International Best Practices of ESO Implementation in the Oil Refining Industry

Prof. V. Mahalec McMaster University

Hamilton, Ontario, Canada mahalec@mcmaster.ca

Topics

• Components of ESO Success • Overview of potential energy efficiency improvements • Improvements in the Operating Practices • Redesign of the Plant Structure

– High efficiency equipment – Maximum energy recovery

• Measurement of Performance • Management Systems • Information Systems • Summary

Components of ESO Success

Equipment

People & ManagingSystemsInformation Systems

Potential Energy Efficiency Improvements M

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Desalting x x xCrude Distillation x x x x x x x x xVacuum Distillation x x x x x x xHydrotreater x x x x x x xCatalytic Reformer x x x x x x xFCC x x x x x x xHydrocracker x x x x x x xCoker x x x x x x xAlkylation x x x x x x xLight Ends x x x x x xAromatics x x x x x x xHydrogen x x x x x xUtilities x x x x x x x

Crude Distillation 54%Vaccum Distillation 39%FCC 28%Hydrotreater 32%Catalytic Reformer 23%Alkylation 38%

Potential Energy Savings in US Refineries % of 2005 Energy Usage

Equipment

“Energy bandwidth for petroleum Refining Processes” , Energetics, 2006

Potentially 25% to 30% energy savings.

Process Control and Real Time Optimization

• Throughput increase: 5% to 10% • Energy savings: 2% to 5% • Yield of most valuable product: 1% to 5% • Value added by the unit: 5% to 10%

• APC is a standard practice • RTO will operate properly only if all other systems

function well: – Equipment operates as expected – Instruments are accurate and reliable – Advanced control applications service factor close to 100% – Competent staff to implement and maintain

Equipment Operating Practices

Equipment Maintenance – Enhances Efficiency

• Heat Exchangers: monitor fouling & clean as needed – Optimal heat exchanger cleaning schedule maintains desired

performance while some HX are off-line (MINLP problem)

• Process Heaters – target 1% to 2% excess oxygen – Eliminate air leaks – Optimize burner operation (flame monitoring)

• Distillation – Minimize operating pressure; – Clean fouled trays

• Steam distribution – minimize header pressure, maintain steam traps, repair

leaks, insulate

Equipment Operating Practices

Maximize efficiency of individual equipment

• High efficiency heat exchangers – High pressure spiral HE for fouling service – HE Plate exchangers – Packinox (for some feed/reactor effluent applications)

• Process Heaters – air preheat, efficient burners • Distillation

– Install more efficient trays – Heat integrated distillation columns – Alter separation sequence: Progressive Crude Distillation

(15%+ energy saving)

• Steam distribution - return condensate

Equipment Re-Design

Process Integration

• Energy Systems Integration – Total Site (process units, utilities, cogeneration, power generation) – Caution: must be able to start-up and shut-down after the

integration projects are implemented. – Savings: 15% to 40%+ of the energy consumed by the

units that are integrated.

• Hydrogen System Integration – Optimize usage – Decide where to install hydrogen recovery equipment

• Water System Integration

Equipment Site Re-Design

Strong Interaction Among All Decision Levels

People & Managing Systems

Plan Production

Schedule Production

Run to Targets; Optimize Operating Targets

Monitor / Analyze Operations

Plant (Re)Design

Equipment Modifications Maintenance

Visibility / access to information is vital for good decision making

Enterprise Wide Monitoring

Equipment Unit/Plant Plant/Region

People & Managing Systems

If Boss monitors it, it will be done

Region

Refinery 1

Refinery n

CDU FCC Utilities …

…

Management System – Continuous Improvement

Assess Performance Identify Opportunities

Set Goals

Create Plan

Implement

Evaluate

Reward Achievement

Sustainable, long term improvements require continuous commitment of the management team and of the employees.

From organizational viewpoint, the responsibility for energy optimization performance resides with the operating arm of the enterprise.

People & Managing Systems

Company Wide Enterprise Architecture

Federated Databases

Business Intelligence

Plan Production

Schedule Production Run to Targets;

Optimize Operating Targets

Business Applications (monitoring, APC, RTO, planning, scheduling, maintenance…)

Operating Data

Equipment Data

… Data . . .

Information Systems

Monitor / Analyze Operations

Enterprise Content

Management

Maintain Equipment Manage Business

Processes

Summary

Technical Systems

Human (Organizational)

Systems

Technical System Performance Guidelines

Managing Systems

Guidelines

• Very significant reduction in energy consumption is possible. • Energy Savings Guidelines / Standards should encompass both technical and human systems.

Scope of the Guidelines

End