVERY SYSTEMCONDENSATE RECOVERY SYSTEM


LOAD, KW STEAM R ATE, KG/KW-HR

STEAM CONSUMPTION, TPH

LOSS, TPH

495 48.8 24.0

250 63.08 15.0 6.0




POWER SYSTEMS

CO-GENERATION OR COMBINED HEAT AND POWER PLANTS ARE WIDELY EMPLOYED FOR PRODUCTION OF POWER & HEAT ( STEAM ) IN REFINERIES AND PETROCHEMICAL PLANTS 30% PLUS MORE EFFICIENT THAN SEPARATE PRODUCTION EQUIPMENTS WITH VARYING POWER TO HEAT RATIO ARE

AVAILABLE

Cogeneration System Heat – to – power ratio ( KWth/KWe )

Power Output ( as% of fuel input )

Overall Efficiency, %

Back Pressure Turbine 4.0 – 14.3 14 - 28 84 - 92

Extraction Condensing Steam Turbine

2.0 – 10.0 22 - 40 60 - 80

Gas Turbine 1.0 – 2.0 24 - 35 70 - 85

Combined Cycle 1.0 – 1.7 34 -40 69 - 83




GAS TURBINES GENERATORSGAS TURBINES GENERATORS A PREFERRED CHOICE OVER STEAM TURBINE BASED A PREFERRED CHOICE OVER STEAM TURBINE BASED

POWER GENRATING SYSTEMSPOWER GENRATING SYSTEMS LOWER CAPITAL COSTLOWER CAPITAL COST MODULAR DESIGN – SHORTER INSTALLATION TIMEMODULAR DESIGN – SHORTER INSTALLATION TIME QUICK TO STARTQUICK TO START HIGH EFFICIENCYHIGH EFFICIENCY LOWER EMISSIONSLOWER EMISSIONS

USED IN COMBINATION WITH HEAT RECOVERY STEAM USED IN COMBINATION WITH HEAT RECOVERY STEAM GENERATOR (HRSG)GENERATOR (HRSG)

STEAM PRODUCED IN HRSG CAN BE USED TO MEET SITE STEAM PRODUCED IN HRSG CAN BE USED TO MEET SITE HEATING REQUIREMENT OF FOR POWER GENERATION HEATING REQUIREMENT OF FOR POWER GENERATION THROUGH STGTHROUGH STG

POWER GENERATION




COOLING OF INLET AIRCOOLING OF INLET AIR LOW COST AND LOW PAYBACK PERIODLOW COST AND LOW PAYBACK PERIOD EASY TO INSTALLEASY TO INSTALL CHANGES ARE EXTERNAL TO GAS TURBINECHANGES ARE EXTERNAL TO GAS TURBINE OVER 700 WORLDWIDE INSTALLATIONSOVER 700 WORLDWIDE INSTALLATIONS

SUCH A SYSTEM IS WORKING SATISFACTORILY IN A MEGA SUCH A SYSTEM IS WORKING SATISFACTORILY IN A MEGA REFINERY IN THE COUNTRYREFINERY IN THE COUNTRY

METHODOLOGY COMMONLY APPLIEDMETHODOLOGY COMMONLY APPLIED EVAPORATIVEEVAPORATIVE

FOGGING / WET COMPRESSIONFOGGING / WET COMPRESSION DROPLET SIZE 25 -35 MICRONS, VERY HIGH PRESSURE PUMP : 100 DROPLET SIZE 25 -35 MICRONS, VERY HIGH PRESSURE PUMP : 100

– 150 BAR– 150 BAR

CHILLERSCHILLERS MECHANICAL / ABSORPTIONMECHANICAL / ABSORPTION

LOW LEVEL RECOVERED HEAT CAN BE GAINFULLY UTILIZEDLOW LEVEL RECOVERED HEAT CAN BE GAINFULLY UTILIZED OFFERS BETTER CONTROL OF TEMPERATUREOFFERS BETTER CONTROL OF TEMPERATURE APPROX. 3 TIMES COSTLY THAN FOGGING SYSTEMAPPROX. 3 TIMES COSTLY THAN FOGGING SYSTEM

