energy efficiencies in refineries_uop.pdf
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Opportunities for energy efficiencies inRefineries & Petrochemical PlantsOpportunities for energy efficiencies inRefineries & Petrochemical Plants
November 2009November 2009
2008 UOP LLC. All rights reserved. UOP 5033B-01
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2020
Waxman- Markey: 20% reduction in GHG by 2020
0
CO2eq
milliontes
Business as usual
2012
5800
2005Baseline
4600
6400
Proposed Levels
3%
9% by 2030
2050
20% 83%
2030
23% 32%
53%
%
RenewablesofT
otalEnergyDem
and
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Background
The current state of the economy, along with the need forbetter environmental performance are driving moreefficient operations and improved process technologies
We must find the synergy betweenenergy efficiency and profitability
Making basic energy efficiency improvements is a relativelylow-cost way refiners and petrochemical producers canreduce operating costs, and GHG emissions
Few refiners today are taking a holistic, multi-facetedperspective that looks at process conditions, processdesign changes and technology to explore
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Energy & CO2 in a Refinery
700,000 million cubic feet of naturalgas/year
8% of crude is consumed as energy
Energy costs 50% to 60% of total variableoperating costs (excluding feedstocks)
$80 to $100 million/year on energy & 1.2to 1.5 million metric tons/year of CO2
CO2 emissions increase with heavierfeedstock, cleaner fuels, conversion andcomplexity
17CDU/VDU
% ofEnergy
ConsumedRefining Unit
5Offsite
15Utilities
4Coker
15Alkylation andHydrotreating
10Hydrocracking
14Reformer
20Fluid CatalyticCracking (FCC) Unit
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Our Goal is NOT Energy Minimization
Minimum energy is not always optimum profit
Energy is an enabler
More energy, can be used to realize greatercapacity, better yield, and better products
The overall process impact must be included inthe economic evaluation
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Finding the Right Solution
Need a holistic, multi-faceted approach to explore the synergybetween energy efficiency and profitability
Optimized energy use,control, and processconditions to unlock
hidden energyopportunities
LowCost Solutions
Minimum processdesign changes to
seek synergy ofenergy saving andthroughput/yield
enhancement
ModerateCost Solutions
Advancedtechnology to
maximize processefficiency in reaction,separation, heat and
power recovery
HigherCost Solutions
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Opportunities
32,000 to 44,000metric tons/year$8 to
10M/year1 to 2 %
Optimize H2 recovery
Maximize LPG recoveryH2 and Fuel Gas
Management
Total
Optimization and controls for onsitesteam and power production/supplyand demand optimization
Employ new process technology,design, equipment and catalysttechnology
Increase heat recovery within andacross process units.
Improve online monitoring, controland optimization throughmultivariable, predictive control andoptimization applications
Actions
24,000 to 36,000metric tons/year
$3M to6M/year
2 to 3%Utilities
Optimization
36,000 to 84,000metric tons/year
$5M to10M/year
3 to 7%AdvancedProcess
Technology
164,000 to320,000 tons/yr
$23M to39M/year
12 to 25%
48,000 to 108,000metric tons/year
$4M to8M/year
4 to 9%Improved heat
recovery
24,000 to 48,000metric tons/year
$3 to 5M/year2 to 4%Improved
operation andcontrol
CO2Reduction
ProfitIncrease
EnergyImprovement
Area of Savings
Basis: for a 100,000 BPSD refinery; natural gas cost @ $6/MMbtu
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Where Energy Savings Come From
UseCarbonCredits
GetEnergy
Cheaper
Improve ResourceAllocation
Balance Supply& Demand
Boiler/Turbine
Performance
Online Control& Optimization
Improve Monitoring& OperationOperate More
Efficiently
GHG Capture& Storage
RenewableEnergy Source
Improve Heat IntegrationRecover
More Heat
Utilize NewProcess
Technology
Advanced ProcessTechnology, Equipment
& Catalysts
Reduce Waste/Leaks
ManagingH2/Fuel
SystemsEfficiently
Minimize H2 to FuelBetterManage H2 Manage H2 Partial
Pressure
Maximize Recover ofValuable Components
Minimize FuelGas Flare
Better ManageFuel
Gas System
UseEnergyMore
EfficientlyIn Process
ReduceEmissions
ReduceEnergy
Costs andEmissions
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Operate More Efficiently
Online Control& Optimization
Improve Monitoring& OperationOperate More
EfficientlyUse
EnergyMore
EfficientlyIn Process
ReduceEmissions
ReduceEnergy
Costs andEmissions
UseCarbonCredits
GetEnergy
Cheaper
Improve ResourceAllocation
Balance Supply& Demand
