energy efficiency at marathon petroleum
DESCRIPTION
Energy Efficiency at Marathon Petroleum. Wayne Kinnel Catlettsburg Energy Coordinator. Marathon Petroleum Statistics at a Glance. Fortune 50 company Established in 1887 4th largest U.S. refiner Largest in Midwest Employees: approximately 28,000 Headquartered in Findlay, Ohio - PowerPoint PPT PresentationTRANSCRIPT
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Energy Efficiencyat Marathon Petroleum
Wayne KinnelCatlettsburg Energy Coordinator
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Marathon Petroleum Statistics at a Glance Fortune 50 company
Established in 1887
4th largest U.S. refiner Largest in Midwest
Employees: approximately 28,000
Headquartered in Findlay, Ohio
Approximately 1,460 Speedway convenience stores
Approximately 5,000 Marathon Brand retail outlets
Extensive terminal and pipeline network
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Marathon Petroleum Refining SystemSystem capacity: 1,699,000 BPCD
Garyville (LA)522,000 BPCD
Texas City (TX)80,000 BPCD
Catlettsburg (KY)240,000 BPCD
Detroit (MI)120,000 BPCD
BPCD = barrels per calendar daySource: Oil & Gas JournalAs of 2/1/2013
Canton (OH)80,000 BPCD
Robinson (IL)206,000 BPCD
Galveston Bay TX 451,000 BPCD
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Catlettsburg Refining Complex and energy intensive processes
Continuous operation 24/7
Energy is second largest operating cost Natural gas – 75%
Electricity – 25%
Managing energy is imperative to remaining competitive/viable
Resources and systems in place to monitor and improve Daily operational Medium-term activities Long-term strategy and projects
Significant investments made and planned
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Catlettsburg Refining Expansive electrical infrastructure required
Refinery footprint is 600+ acres
There are 130 electric substations and approximately 2,000 electric motors 120-130 MW of demand to operate refinery
Largest Kentucky Power customer
>95% of consumption is for continuously running process equipment
Significant people resources monitor and maintain electricity infrastructure 13 engineers 25 electricians 60-80 electrical contractor personnel onsite daily
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Improving Energy Efficiency Part of our standard work practices
Short-term – daily operational monitoring
Medium-term – maintenance planning activities
Long-term – strategic projects
Effective energy management is an “all-above” approach
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Monitoring Daily Operations Significant benefits from daily attention to process operations
Tuning process heaters
Optimizing utilization of energy from process operations
Monitoring sources and uses of steam
Controlling the operation of large electrical users
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Monitoring Daily Operations Formal assessment program - Focus On Energy initiative – “FOE”
To accomplish – set standards for performance
Measure actual performance in real time
Communicate deviations from standards
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Monitoring Daily Operations Supported by technical, operations, and management personnel
Completed process unit reviews and identified 148 individual monitoring points
Each point assigned a dollar value, tracked and reported
35% reduction with no investment
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Medium-Term Activities Equipment maintained to perform at optimum efficiency
Equipment upgrades and major maintenance efforts normally require a unit shutdown
Cycle times between shutdowns can be 5-7 years
Data from routine equipment monitoring is used to develop shut down work scope
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Long-Term Strategy/Projects On-going efforts to identify and implement energy reduction opportunities
Energy specific projects – Insulation upgrades, steam leak repairs and upgrades, on-line analyzers, exchanger bundle upgrades
Energy assessment for other projects
Crude unit project example Significant investment currently underway
Process and energy efficiency improvements incorporated into scope Redesign of heat integration system to reduce consumption Improvements to fired heater for improved efficiency Fuel reduction of 720 MMBTU/day Electricity reduction of 3,000 kwh/day
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Long-Term Strategy/Projects All projects reviewed for energy efficiency improvement opportunities
Standard practice to consider high efficiency motors
Participate in industry benchmarking studies Identifies opportunities for improvement
Share and implement best practices across all MPC sites
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Summary Efficiently using all energy sources is a business imperative
Resources employed to manage and maintain energy infrastructure
Programs in place to monitor and improve performance
Efforts range from daily optimization to large multi-year, multi-million dollar projects