POWER SYSTEM PERFORMANCE IMPROVEMENTPOWER SYSTEM PERFORMANCE IMPROVEMENT




Efficient Heat Recovery-Gas Turbine ExhaustEfficient Heat Recovery-Gas Turbine Exhaust

CHP MODELING & OPTIMISATION24/05/2007

Slide Number - 15Engineers India Ltd – Delivering excellence through people

Refinery With HRU/HRSGRefinery With HRU/HRSG



Impact of HRU/HRSG On EIIImpact of HRU/HRSG On EII




COMBINED HEAT AND POWER SYSTEMCOMBINED HEAT AND POWER SYSTEM




COMBINED HEAT & POWER NETWORK

POWER GENERATION GAS TURBINE GENERATOR STEAM TURBINE GENERATOR

POWER DEMAND IS LINKED TO PLANT THROUGHPUT AND AFFECTS STEAM GENERATION

STEAM GENERATION UTILITIES BOILERS ( GENERATION LINKED TO PLANT THROUGHPUT AND POWER

OUTPUT FROM STG / GTG) HRSG ( STEAM GENERATION LINKED TO POWER OUTPUT ) WASTE HEAT RECOVERY STEAM GENERATION AT 2 TO 3 PRESSURE /

TEMPERATURE LEVELS GNERATION LINKED TO PLANT LOAD AND FEED QUALITY

HIGH H2S CONTENT IN ACID GAS WILL GENERATE MORE STEAM IN WHB

PRDS FOR MAINTAING STEAM PRESSURE AT DIFFERENT LEVELS STEAM CONSUMPTION

3 TO 4 PRESSURE / TEMPERATURE LEVELS BPT WITH INLET STEAM AND EXHAUST STEAM AT 2 OR MORE PRESSURE

LEVELS




COMBINED HEAT & POWER NETWORK

CONDENSATE RECOVERY SYSTEM CONDENSATE FLASH DRUMS OPEATING AT VARIOUS PRESSURE /

TEMPERATURE LEVEL VENT STEAM CONDENSER

AFFECTS DM WATER REQUIREMENT PROVIDES HEAT FOR HEATING DM WATER GOING TO DEAERATOR

DE-AERATOR STEAM CONSUMPTION LINKED TO BFW REQUIREMENT AND ITS

TEMPERATURE

HEAT AND POWER NETWORK OF A REFINERY IS COMPLEX

STEAM AND POWER GENERATION AND CONSUMPTION ARE INTELINKED NETWORK MODELING / SIMULATION PROGRAM SHALL BE USEFULL IN

OPTIMIZING THE STEAM AND POWER GENERATION TO MINIMIZE FUEL COST

MODELS ARE SITE SPECIFIC AND ARE DEVELOPED FROM THE OPERATING DATA USING NON-LINEAR REGRESSION METHODS




SIMULATION PROGRAM MULTIVARIABLE EQUATION -SETS FOR MASS & ENERGY

BALANCE FOR EACH SUBSYSTEM ARE DEVELOPED MODEL INPUTS

GAS TURBINE : AMBIENT AIR TEMP., POWER OUT PUT, HEAT RATE, FUEL CONSUMPTION

BOILERS : STEAM GENERATION AND FUEL CONSUMPTION

HRSG : FUEL CONSUMED IN GTG, AMBIENT AIR TEMP.

STEAM TURBINES : STEAM RATE CURVES, STEAM FLOW DATA

EQUATIONS ARE SOLVED USING A SOLVER SUPPORTED ON EXCEL SOLVER USES A NON-LINEAR OPTIMIZATION PROGRAM

PROGRAM PROVIDES TOTAL QUANTITY AND COST OF BOTH POWER AND

STEAM UTILITIES.