Boiler/Turbine
Performance
GHG Capture& Storage
RenewableEnergy Source
Improve Heat IntegrationRecover
More Heat
Utilize NewProcess
Technology
Advanced ProcessTechnology, Equipment
& Catalysts
Reduce Waste/Leaks
ManagingH2/Fuel
SystemsEfficiently
Minimize H2 to FuelBetterManage H2 Manage H2 Partial
Pressure
Maximize Recover ofValuable Components
Minimize FuelGas Flare
Better ManageFuel
Gas System
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How to capture hidden operational opportunities:
Optimize complex fractionation/separation systems
Pump-arounds; Feed temperature; Operating pressure
Minimize product give-away
Maximize throughput/lift/desirable products
Optimize complex interactions
Interactions between heaters, heat recovery systemsand processes
Interactions between process energy demand and utilityenergy supply sides
Operate More Efficiently
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Optimize energy/processes under changing conditions
Variations in feeds, products, production rate Fouling in heat exchangers, condensers and heaters
Energy Dashboard
Determine targets for key processand energy variables
Monitor actual vs. predicted energyconsumption
Instrumentation for measurement
The key is to optimizecomplex systems and interactions
Operate More Efficiently
Capture hidden operational opportunities:
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Advanced Control and Optimization
Multi-variable control and optimization tools
Maximize production, improve yields, minimize energy
Include energy costs as part of overalleconomic operating objectives
Energy related solutions include:
Furnace Pass Balancing and Excess Air
Distillation Quality and Pressure Control
Reactor Conversion Control
Preheat Maximization
Process know-how workingtogether with powerful tools
Operate More Efficiently
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Advanced Controls Case Study
YNCC, South Korea
400 ktes/yr Ethylene Plant
Naphtha feedstock to 7 furnaces Constraints in furnaces, refrigeration compressors and fractionators
Implemented 17 MPC controllers and an optimizer with non-linearcracking model
Operating Results
Increased naphtha feed rate by 3.0%
Reduced energy consumption by 3.25% -reduced steam consumption in fractionators;furnace excess O2
Project payback ofless than5 months
Operate More Efficiently
1. Normal Operation w/o APC
2. W/ APC3. Maximum Load
(W/ APC + OPT)
Operating Results
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Operate More Efficiently
CO2 Reduction of 24-48 kMt/yrfrom a typical
100,000 bbl/day refinery
Whats It Worth ?
2~4% improved energy efficiency
$3 to 5M/year
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Heat recovery within and across process units
Integration of process energy with utility systems
Energy savings combined with increased throughput Determine process bottlenecks
Transfer expensive bottlenecks to cheap ones
Optimize operating conditions simultaneouslypressures / specs / pump-arounds / rundowns
Practical considerations for any changes
Safety, operability, reliability
Recover More Heat
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Recover More Heat
A = Effluent Frac Feed Exchanger 1B = Effluent Frac Feed Exchanger 2C = CFE 1 (Effluent Feed Exchanger)D = CFE 2 (Effluent Feed Exchanger)E = Diesel P/A Heavy Naphtha Exchanger
PRT
Add powerrecovery turbine
Medium energy benefit
at medium costAdd 4-Hx (A-D) to beforeRx & Frac charge heaters
Energy & Throughput benefit
Low Cost
A
C
C
B
D
D
B
A
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A = Effluent Frac Feed Exchanger 1B = Effluent Frac Feed Exchanger 2C = CFE 1 (Effluent Feed Exchanger)D = CFE 2 (Effluent Feed Exchanger)E = Diesel P/A Heavy Naphtha Exchanger
PRT
Install combinedconvection section for two
charge heaters
Large energy benefitat high cost
Optimize the ratioof flow through the
split (non-symmetric)raw feed trains
No cost energy benefit
Recover More Heat
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A = Effluent Frac Feed Exchanger 1B = Effluent Frac Feed Exchanger 2C = CFE 1 (Effluent Feed Exchanger)D = CFE 2 (Effluent Feed Exchanger)E = Diesel P/A Heavy Naphtha Exchanger
PRT
Charge heatersare less full
More feed can be addedto the unit
Change catalyst forbetter cold flow property
Change Rx internal forbetter vapor/liquid
distribution
More product
Recover More Heat
Charge Frac/separatorinternals
Improved throughputButpoorer diesel
cold-flow properties
~100 MMBtu/h saved
and 15% increase inthroughput
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$4 to 8M/year
CO2 Reduction of 48-108 kMt/yrfrom a typical
100,000 bbl/day refinery
Recover More Heat
Whats It Worth ?
