Solutions for Energy Efficiency Challenges

Ccile Plain

Agenda

Energy and CO2 Challenge

Axens as a key partner Equipment optimization

Case Studies

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

Operating Expenses Split 59.0% 61.5% 0% 41.0% Energy 38.5% Non-Energy

Product specification developments and dieselization lead to an increase in energy consumption

2006 2008

20% 40% 60% 80% 100%

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Agenda

Energy and CO2 Challenge

Axens as a key partner Equipment optimization

Case Studies

Axens as a Key Partner

Axens as a licensor:

Extensive know-how and experience on whole refining & petrochemical scheme.

Axens has been awarded a total licenses as of 31st December 2012:

2205

Axens as catalyst &

special equipment provider:

Innovative solutions for OPEX reduction in existing assets

Eastern Europe + CIS 8% Western Europe 19% Latin Middle East America North Africa 14% 8% America 4% 12% Asia 35%

Axens has set up a structured knowledge management process to capitalize on each project
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Energy Efficiency & GHG Mitigation

Establish Referential
Unit energy consumption 2004 Solomon standard - Case study 2004 - Case study 2006
4000 3000

Propose Options
Reactor Quench Gas Stripper Light Ends 173
153

Cost Estimate & Financial Analysis

9 8 16 19
Gas Oil Product

133 Steam MP

Fuel Oil
113

2000

Packinox Exchangers
1000

Recycle Gas
93

over 80 options screened

H2
73

Sour Oil Feed

0 ADU 1 ADU 2 ADU 3 VDU 1 VDU 2 HCK REF 1 REF 2 SMR PSA NHDT NHDT KHDS KHDS Others 1 2 1 2

53

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Current EII

Operation Optimisation

Maintenance

Low CAPEX

High CAPEX

EII Potential

On-site Data collection:

- Utilities network - Process units performance - Large thermal & power equipment performance - Flare system - Emissions assessment - Maintenance & Operational good practices

Screen projects options that could improve energy efficiency:

- Non-CAPEX options - Low CAPEX options - High CAPEX options

Detailed study of selected projects (CAPEX, IRR, NPV) Estimation of related saving (including Solomon EIITM

Evaluation compliance to CDM criteria

Customer selection of projects to be further developed

Baseline setting: - KPIs, EIITM, CO2

- Energy consumption / cost

Case ranking Validation of project options to be developed during the next phase
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Axens / SES Combined Expertise for Refiners

Axens & Solvay Energy Services combine their expertise to provide an integrated services to the refining industry

ENERGY SOURCING CONSUMPTION IMPROVEMENT REDUCTION CO2 Spot market access Energy equipement expertise & Shipping/Transmission Heat integration Energy Balancing Processes optimization Renewables sourcing Refining scheme integration CO2 Allowances Emissions capture Peak shaving ASSET Work organization OPTIMISATION Combined Heat and Power Energy performance Load curve management Management Supply / Demand Response Renewables 7

Use benchmark
UNITS Benchmark Measured energy consumption and EII

2nd Quartile

1st Quartile

But go beyond a first level analysis Process expertise is required to assess energy performance
and identify improvements in any refinery process unit
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Example of High Severity CCR Reforming

Includes: catalyst regeneration recycle compressor Stabilization section H2 export compressor Others 44% Reactor Furnaces 56% Aromatics yields: Heat of reaction governed by thermodynamics

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

10

High Efficiency Heat Exchangers

Light Ends Heater Reactor Quench Gas MP Steam Fuel Oil Recycle Gas H2 Stripper

Reactor Quench Gas

Stripper

Fuel Oil Recycle Gas H2

S&T Exchangers

Packinox Exchangers Gas Oil Product

Sour Oil Feed

Sour Oil Feed

High efficiency HX gains Heat Duty Electrical power - 48% - 8%

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High Efficiency Furnace

Optimising heat recovery Efficiencies above 92%? Consultation with equipment manufacturers
FLUE GAS

Temperature (C) Flue Gas Temperature (C)

ATM

COLD FLUE GAS DUCT

150 BFW BFW

HOT FLUE GAS DUCT

FLUE GAS
257 BFW / HP STEAM 257 BFW

305
307 SUPERHEATED HPS 257 HP STEAM

320
26390 kg/h FLUE GAS

13027 kg/h

283 PROCESS 296 PROCESS FLUID

Heat release

Heat release

9.37

18.98

PH-47103
AIR PREHEATER

2.0 (est.)

