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13/11/2009 Slide Number- 1 Delivering excellence through people IDENTIFYING POTENTIAL - IN OFFSITES AND UTILITIES INCLUDING STEAM & POWER Dr S BANIK and.

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Presentation on theme: "13/11/2009 Slide Number- 1 Delivering excellence through people IDENTIFYING POTENTIAL - IN OFFSITES AND UTILITIES INCLUDING STEAM & POWER Dr S BANIK and."— Presentation transcript:

1 13/11/2009 Slide Number- 1 Delivering excellence through people IDENTIFYING POTENTIAL - IN OFFSITES AND UTILITIES INCLUDING STEAM & POWER Dr S BANIK and Mr A K VOHRA ENGINEERS INDIA LTD WORKSHOP ON ENERGY MANAGEMENT & EFFICIENCY IMPROVEMENT IN OIL & GAS SECTOR 13 TH NOV., 2009, DELHI

2 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 2 Engineers India Ltd – Delivering excellence through people REFINING CHALLENGES REFINING CHALLENGES UTILITIES & OFFSITE GROUP OF PLANTS UTILITIES & OFFSITE GROUP OF PLANTS STEAM SYSTEM STEAM SYSTEM STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES POWER SYSTEM POWER SYSTEM POWER SYSTEM ENERGY CONSERVATION OPPORTUNITIES POWER SYSTEM ENERGY CONSERVATION OPPORTUNITIES COMBINED STEAM & POWER NETWORK OPTIMIZATION COMBINED STEAM & POWER NETWORK OPTIMIZATION HEAT RECOVERY & CHP HEAT RECOVERY & CHP SMR & COGEN INTEGRATION SMR & COGEN INTEGRATION UTILITIES SAVING THROUGH REFINERY & PETROCHEMICAL INTEGRATION UTILITIES SAVING THROUGH REFINERY & PETROCHEMICAL INTEGRATION HYDROGEN SYSTEM & HYDROGEN CONSUMPTION OPTIMIZATION HYDROGEN SYSTEM & HYDROGEN CONSUMPTION OPTIMIZATION CONCLUSION CONCLUSIONCONTENTS

3 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 3 Engineers India Ltd – Delivering excellence through people REFINING CHALLENGES Distillate Yield Improvements Fuel Quality Up-gradation Optimize Energy Performance Strict Environmental Norms Maximize Margins Process High Sulfur Crudes Process High TAN/ Heavy Crudes Synergy- Refinery and Petrochemical

4 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 4 Engineers India Ltd – Delivering excellence through people Energy Performance Challenge REFINERY CONSUMES ABOUT 7 – 8% OF THE CRUDE PROCESSED AS FUEL REFINERIES ARE CONTINUOUSLY MAKING EFFORTS TO BRING DOWN THE ENERGY CONSUMPTIONS REFINERIES ARE CONTINUOUSLY MAKING EFFORTS TO BRING DOWN THE ENERGY CONSUMPTIONS SPECIFIC FUEL CONSUMPTION HAS REDUCED BY ABOUT 20% - FROM 89.0 TO 71.0 MMBTU/BBL/NRGF, OVER THE LAST 8-10 YEARS FUEL COST CONTRIBUTES 40-45% TOWARDS THE COST OF REFINERY OPERATION 30-40% OF THE FUEL COST IS ATTRIBUTED TO GENERATION OF UTILITIES LIKE STEAM / POWER FOCUS IS NOW ON UTILITIES CONSERVATION

5 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 5 Engineers India Ltd – Delivering excellence through people UTILITIES & OFFSITE SYSTEM UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF: UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF: BOILERS BOILERS STEAM TURBINE GENERATORS STEAM TURBINE GENERATORS GAS TURBINE GENERATORS / HEAT RECOVERY STEAM GENERATORS GAS TURBINE GENERATORS / HEAT RECOVERY STEAM GENERATORS HYDROGEN GENERATION UNIT HYDROGEN GENERATION UNIT NITROGEN GENERATION UNIT NITROGEN GENERATION UNIT COOLING TOWERS COOLING TOWERS INSTRUMENT AIR SYSTEM INSTRUMENT AIR SYSTEM WATER TREATMENT UNITS WATER TREATMENT UNITS STEAM & POWER CONSUME BULK OF THE ENERGY IN OFFSITE & UTILITIES SYSTEM STEAM & POWER CONSUME BULK OF THE ENERGY IN OFFSITE & UTILITIES SYSTEM