4~9% improved energy efficiency
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Utilize NewProcess
Technology
Where Energy Savings Come From
UseEnergyMore
EfficientlyIn Process
ReduceEmissions Advanced Process
Technology, Equipment& Catalysts
ReduceEnergy
Costs and
Emissions
UseCarbonCredits
GetEnergy
Cheaper
Improve ResourceAllocation
Balance Supply& Demand
Boiler/TurbinePerformance
Online Control& Optimization
Improve Monitoring& OperationOperate More
Efficiently
GHG Capture& Storage
RenewableEnergy Source
ManagingH2/Fuel
Systems
Efficiently
Minimize H2 to FuelBetterManage H2 Manage H2 Partial
Pressure
Maximize Recover ofValuable Components
Minimize FuelGas Flare
Better ManageFuel
Gas System
Improve Heat IntegrationRecover
More HeatReduce Waste/Leaks
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B
A
ABC
C
Take advantage of new technology, equipmentand catalysts
High selectivity/activity catalyst
High efficiency reactor internals
High capacity fractionator internals
Enhanced heat exchangers
Modern power recovery turbines
Novel process design
UOP 5027I-18
Utilize New Process Technology
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SpongeAbsorber
MainColumn
Stripper DEC4
PrimaryAbsorber
NaphthaSplitters
HCN
LightNaphtha
MiddleNaphtha
Aromatics RichNaphtha
Heavy Gasoline
LCO
CSO
LPG
Unstabilized Gasoline
LCO PA
DEC4 BTMSRecycle
To Fuel GasSystem
Can this beimproved?
Feed
Wet GasCompressors
Utilize New Process Technology
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SpongeAbsorber
MainColumn
Stripper DEC4
PrimaryAbsorber
NaphthaSplitter
HCN
LCO
CSO
LPG
Unstabilized Gasoline
LCO PA
LNRecycle
To Fuel GasSystem
Feed
Wet GasCompressors
HG
ARN
MN
LN
Modifications:
LN for primary absorber Dividing wall columns
Benefit:
9 MkCal/h or 3% energy savingfor 70 kBPD FCC
Utilize New Process Technology
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Thermal Efficiency In DividingWall Column
A
ABC
B
C
Colum
nTray
Top
BottomComponent B mole fraction
Col 1 Col 2
Remixing occurs
A
ABC
B
C
Vertical wall separates columnsections
Eliminates thermal inefficiency 3 products using a single column
Typically 25-40 % savings in capitaland energy costs
Dividing Wall Column
Utilize New Process Technology
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Whats It Worth ?
3~7% improved energy efficiency
CO2 Reduction of 36-84 kMt/yrfrom a typical 100,000
bbl/day refinery
Utilize New Process Technology
$5 to 10M/year
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Where Energy Savings Come From
ManagingH2/Fuel
Systems
Efficiently
Minimize H2 to FuelBetterManage H2 Manage H2 Partial
Pressure
Maximize Recover ofValuable Components
Minimize FuelGas Flare
Better ManageFuel
Gas System
RecoverMore Heat
Utilize NewProcess
Technology
Advanced ProcessTechnology, Equipment
& Catalysts
Reduce Waste/Leaks
UseEnergyMore
EfficientlyIn Process
ReduceEmissions
UseCarbonCredits
GetEnergy
Cheaper
Improve ResourceAllocation
Balance Supply& Demand
Boiler/TurbinePerformance
GHG Capture& Storage
RenewableEnergy Source
Online Control& Optimization
Improve Monitoring& OperationOperate More
Efficiently
Improve Heat Integration
ReduceEnergy
Costs and
Emissions
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Better Manage H2 & Fuel Gas System
Advantages of Improved H2 Management:
H2 Plant is one of the largest emitters of CO2
Can improve refinery margin through processperformance improvement
Avoid capital expense on new H2 plant
Alleviate H2 constraints
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Better Manage H2 & Fuel Gas System
H2 Network AnalysisMatching purities of producers & consumers
Cascades
Purge Rates
H2 purificationRecover H2 now going to fuel
Revamp existing purifiers
Add new purification capacity
Optimize processMaximize H2 yield in reformers
Set / maintain H2 partial pressure targets
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Better Manage H2 & Fuel Gas System
Monitor C3/C4 % in refinery fuel gas
Recover valuable components in refinery fuel gas
Use excess fuel gas for cogeneration
Have a mitigation plan for
fuel gas long scenarios
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Whats It Worth ?
