energy efficiency a p rocess l icencor 's v iew
DESCRIPTION
Energy Efficiency A P rocess L icencor 's V iew. XXVI Russian National Inter-Industry Meeting September 12 th - 14 th , 2012. Agenda. Energy and CO 2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion. Agenda. - PowerPoint PPT PresentationTRANSCRIPT
1
Energy EfficiencyA Process Licencor 's View
XXVI Russian National Inter-Industry Meeting
September 12th - 14th, 2012
2XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
3XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
4XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
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 on average more than 50% of total operating cost
• Product specification developments and dieselization lead to an increase in energy consumption
59.0% 41.0%
61.5% 38.5%
0% 20% 40% 60% 80% 100%
2006
2008
Solomon & AssociatesOperating Expenses split
Energy
Non Energy
5XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
6XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
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 equipment provider:
Innovative solutions for OPEX reduction in existing assets
0
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600
800
1000
1200
1400
1600
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2200
2400
1960 1970 1980 1990 2000 2010
Cumulative Number of Licenses
Western Europe
19%
Middle East 14%
Africa4%
North America
12%
Latin America
8%
Asia35%
Eastern Europe + CIS 8%
2205 licenses as of 31st December 2011
7XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Energy Efficiency & GHG Mitigation
Methodology for Energy Audit
Step 1:
Preliminary phase
Step 1:
Preliminary phase
Phase 2:
Refinery survey
Phase 2:
Refinery surveyPhase 3:
Baseline setting
Phase 3:Baseline setting
Phase 4:Opportunity Identification
Phase 4:Opportunity Identification
Phase 5:Opportunity
Selection
Phase 5:Opportunity
Selection
• Step 1: Dispatching questionnaire to site Preparation of KOM
• Step 2: KOM & Energy Survey on site
• Step 3: Reconciled baseline for energy balance
• Step 4: Identify energy conservation opportunities Meeting with customer for projects selection
• Step 5: Development of the selected projects
8XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
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
Propose Options
•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 rankingValidation of project options to be developed during the next phase
Unit energy consumption2004 Solomon standard - Case study 2004 - Case study 2006
0
1000
2000
3000
4000
ADU 1 ADU 2 ADU 3 VDU 1 VDU 2 HCK REF 1 REF 2 SMR PSA NHDT1
NHDT2
KHDS1
KHDS2
Others
98
16
19
33
53
73
93
113
133
153
173
Current EII OperationOptimisation
Maintenance Low CAPEX High CAPEX EII Potential
RecycleGas
H2
QuenchGas
Fuel Oil
MP Steam
Sour OilFeed
Gas OilProduct
Light EndsReactor Stripper
PackinoxExchangers
9XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
CO2
&Energy
SOURCINGIMPROVEMENT
ENERGY CONSUMPTION
REDUCTION
ASSETOPTIMISATION
Axens / SESCombined expertise for refiners
• Combined Heat and Power
• Load curve management• Supply / Demand
Response• Renewables
• Combined Heat and Power
• Load curve management• Supply / Demand
Response• Renewables
• Spot market access• Shipping/Transmission• Balancing• Renewables sourcing• CO2 Allowances
• Spot market access• Shipping/Transmission• Balancing• Renewables sourcing• CO2 Allowances
• Energy equipements expertise
• Heat integration • Processes optimization• Refining scheme integration• Emissions capture• Peak shaving• Work organization• Energy performance
management
• Energy equipements expertise
• Heat integration • Processes optimization• Refining scheme integration• Emissions capture• Peak shaving• Work organization• Energy performance
management
Axens & Solvay Energy Services combine their expertise to provide an integrated services to the refining industry
10XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Use Solomon benchmark
• But go beyond a first level analysis
• Process expertise is required to assess energy performance and identify improvements in any refinery process unit
1st Quartile
2nd Quartile
UNITS Benchmark Measured energy consumption and EIITM
Measured consumption ( kBTU/bbl)
EII
11XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Example of High Severity CCR Reforming
Reactor Furnaces
56%
Others 44%
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
12XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
13XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
High efficiency Heat Exchangers
RecycleGas
H2
QuenchGas
Fuel Oil
MP Steam
Sour OilFeed
Gas OilProduct
Light EndsReactor Stripper
S&TExchangers
Heater
RecycleGas
H2
QuenchGas
Fuel Oil
MP Steam
Sour OilFeed
Gas OilProduct
Light EndsReactor Stripper
S&TExchangers
Heater
High efficiency HX gains
Heat Duty - 48%
Electrical power - 8%
RecycleGas
H2
QuenchGas
Fuel Oil
MP Steam
Sour OilFeed
Gas OilProduct
Light EndsReactor Stripper
PackinoxExchangers
14XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
High Efficiency Furnaces
• Optimising heat recovery
• Efficiencies above 92%?
• Consultation with equipment manufacturersTemperature (°C)
Flue Gas Temperature (°C)
COMBUSTIONAIR
283
FDF
LP STEAMHEATER
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
COMBUSTIONAIR
FLUE GAS
FLUE GAS305 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
15XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
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 minimizewasted heat (air coolers, trim coolers)
• Last: Use Licensor’s experience to define schemes that provide operability and flexibility
Stripper FeedStripper
TC
Reactor FeedFract. Feed
Reactor Effluent
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 Reactor Effluent Air Cooler
XXXTemperature (°C)
Duty (Gcal/h) YYY
LEGEND
16XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Non-conventional equipment
• Dividing Wall Columns lower energy requirement for reboiler of the combined column
Example: Benzene-Toluene distillation column
• Plate heat exchangers reduce T° approach and increase heat recovery replace several heat exchangers in series
Example: Feed/bottom of a distillation column
17XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
18XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Aromatics Complex Scheme Overview
Benzene
Paraxylene
Extractive Distillation
Xylenes Isom.