6 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 6 Engineers India Ltd – Delivering excellence through people REFINERY STEAM SYSTEM STEAM GENERATION STEAM GENERATION STAND ALONE BOILERS STAND ALONE BOILERS HEAT RECOVERY STEAM GENERATORS HEAT RECOVERY STEAM GENERATORS PROCESS WASTE HEAT BOILERS PROCESS WASTE HEAT BOILERS WASTE HEAT FROM SMR WASTE HEAT FROM SMR STEAM DISTRIBUTION STEAM DISTRIBUTION RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS & TURBINE EXHAUST RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS & TURBINE EXHAUST NORMALLY STEAM IS DISTRIBUTED AT 3 – 4 PRESSURE LEVELS NORMALLY STEAM IS DISTRIBUTED AT 3 – 4 PRESSURE LEVELS END USE END USE PROCESS STREAM HEATING PROCESS STREAM HEATING AS A SOURCE OF WATER ( HYDROGEN GENERATION ) AS A SOURCE OF WATER ( HYDROGEN GENERATION ) COMPONENT SEPARATION COMPONENT SEPARATION SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. ) SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. ) RECOVERY RECOVERY CONDENSATE RECOVERY CONDENSATE RECOVERY

7 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 7 Engineers India Ltd – Delivering excellence through people STEAM GENERATION STEAM GENERATION AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF RELIABILTY OF STEAM SUPPLY) AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF RELIABILTY OF STEAM SUPPLY) LEADS TO GENERATION OF EXTRA STEAM WHICH IS FINALLY CONDENSED IN COOLRS AND CONDENSATE IS RECYCLED LEADS TO GENERATION OF EXTRA STEAM WHICH IS FINALLY CONDENSED IN COOLRS AND CONDENSATE IS RECYCLED PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN EFFICIENCY OF ~ 85 – 86%. PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN EFFICIENCY OF ~ 85 – 86%. EFFICIENCY CAN BE IMPROVED TO +90% EFFICIENCY CAN BE IMPROVED TO +90% AVAILABILTY OF SPACE COULD BE A LIMITATION AVAILABILTY OF SPACE COULD BE A LIMITATION LOW EXCESS AIR BURNERS LOW EXCESS AIR BURNERS WILL REDUCE STACK LOSS AND FUEL WILL REDUCE STACK LOSS AND FUEL USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE RUN ON PART LOAD FOR RELIABILTY USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE RUN ON PART LOAD FOR RELIABILTY BOILER FEED-WATER PUMPS BOILER FEED-WATER PUMPS BLOWERS BLOWERS REFINERY STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIES

8 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 8 Engineers India Ltd – Delivering excellence through people IMPROVE WATER TREATMENT TO MINIMIZE BOILER BLOW DOWN IMPROVE WATER TREATMENT TO MINIMIZE BOILER BLOW DOWN RECOVER ENERGY FROM BOILER BLOW DOWN RECOVER ENERGY FROM BOILER BLOW DOWN OPTIMIZE DEAERATOR VENT RATE TO MINIMIZE AVOIDABLE LOSS OPTIMIZE DEAERATOR VENT RATE TO MINIMIZE AVOIDABLE LOSS MAINTAIN REFRACTORY IN GOOD CONDITION TO REDUCE SURFACE LOSS MAINTAIN REFRACTORY IN GOOD CONDITION TO REDUCE SURFACE LOSS STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIES

9 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 9 Engineers India Ltd – Delivering excellence through people IMPROVE STEAM DISTRIBUTION SYSTEM IMPROVE STEAM DISTRIBUTION SYSTEM AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & MAINTENANCE PROGRAM IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & MAINTENANCE PROGRAM LEAKING TRAPS SHOULD NOT EXCEED 5% OF THE TRAPS LEAKING TRAPS SHOULD NOT EXCEED 5% OF THE TRAPS FAULTY TRAP WITH 1/8 INCH ORIFICE INSTALLED ON 6.5 KG/CM 2 G LINE MAY CAUSE STEAM LOSS OF 300 TPA FAULTY TRAP WITH 1/8 INCH ORIFICE INSTALLED ON 6.5 KG/CM 2 G LINE MAY CAUSE STEAM LOSS OF 300 TPA RECOMMENDED STEAM TRAP SURVEY RECOMMENDED STEAM TRAP SURVEY UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIES STEAM LINE PRESSURE, KG/CM 2 GTRAP TESTING FREQ KG/CM 2 G AND ABOVEWEEKLY TO MONTHLY 2.0 TO 10.0 KG/CM 2 GMONTHLY TO QUARTERLY < 2.0 KG/CM 2 GANNUALLY

