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7/28/2019 17_Solutions for Energy Efficiency Challenges Proceedings.pdf
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Solutions for Energy Efficiency Challenges
Ccile Plain
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
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Energy and GHG Challenge in Refining
Energy sector represents 66.5% of the total Greenhouse Gas(GHG) emissions:
GHG from Oil & Gas (O&G) industry: about 6% of the total GHG
Chemicals & petrochemicals: about 4% of the total GHG
Energy costs represents onaverage more than 50% oftotal operating cost
Product specificationdevelopments anddieselization lead to anincrease in energyconsumption
61.5%
59.0%
38.5%
41.0%
0% 20% 40% 60% 80% 100%
2008
2006Energy
Non-Energy
Operating Expenses Split
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
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Axens as a Key Partner
Axens has set up a structured knowledge
management process to capitalize on each project
Axens as a licensor:
Extensive know-how and
experience on whole refining &
petrochemical scheme.
Axens as catalyst &special equipmentprovider:
Innovative solutions for OPEX
reduction in existing assets
Western
Europe
19%
Middle East
14%Africa
4%
North
America
12%
Latin
America
8%
Asia
35%
Eastern Europe +
CIS 8%
Axens has been awarded a total
2205licensesas of 31st December 2012:
5
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Establish Referential
On-site Data collection:
- Utilities network
- Process units performance
- Large thermal & power equipment
performance
- Flare system
- Emissions assessment- Maintenance & Operational good
practices
Baseline setting:
- KPIs, EIITM, CO2- Energy consumption / cost
Energy Efficiency & GHG Mitigation
Cost Estimate &Financial Analysis
Detailed study of selected
projects (CAPEX, IRR, NPV)
Estimation of related saving
(including Solomon EIITM
Screen projects options
that could improve energy
efficiency:- Non-CAPEX options
- Low CAPEX options
- High CAPEX options
Evaluation compliance to
CDM criteria
Customer selection of
projects to be further
developed
over 80 options
screened
Case ranking
Validation of project
options to be developed
during the next phase
Unit energy consumption
2004 Solomon standard - Case study 2004 - Case study 2006
0
1000
2000
3000
4000
AD U1 AD U2 AD U3 VD U1 VD U2 HC K RE F 1 RE F 2 SMR PS A NHD T1
NHDT2
KHDS1
KHDS2
Others
98
16
19
7
7
C ur re nt E II O pe ra ti on
Optimisation
M ai nt en an ce L ow CA PE X H ig h C AP EX E II Po te nt ia l
RecycleGas
H2
QuenchGas
Fuel Oil
Sour OilFeed
Reactor Strip
PackinoxExchangers
Propose Options
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CO2&
Energy
SOURCING
IMPROVEMENT
ENERGY
CONSUMPTIONREDUCTION
ASSET
OPTIMISATION Combined Heat and Power
Load curve management
Supply / Demand Response
Renewables
Spot market access
Shipping/Transmission
Balancing
Renewables sourcing
CO2 Allowances
Energy equipement expertise
Heat integration
Processes optimization
Refining scheme integration
Emissions capture Peak shaving
Work organization
Energy performance
Management
Axens & Solvay Energy Services combine their expertise toprovide an integrated services to the refining industry
Axens / SES Combined Expertise for Refiners
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1st Quartile
2nd Quartile
UNITS BenchmarkMeasured energy consumption and EII
Use benchmark
But go beyond a first level analysis
Process expertise is required to assess energy performance
and identify improvements in any refinery process unit 8
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Example of High Severity CCR Reforming
ReactorFurnaces
56%
Others44%
Aromatics yields:
Heat of reaction
governed by
thermodynamics
Includes:
catalyst regeneration
recycle compressor
Stabilization section
H2
export compressor
80% of CCR reforming net energy consumption
is directly linked to production objectives
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
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High Efficiency Heat Exchangers
High efficiency HX gains
Heat Duty - 48%
Electrical power - 8%
RecycleGas
H2
QuenchGas
Fuel Oil
Sour OilFeed
Reactor Strip
PackinoxExchangers
RecycleGas
H2
QuenchGas
Fuel Oil
Sour OilFeed
Reactor Strip
S&TExchangers
Heater
RecycleGas
H2
QuenchGas
Fuel Oil
Sour OilFeed
Reactor Strip
S&TExchangers
Heater
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High Efficiency Furnace
Optimising heat recovery Efficiencies above 92%?