COMBINED HEAT & POWER SYSTEM MODELING/OPTIMIZATION




CHP SYSTEM MODELING

CHP SUB-SYSTEMS BOILER CGTG STG HRSG SMR HRU PRDS DEAERATOR CONDENSATE & BFW SYSTEM



SMR COGEN INTEGRATIONSMR COGEN INTEGRATION



CHP COGEN INTEGRATIONCHP COGEN INTEGRATION



SMR COGEN INTEGRATIONSMR COGEN INTEGRATION




Typical CHP SYSTEM MODELING

BOILER MODEL ANNUAL FUEL / STEAM GENERATION DATA OF EACH

BOILER IS PLOTTED AND NON LINEAR EQUATIONS ARE OBTAINED

F = A+ B.S+ C.S2

F : FUEL CONSUMPTION S : STEAM PRODUCED FROM BOILER A,B & C ARE CONSTANTS CALCULATED FROM THE

OPERATING DATA LOWER AND UPPER LIMITS OF STEAM GENERATION CAN

BE PROVIDED IN THE MODEL MODEL PROVIDE ADDITIONAL STEAM GENERATION LOAD

ON BOILER HAVING HIGER EFFICIENCY SIMILAR MODEL FOR HRSG IS DEVELOPED




COMBINED HEAT & POWER SYSTEM MODELING

GAS TURBINE MODEL HEAT RATE CURVE ANNUAL POWER / FUEL CONSUMPTION DATA OF

EACH TURBINE AMBIENT AIR TEMPERATURE

F = A+ B.P+ C.P2+ D.T+ E.T2

F : FUEL CONSUMPTION P : POWER , T : AMBIENT AIR TEMP A,B,C,D & E ARE CONSTANTS CALCULATED FROM

THE OPERATING DATA

SIMILAR MODEL FOR STEAM TURBINE IS DEVELOPED



Engineers India Ltd – Delivering excellence through peopleENERGY AUDIT 27

TYPICAL STEAM NETWORKTYPICAL STEAM NETWORK

182 0 68 0 92.4Kg/cm2a 50

21133 151.8 3 20 13.7 0.0

24Kg/cm2a 1745 41

2096 148.1 0

0 00 Kg/cm2a 20

238.8 8.4 3 15

08.4 3 15 Kg/cm2a 5

1211 24 0.5

291BlowDown

98.3

168

BoilerExternal steam

source. HRSG

Process steam

generator

Boiler atomizing

steam

Alternator Turbine

Process Users

BFW pump Turbine

Compressor Turbine

Process Users

Treated FW pump

Turbine

Compressor Aux Turbines

Boiler Fan

Deaerator

Condensate quench drum

Blow Down flash drum

Treated make-up water

215 Steam User

215 Steam Genera

HRSG atomizing



Engineers India Ltd – Delivering excellence through peopleENERGY AUDIT 28

SAMPLE STEAM NETWORKSAMPLE STEAM NETWORK



CHP MODELCHP MODEL

ENERGY AUDIT 29




CHP NETWORK SIMULATION / OPTIMIZATION

APPLICATION OF SIMULATION PROGRAM

ESTABLISH OPTIMAL GENERATION / PURCHASE / EXPORT OF POWER AND STEAM SO AS TO MINIMIZE THE SITE FUEL / UTILITIES COST

EVALUATE ENERGY CONSERVATION SCHEMES FROM GLOBAL ( PLANT ) PERSPECTIVE

EVALUATE STRATEGIES FOR POWER / STEAM GENERATION CAPACITY EXPANSION FOR NEW REQUIREMENTS




GAS PLANT CAPACITY : 2600 MMSCFDGAS PLANT CAPACITY : 2600 MMSCFD GAS SWEETENING UNITGAS SWEETENING UNIT GAS DEHYDRATION UNITGAS DEHYDRATION UNIT NGL RCOVERY ( LOW TEMP. )NGL RCOVERY ( LOW TEMP. ) SRUSRU COMPRESSOR STATION FOR GAS PIPELINECOMPRESSOR STATION FOR GAS PIPELINE