1~2% improvement in energy efficiencyfrom the refinery
CO2 Reduction of 32-44 kMt/yrfrom a typical 100,000
bbl/day refinery
Better Manage H2 & Fuel Gas System
$8 to 10M/year
Significant process benefit
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Where Energy Savings Come From
GetEnergy
Cheaper
Improve ResourceAllocation
Balance Supply& Demand
Boiler/TurbinePerformance
UseCarbonCredits GHG Capture
& Storage
RenewableEnergy Source
RecoverMore Heat
Utilize NewProcess
Technology
Advanced ProcessTechnology, Equipment
& Catalysts
Reduce Waste/Leaks
UseEnergyMore
EfficientlyIn Process
ReduceEmissions
Online Control& Optimization
Improve Monitoring& OperationOperate More
Efficiently
Improve Heat Integration
ManagingH2/Fuel
Systems
Efficiently
Minimize H2 to FuelBetterManage H2 Manage H2 Partial
Pressure
Maximize Recover ofValuable Components
Minimize FuelGas Flare
Better ManageFuel
Gas System
ReduceEnergy
Costs and
Emissions
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Supply/Demand Optimization
Realtime supply/demand balance
Meet demand forecastaccounting for price, emissions,availability, make vs. buy
Boiler Optimization
Accept steam loads andallocate according toefficiency and constraints
Master Pressure Control
Advanced predictive control
Stabilize header pressures
AdvancedCombustion Control
Tight Fuel/air ratio
Control excess O2
Power Users
Electricity
HPS - 500 psi
MPS - 150 psi
LPS - 50 psi
TG-1TC-1
Boiler-1 Boiler-2
150#Users
500#Users
Power Supply Grid
50#Users
Purchased
Steam
TC-2 TG-2 TG-3
50#Vent
Air Air
Plant AirUsers
CONDENSATE
LDV-1
LDV-2
LDV-3
Power Users
Electricity
HPS - 500 psi
MPS - 150 psi
LPS - 50 psi
TG-1TC-1
Boiler-1 Boiler-2
150#Users150#Users
500#Users500#Users
Power Supply Grid
50#Users
Purchased
Steam
TC-2 TG-2 TG-3
50#Vent
Air Air
Plant AirUsers
CONDENSATE
LDV-1
LDV-2
LDV-3
Get Energy Cheaper
Energy Mix
Optimize choice of fuel
Optimize dual drivemotors
Turbine Optimization
Accept electrical loadsand balance according to
efficiency and price
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Whats It Worth ?
2~3% improvement in energy efficiencyfrom the refinery
CO2 Reduction of24-36 kMt/yr
from a typical 100,000bbl/day refinery
Get Energy Cheaper
$3 to 6M/year
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Energy Solutions Summary
Basis: for a 100,000 BPSD refinery; natural gas cost @ $6/MMbtu
32,000 to 44,000metric tons/year$8 to
10M/year1 to 2 %
Optimize H2 recovery
Maximize LPG recoveryH2 and Fuel Gas
Management
Total
Optimization and controls for onsitesteam and power production/supplyand demand optimization
Employ new process technology,design, equipment and catalyst
technology
Increase heat recovery within andacross process units.
Improve online monitoring, controland optimization through
multivariable, predictive control andoptimization applications
Actions
24,000 to 36,000metric tons/year
$3M to6M/year
2 to 3%Utilities
Optimization
36,000 to 84,000metric tons/year
$5M to10M/year
3 to 7%AdvancedProcess
Technology
164,000 to320,000 tons/yr
$23M to39M/year
12 to 25%
48,000 to 108,000metric tons/year
$4M to8M/year
4 to 9%Improved heat
recovery
24,000 to 48,000
metric tons/year
$3 to 5M/year2 to 4%Improved
operation and
control
CO2Reduction
ProfitIncrease
EnergyImprovement
Area of Savings
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Implement
Operation &MaintenanceSolutions
Implement
Operation &MaintenanceSolutions
SustainBenefits
ImplementEquipment& ControlProjects
ImplementEquipment& ControlProjects
ROI
Prepare FEEDfor Equipment &Control Projects
Prepare FEEDfor Equipment &Control Projects
Execution
Energy OpportunityAssessment
(Benchmarking &Prelim analysis)
Energy OpportunityAssessment
(Benchmarking &Prelim analysis)
Detailed Study
& AnalyzeOpportunities
Detailed Study
& AnalyzeOpportunities
StartReview
OpportunitiesReview
Opportunities
ReviewOpportunitiesReviewOpportunities
Deploy
On-LineMonitoring
Deploy
On-LineMonitoring
PrelimOnline
Monitoring
PrelimOnline
Monitoring
ImplementQuickHits
ImplementQuickHits
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Conclusions
There is NO single approach
Reduce operating costs and CO2 emissions while increasingprofitability
Improved throughput and yields are possible The demands from the process must be tightly linked to supply
from the utilities plant.
Identification of good energy projects requires combined skills in
operation, process design, modeling and energy optimization Sustaining the benefits requires monitoring and
optimization tools, on-line and closed loop control
Technology is the key
Energy savings of12-25% are possible
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Thank You