Consultation with equipment manufacturers
Temperature (C)
Flue Gas Temperature (C)
COMBUSTION
AIR
283
FDF
LP STEAM
HEATER
LP STEAM
HOT AIR DUCT
296
150
PROCESS FLUID
BFWBFW / HP STEAM
HP STEAM
BFWBFW
SUPERHEATED HPS
FLUE GAS
15.6
257
307
150
257
257
PROCESS
H-47102 H-47103
ATM
COMBUSTION
AIR
FLUE GAS
FLUE GAS
305 320
164
32?
FDF
IDF
PH-47103AIR PREHEATER
2.0 (est.)
COLD FLUE GAS DUCT
HOT AIR DUCT
197
Heat release Heat release
9.37 18.98
13027 kg/h 26390 kg/h
HOT FLUE GAS DUCT
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Optimum Heat Exchanger Networks: Pinch Technology
First: Adjust process parameters to improve heat integration
Then: use PINCH technology to
intensify process /process heat
exchanges and minimize wasted
heat (air coolers, trim coolers)
Last: Use Licensors experience to define schemes that provide
operability and flexibility
Stripper FeedStripper
TC
Reactor FeedFract. Feed
ReactorEffluent
Reactor
Fractionator
428 376 307 270 245 213 193 168 152 122
53
122
240
245
193
213
209
263
325
307
376407
12.35 16.63 8.70 5.83 7.87 4.60 6.00 3.76 7.16
5.38
9.81
134
168
10% bypass
90%152
To ReactorEffluent Air Cooler
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Application of Innovative Designs
Dividing Wall Columns
lower energy requirement for reboiling of the combined column
Plate heat exchangers reduce T approach and increase heat recovery
replace several heat exchangers in series
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
Aromatic Complex
Steam Generation
Process Heat Integration
Delayed Coker Unit
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Aromatics Complex Scheme Overview
Benzene
Paraxylene
Extractive
Distillation
Xylenes
Isom.
Transalkylation
Heavies
Reforming
(CCR)
Raffinate
B
C
Eluxyl
B
T
Hydrotreated
Naphtha
C7-
C8+
C9+
C9+C10
C8A
H
A
XC
R
S
C8+
Tol
FG + LPG
Conversion units
Separation units
Fractionation columns
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Aromatics Complex Scheme Overview
Benzene
Paraxylene
Extractive
Distillation
XC
Xylenes
Isom.
Transalkylation
Heavies
Reforming
(CCR)
Raffinate
B
C
Eluxyl
B
T
Hydro-
treated
Naphtha
C7-
C8+
C9+
C9+C10
C8A
H
A
RS
C8+
Tol
FG + LPG
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Energy Efficiency Study for Aromatic Complex Project
Detailed study to reviewpotential energy efficiencyimprovements: Project specific (based on client
requirements) Technical and economical
optimisation (CAPEX & OPEX)
Example of modification toAromatics Complex design:
Maximize heat conservation Minimize air coolers
Produce steam and electricitywhen possible
0
100
200
300
400
500
0 1 0 2 0 3 0 4 0 50 6 0 7 0 8 0 9 0 1 00 1 10 1 20 1 30 1 40 1 50 1 60 1 70 1 80 1 90 2 00 2 10 2 20 2 30 2 40 2 50
Duty (Gcal/h)
Temperature (C)
Cold Composite
Hot Composite
PinchTemp (256C)
Minimum Hot utilities : 86 Gcal/h
Minimum Coldutilities : 43.9 Gcal/h
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
Aromatic Complex
Steam Generation
Process Heat Integration
Delayed Coker Unit
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Steam Generation Study: Basis of design
Several levels of steam considered from LLP to MP steam
Reviewed opportunities for:
Steam recompression from LLP to LP and LP to MP
Pre-heating BFW
Pre-heating furnace air20
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Steam Generation Study: Suggestions
Scheme modifications proposed
Increase column pressure
To generate required steam level
For heat integration with other process streams
Replacement of columns condensers by steam
generators
Installation ofadditional process exchanger on reaction
sections (higher heat recovery on reactor effluentstreams)
Increase heat efficiency of fired heater
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
Aromatic Complex
Steam Generation
Process Heat Integration
Delayed Coker Unit
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Example of Process Heat Integration
Feed 1
Feedheater
Reactor
Feed /
Effluent
exch.
Effluent
air coolerRecycle
comp-
ressorCold
separator
HPpurge
HPst
Distillate
to stab.
Product 1
Feed 2
LP purge
to
Process
stab.Comp.