Transalkylation
Heavies
Reforming (CCR)
Raffinate
BC
Eluxyl
BT
Hydrotreated Naphtha
C7-
C8+
C9+
C9+C10
C8A
HA
XC
RS
C8+
Tol
FG + LPG
Conversion units
Separation units
Fractionation columns
19XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Aromatics Complex Scheme Overview
Benzene
Paraxylene
Extractive Distillation
XC
Xylenes Isom.
Transalkylation
Heavies
Reforming (CCR)
Raffinate
BC
Eluxyl
BT
Hydrotreated Naphtha
C7-
C8+
C9+
C9+C10
C8A
HA
RS
C8+
Tol
FG + LPG
20XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Energy efficiency studyfor Aromatic complex project
• Detailed study to review potential energy efficiency improvements:• Project specific (based
on client requirements)• Technical and
economical optimisation (CAPEX & OPEX)
• Example of modification to Aromatics Complex design:• Maximize heat conservation• Minimize air coolers• Produce steam and
electricity when possible
0
100
200
300
400
500
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Duty (Gcal/h)
Temperature (°C)
Cold Composite
Hot CompositePinch Temp (256°C)
Minimum Hot utilities : 86 Gcal/h
Minimum Cold utilities : 43.9 Gcal/h
21XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Steam generation studyBasis of design
• Several levels of steam considered from LLP to MP steam
• Reviewed opportunities for:• For steam recompression from LLP to LP and LP to MP
• Pre-heating BFW• Pre-heating furnace air
22XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Steam generation studyBasis of design
Example of scheme modifications envisaged:
• Increase or lower operating pressures of columns For heat integration with other process streams
• Installation of additional process exchanger on reaction sections (higher heat recovery on reactor effluent streams)
• Increase heat efficiency of fired heater
23XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Example of Process Heat Integration
Feed 1
Feed heater
Reactor
Feed / Effluent exch.
Effluent air cooler
Recycle compressor
Cold separator
HP purge
HPst
Distillate to stab.
Product 1
Feed 2
LP purge to Process
stab. Comp.
24XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Feed 1
Feed heater
Reactor
Feed / Effluent exch.
Effluent air cooler
Recycle compressor
Cold separator
HP purge
HPst
Distillate to stab.
Product 1
Feed 2
LP purge
Off gas from TP stab
Example of Process Heat Integration
25XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Energy efficiency versus CAPEX
• Gains in performances, an additional: ~ 20%
• Higher CAPEX:• 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)
26XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
• Unit interfaces may be areas of heat losses• Storage lay-out, especially on semi-finished
products, must be reviewed with the energy perspective
2-101-4ARD 1
02
VA
CU
UM
DIS
TIL
LA
TIO
N
2-101-2KERO
10
3
SG
P
2-101-3GO
302HDS GO
303NHT
401ISOM
402CCR
3-003MOGAS 95
2-401-1ISOM
2-402-1REF
3-005JET
2-302-1HDS GO
3-006GO
2-102-1VGO
2-202-2RFO
2-202-1MOGAS
501 A/BAMREG
502 A/B/C/DSRU
FG NETW.
601 A/BSTR
H2 NETW.
3-007HNA
2-105-1LNA
701LPG TREAT.
1-001CRUDE
2-102-2VRD
2-101-1LNA
2-203-3HRD
10
1
AT
MO
S D
IST
ILL
AT
ION
MOGAS
WWT
3-001C3
3-902COKE
3-901SULFUR
301HDS KERO
FG
FG
+ L
PG
203 A/BHCK
FG LPG
RECYCLED WATER
FG LN HN LPG
LCO
FG + LPG + CNA
10
4
UG
P
LNA
HCO / SLU
LC
GO
2-201-1CGO
202FCC + STAB
LNA
LNA
KERO
GO
VGO
HCK RD
HCGO
VRDCOKE
LN
A
H2S + NH3
REF
LPG
HCK GO
HCK
LPG
HP H2S FROM REMOVAL SECTIONS
H2S + NH3 FROM SWS
1-002MTBE
H2S
S
503 A/BTGT + INCIN
201DCK
MP H2S FROM REMOVAL SECTIONS
FG
H2S + NH3
FG + LPG + NA
FG + LPG + NA
504 A/BSWS
HDS GO
HDS KERO
HNA
VRD
2-203-2HCK GO
2-301-1HDS KERO
2-203-1HCK KERO
10
5
NS
P
3-004MOGAS 92
3-002C4
2-105-2HNA
DRAWING BLOCK FLOW DIAGRAM: UNITS - STORAGES
PROJECT CASE 16° API COKER - 1300 KTPY GASOLINE
Job Number Unit Type Date By Check Issue
07-3023S 1000 3D 03/07/07 YCH RGR 1
Interfaces & Off-sites
27XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Agenda
• Energy and CO2 Challenge
• Axens as a key partner
• Equipment optimisation
• Examples of process design optimisation
• Conclusion
28XXVI Russian National Inter-Industry Meeting - September 12th - 14th, 2012
Conclusion
• Energy efficiency practices presented earlier 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 (process integration,
equipments)• Consulting services (offer can be combined with
Solvay Energy Services)
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Thank you
Energy EfficiencyA Process Licencor 's View