H-47102

H-47103 164 197

150

LP STEAM HEATER HOT AIR DUCT FDF 15.6 COMBUSTION AIR

IDF

?
HOT AIR DUCT

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COMBUSTION AIR FDF

LP STEAM

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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
Fractionator 325 193 307 9.81 263 168 122

Reactor Effluent

428

376

307

270

245

213

193

168

152

122

To Reactor Effluent Air Cooler

12.35

16.63 213

8.70

5.83

7.87 152

4.60

6.00

3.76

7.16 90%

407

376

245 10% bypass

5.38

209

240

TC

134

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Reactor

Fract. Feed

Stripper

Reactor Feed

Stripper Feed

LEGEND
Temperature (C)
XXX YYY

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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

FG + LPG
Extractive Distillation B C B T Tol Transalkylation

Raffinate Benzene

C7-

Hydrotreated Naphtha

C8+ Reforming (CCR) C8+

R S

Paraxylene
C8A
Eluxyl

Xylenes Isom. C9+C10

Conversion units Separation units Fractionation columns

XC

C9+

H A 16

Heavies

Aromatics Complex Scheme Overview

FG + LPG
Extractive Distillation

Raffinate Benzene
B C
B T Tol Transalkylation

C7-

Hydrotreated Naphtha

C8+
Reforming (CCR)
RS

Paraxylene
C8A Eluxyl
Xylenes Isom.

C8+
X C C9+

C9+C10

H A

Heavies

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Energy Efficiency Study for Aromatic Complex Project

Detailed study to review

potential energy efficiency improvements:
Project specific (based on client requirements) Technical and economical optimisation (CAPEX & OPEX)
Temperature (C) Minimum Hot utilities : 86 Gcal/h 500

400

300 Pinch Temp (256C)

Cold Composite Hot Composite

Example of modification to
Aromatics Complex design:
Maximize heat conservation Minimize air coolers Produce steam and electricity when possible

200

Minimum Cold utilities : 43.9 Gcal/h 100

0
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)

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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 air

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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 of additional process exchanger on reaction sections (higher heat recovery on reactor effluent streams) 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 Reactor Feed 2 LP purge to Process stab. Comp. HP purge

Feed heater

Recycle compressor

Effluent air cooler

Cold separator

Distillate to stab.

Feed / Effluent exch.

HPst

Product 1 23

Example of Process Heat Integration

Feed 1 Reactor Feed 2 HP purge
LP purge

Feed heater

Off gas from TP stab Recycle compressor Effluent air cooler Distillate to stab.

Cold separator

Feed / Effluent exch.

HPst

Product 1

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Energy efficiency versus CapEx

Gains in performances, an additional 20% 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

Energy
Fuel gas
Steam (MP) Electricity Total

GJ/d
4 600
700 600 5 900

Percent
78%
12%

Exhaustive energy balance

78% of total energy is fuel gas

Benchmark with top performers / best design

2.5 times more than top performers

Questionnaire 10%

Identify and check top energy consumers

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The Right Start: Identify Energy Losses

E4 E5

V5
Unstabilized Naphtha

Water Air cooler cooler Air cooler

E3

Air cooler
E6

Unstabilized Naphtha Heat Exchanger

E7

Legend

C 2 C Site Visit V 3 1
Upper feed

LOST ENERGY
HCGO

LCGO

Water cooler
E1

C1

C4 Reboiler

E2

V 2

V 3

V 4

Coker Drums

Cold Feed

F1
Feed Heater

Lower feed

F2 /A

F2 /B

Coker Heater Efficiency

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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 Focus on fuel gas savings projects (78% of total energy consumed)

Delayed Coker Unit: Interim Meeting

Project Short List 1. Shutdown Feed Heater
Most DCU do not have one!

2. Improve coker heater efficiency

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Shutdown Feed Heater: 1000 kg/h of fuel gas saved

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 Hot Feed

New Line from Vacuum Distillation Unit

New Cold Feed Pre-Heat Exchangers

To C1

Cold Feed

New Mixed Feed Heat Exchanger

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Improved Coker Heater Efficiency 770 kg/h of Fuel Gas Saved

CO F2A/B

02 QC

Flue gas To Heat Mixed Feed Feed from C1 bottom

6 projects
New Burners Control Inlet & Outlet heater Temperature Measure and Control Oxygen Measure CO Pre-Heat Combustion Air

TC

TC

New Burners

To C1

Fuel gas

Air Damper

Pre-heated Combustion Air

Heater Efficiency improved by 20%

(calculation with heater simulation software)
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Projects Economic Summary

Projects
F2 shutdown Coker Heater Efficiency Total Fuel Gas Savings kg/H

Gap Closure

Savings M$/year

Costs M$

POT Years

1,000 770 1,770

32% 25% 57%

3.8 3.0 6.8

3.7 2.4 6.1

1,0 0,7 0,9

Feed heater is bypassed and shutdown Other projects on Coker heaters

= Beyond Energy Efficiency, improved heaters and yield stability ! = Extra savings on maintenance !

Gap to top performers normalized at 100

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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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