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Product 1
LPpurge
Off gas fromTP stab
Feed 1
Feed
heater
Reactor
Feed /
Effluent
exch.
Effluent
air coolerRecycle
comp-
ressorCold
separator
HP
purge
HPst
Distillate
to stab.
Feed 2
Example of Process Heat Integration
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Energy efficiency versus CapEx
Gains in performances, an additional20%
Impacts on Capital Expenditure
Adjusting columns operating pressure: Higher pressure to improve heat integration
Lower pressure to reduce reboiler duty (offgas compressor)
More equipment: large heat exchangers and steam
generators Risk mitigation of water leakages (Special HX design,
equipment test & inspection, S/D S/U procedures)
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Agenda
Energy and CO2 Challenge
Axens as a key partner
Equipment optimization
Case Studies
Aromatic Complex
Steam Generation
Process Heat Integration
Delayed Coker Unit
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Energy Efficiency Results: Delayed Coker Unit
Savings: 6.8 M US$/y
Close the gap versus DCU top energy performers by 57%
Focused delivery:
Short list of Energy Projects
Less than 1 year pay out time
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The Right Start: Strategic Energy Review
Exhaustive energy balance 78% of total energy is fuel gas
Benchmark with top
performers / best design 2.5 times more than top
performers
Identify and check top energy
consumers
Energy GJ/d Percent
Fuel gas 4 600 78%
Steam (MP) 700 12%
Electricity 600 10%
Total 5 900
Questionnaire
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C1C
3
C
2
F2
/A
F2
/B
V
2
V
1
V
3
V
4E1
E3
E5E4
V5
E6 E7
LCGO
HCGO
Unstabilized
Naphtha
Coker HeaterEfficiencyFeed Heater
Coker
Drums
Water
cooler
Air
cooler
Water
cooler
Air
cooler
Air
cooler
UnstabilizedNaphtha
Heat
Exchanger
Upper feed
Lower feedF1
E2
C4
Reboiler
The Right Start: Identify Energy Losses
LOST
ENERGY
Legend
Cold Feed
Site Visit
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Identify most valuable energy projects
Long list of energy saving projects Select with customer most attractive projects
Providing highest efficiency improvements
Strong Pay Out Time
Delayed Coker Unit:
Focus on fuel gas savings projects (78% of total energyconsumed)
Project Short List
1. Shutdown Feed Heater
Most DCU do not have one!
2. Improve coker heater efficiency
Interim Meeting
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Shutdown Feed Heater: 1000 kg/h of fuel gas saved
Cold Feed
Hot Feed
New Line from
Vacuum Distillation Unit
New Cold Feed
Pre-Heat Exchangers
New Mixed Feed
Heat Exchanger
Recover hot feed duty: Blend hot and cold feed Recover process duty to pre-heat cold feed
Recover coker heater duty to heat mixed feed
To C1
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TC
Pre-heated
F2A/B
Fuel gas
Flue gas
To HeatMixed Feed
Air Damper
02
QC
CO
New
Burners
Improved Coker Heater Efficiency 770 kg/h of Fuel Gas Saved
Feed from
C1 bottomTC
To
C1
6 projects New Burners
Control Inlet & Outlet
heater Temperature
Measure and ControlOxygen
Measure CO
Pre-Heat Combustion Air
Combustion Air
Heater Efficiency improved by 20%(calculation with heater simulation software)
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Projects Economic Summary
Projects Fuel GasSavingskg/H
GapClosure
SavingsM$/year
CostsM$
POTYears
F2 shutdown 1,000 32% 3.8 3.7 1,0
Coker HeaterEfficiency 770 25% 3.0 2.4 0,7
Total 1,770 57% 6.8 6.1 0,9
Feed heater is bypassed and shutdown
= Extra savings on maintenance !
Other projects on Coker heaters= Beyond Energy Efficiency, improved heaters and yield stability !
Gap to top performers normalized at 10033
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Delayed Coker Study Key Lessons
Major step towards high performance
Study was performed in 2 months time
Quality of collected data
Good relationship between staff
Energy savings are not obtained at the expense of
the process
The implementation remains simple: Short list of items easier to manage
Focused on feed and Coker heaters
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Conclusion
Energy efficiency practices can be applied to new process unit
design as well as existing units
However, expected gains for existing assets will be more
limited than for new built
Energy efficiency improvements have to be economically viable
and sustainable
Axens is actively working on energy efficiency improvements:
Technologies & products even beyond Axens technology
portfolio (process integration, equipment)
Consulting services
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