ENERGY CONSERVATION SCHEMES IDENTIFIEDENERGY CONSERVATION SCHEMES IDENTIFIED ENHANCED PROCESS TO PROCESS COLD EXCHANGEENHANCED PROCESS TO PROCESS COLD EXCHANGE PROVISION OF LEAN / RICH AMINE EXCHANGERPROVISION OF LEAN / RICH AMINE EXCHANGER POWER GENERATION FROM HYDRAULIC TURBINE IN DGA UNITPOWER GENERATION FROM HYDRAULIC TURBINE IN DGA UNIT OBSG ON HEATERSOBSG ON HEATERS VARIAABLE SPEED DRIVES FOR PUMPS & AIR COOLERSVARIAABLE SPEED DRIVES FOR PUMPS & AIR COOLERS

ENERGY SAVEDENERGY SAVED POWERPOWER : 21 MW : 21 MW STEAM GENERATIONSTEAM GENERATION : 416 MLBH : 416 MLBH FUEL SAVINGFUEL SAVING : 100MSCFH : 100MSCFH

ENERGY SAVING SCHEMES HAD GOOD PAYBACK PERIODENERGY SAVING SCHEMES HAD GOOD PAYBACK PERIOD CHP ANALYSIS SHOWED THAT BANEFITS OF ENERGY CONSERVATION CAN BE ACHIEVED CHP ANALYSIS SHOWED THAT BANEFITS OF ENERGY CONSERVATION CAN BE ACHIEVED

IFIF POWER IS GENERATED FROM THE STEAM GENERATED IN THE ENCON SCHEME AND EXPORTEDPOWER IS GENERATED FROM THE STEAM GENERATED IN THE ENCON SCHEME AND EXPORTED

ENERGY CONSERVATION OPPORTUNITY ASSESSMENT ENERGY CONSERVATION OPPORTUNITY ASSESSMENT STUDIES AT SAUDI ARAMCO GAS PLANTSTUDIES AT SAUDI ARAMCO GAS PLANT



REFINERY-PETROCHEMICAL INTEGRATION(Typical)REFINERY-PETROCHEMICAL INTEGRATION(Typical)




VALUE Chain Integration of Refinery Products to VALUE Chain Integration of Refinery Products to Petrochemical FeedPetrochemical Feed

Sharing and Efficient Use of UtilitiesSharing and Efficient Use of Utilities Sharing of Offsites and InfrastructureSharing of Offsites and Infrastructure Sharing of All Plant Resources Including Human Sharing of All Plant Resources Including Human

ResourcesResources Overall Reduction in CAPEX and OPEXOverall Reduction in CAPEX and OPEX

REFINERY-PETROCHEMICAL INTEGRATIONREFINERY-PETROCHEMICAL INTEGRATION




Integrated Common Facilities Achieving Economies Integrated Common Facilities Achieving Economies of Scale for:of Scale for: FlareFlare Waste Water TreatingWaste Water Treating BuildingsBuildings Control RoomControl Room LaboratoryLaboratory

Refinery/Petrochem –Offsite/Infrastructure Refinery/Petrochem –Offsite/Infrastructure IntegrationIntegration




Steam System: Excess MP/LP Steam from Cracker Steam System: Excess MP/LP Steam from Cracker to the Refinery for Overall Steam System Efficiencyto the Refinery for Overall Steam System Efficiency

Excess Hydrogen from Petrochemical to RefineryExcess Hydrogen from Petrochemical to Refinery Integrated Common Facilities Achieving Economies Integrated Common Facilities Achieving Economies

of Scale for:of Scale for: Cooling WaterCooling Water AirAir NitrogenNitrogen Fire WaterFire Water FuelFuel

Refinery/Petrochemicals-Refinery/Petrochemicals-Utilities Integration and Energy EfficiencyUtilities Integration and Energy Efficiency



Hydrogen SystemHydrogen System



HYDROGEN GENERATION PROCESS SCHEMESHYDROGEN GENERATION PROCESS SCHEMES



MODEL BASED ASSESSMENT MODEL BASED ASSESSMENT




HH22 internal optimization internal optimization Optimized performance of the new on-purpose HOptimized performance of the new on-purpose H22

facility, while best satisfying the refinery-wide utilities facility, while best satisfying the refinery-wide utilities and operational requirements, especially in terms of and operational requirements, especially in terms of reliability and flexibility. reliability and flexibility.

Degree of ROG utilization, HDegree of ROG utilization, H22 recovery and multiple recovery and multiple

feed flexibility feed flexibility Reforming severityReforming severity Minimization of involuntary HP steam exportMinimization of involuntary HP steam export Level of COLevel of CO22 capture capture

H2 Network OptimizationH2 Network Optimization




HH22 external optimization external optimization Developing of HDeveloping of H22 balance model balance model

Identification of limitations and/or flexibility of the HIdentification of limitations and/or flexibility of the H22 usage usage

HH22 network LP modelling or H network LP modelling or H22 off-line analysis off-line analysis

Identification of the key inefficiency of the HIdentification of the key inefficiency of the H22 network network

Integration of possible alternatives for HIntegration of possible alternatives for H22 re-use and re-use and

regenerationregeneration Identification of the optimum size for a new “on-purpose” Identification of the optimum size for a new “on-purpose”

HH22 generation Unit generation Unit

Hydrogen Network OptimizationHydrogen Network Optimization




Refinery-wide parameters Refinery-wide parameters Crude evaluation/substitutionCrude evaluation/substitution Overall refinery scheme and unit operation interactionsOverall refinery scheme and unit operation interactions Residue upgrading options assessmentResidue upgrading options assessment Fuel substitutionFuel substitution Carbon separation/sequestration solutionsCarbon separation/sequestration solutions Utilities LP modelling Utilities LP modelling COCO22 LP modelling LP modelling

Hydrogen Network OptimizationHydrogen Network Optimization



Typical Refinery Hydrogen NetworkTypical Refinery Hydrogen Network




Optimization of Hydrogen UsageOptimization of Hydrogen Usage Technology Up-gradation Technology Up-gradation

Feed + Fuel ( NG case) is 7% lower for PSA based Feed + Fuel ( NG case) is 7% lower for PSA based PlantPlant

Fuel Required is 37% lower for PSA based plantFuel Required is 37% lower for PSA based plant Switching to Lower Mol Wt Hydrocarbon saves utilitySwitching to Lower Mol Wt Hydrocarbon saves utility

Benefits of Switching of Feed from Naphtha to PentaneBenefits of Switching of Feed from Naphtha to Pentane Pre-desulphurisation is omittedPre-desulphurisation is omitted Steam Flow at Mixing point Reduced by 12%Steam Flow at Mixing point Reduced by 12% Fuel Requirement Reduced by 14.2%Fuel Requirement Reduced by 14.2% H2 Yield Increased by 1 %H2 Yield Increased by 1 % CO2 Emissions Reduced By 1.5%CO2 Emissions Reduced By 1.5%

HYDROGEN GENERATION-Saving in UtilityHYDROGEN GENERATION-Saving in Utility




OFFSITES AND UTILITIES CONSUME ABOUT 40 OFFSITES AND UTILITIES CONSUME ABOUT 40 % OF ENERGY% OF ENERGY

STEAM, POWER ARE MAJOR UTILITIES STEAM, POWER ARE MAJOR UTILITIES CONSIDEREDCONSIDERED

SCOPE FOR REDUCTION IN ENERGY SCOPE FOR REDUCTION IN ENERGY CONSUMPTIO IDENTIFIEDCONSUMPTIO IDENTIFIED

INTEGRATION OF REFINERY/PETROCHEMICAL INTEGRATION OF REFINERY/PETROCHEMICAL PLANT SAVES COST AND ENERGYPLANT SAVES COST AND ENERGY

HYDROGEN SYSTEM MANAGEMENT CAN HELPHYDROGEN SYSTEM MANAGEMENT CAN HELP

TO IDENTIFY OPPORTUNITY FOR UTILITY SAVINGSTO IDENTIFY OPPORTUNITY FOR UTILITY SAVINGS

CONCLUSIONSCONCLUSIONS

www.engineersindia.com

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13/11/2009 slide number- 1 delivering excellence through people identifying potential - in offsites...

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