10 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 10 Engineers India Ltd – Delivering excellence through people END USE IMPROVEMENTS END USE IMPROVEMENTS REQUIRES CASE BY CASE ASSESSMENT REQUIRES CASE BY CASE ASSESSMENT RUNNING SINGLE TURBINE DRIVEN PUMP / BLOWER RUNNING SINGLE TURBINE DRIVEN PUMP / BLOWER TWO TURBINE DRIVEN 495 KW AIR BLOWERS WERE RUN IN SRU UNIT INSTEAD OF ONE AT PART LOAD OF 250 KW. TWO TURBINE DRIVEN 495 KW AIR BLOWERS WERE RUN IN SRU UNIT INSTEAD OF ONE AT PART LOAD OF 250 KW. OPTIMIZATION OF STRIPPING STEAM OPTIMIZATION OF STRIPPING STEAM MINIMIZE DEAERATOR VENT STEAM MINIMIZE DEAERATOR VENT STEAM CONDENSATE RECOVERY SYSTEM CONDENSATE RECOVERY SYSTEM STEAM SYSTEM – ENERGY CONSERVATION OPPORTUNITIES LOAD, KWSTEAM R ATE, KG/KW- HR STEAM CONSUMPTION, TPH LOSS, TPH

11 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 11 Engineers India Ltd – Delivering excellence through people POWER SYSTEMS CO-GENERATION OR COMBINED HEAT AND POWER PLANTS ARE WIDELY EMPLOYED FOR PRODUCTION OF POWER & HEAT ( STEAM ) IN REFINERIES AND PETROCHEMICAL PLANTS 30% PLUS MORE EFFICIENT THAN SEPARATE PRODUCTION EQUIPMENTS WITH VARYING POWER TO HEAT RATIO ARE AVAILABLE Cogeneration SystemHeat – to – power ratio ( KW th /KW e ) Power Output ( as% of fuel input ) Overall Efficiency, % Back Pressure Turbine4.0 – Extraction Condensing Steam Turbine 2.0 – Gas Turbine1.0 – Combined Cycle1.0 –

12 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 12 Engineers India Ltd – Delivering excellence through people GAS TURBINES GENERATORS GAS TURBINES GENERATORS A PREFERRED CHOICE OVER STEAM TURBINE BASED POWER GENRATING SYSTEMS A PREFERRED CHOICE OVER STEAM TURBINE BASED POWER GENRATING SYSTEMS LOWER CAPITAL COST LOWER CAPITAL COST MODULAR DESIGN – SHORTER INSTALLATION TIME MODULAR DESIGN – SHORTER INSTALLATION TIME QUICK TO START QUICK TO START HIGH EFFICIENCY HIGH EFFICIENCY LOWER EMISSIONS LOWER EMISSIONS USED IN COMBINATION WITH HEAT RECOVERY STEAM GENERATOR (HRSG) USED IN COMBINATION WITH HEAT RECOVERY STEAM GENERATOR (HRSG) STEAM PRODUCED IN HRSG CAN BE USED TO MEET SITE HEATING REQUIREMENT OF FOR POWER GENERATION THROUGH STG STEAM PRODUCED IN HRSG CAN BE USED TO MEET SITE HEATING REQUIREMENT OF FOR POWER GENERATION THROUGH STG POWER GENERATION

13 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 13 Engineers India Ltd – Delivering excellence through people COOLING OF INLET AIR COOLING OF INLET AIR LOW COST AND LOW PAYBACK PERIOD LOW COST AND LOW PAYBACK PERIOD EASY TO INSTALL EASY TO INSTALL CHANGES ARE EXTERNAL TO GAS TURBINE CHANGES ARE EXTERNAL TO GAS TURBINE OVER 700 WORLDWIDE INSTALLATIONS OVER 700 WORLDWIDE INSTALLATIONS SUCH A SYSTEM IS WORKING SATISFACTORILY IN A MEGA REFINERY IN THE COUNTRY SUCH A SYSTEM IS WORKING SATISFACTORILY IN A MEGA REFINERY IN THE COUNTRY METHODOLOGY COMMONLY APPLIED METHODOLOGY COMMONLY APPLIED EVAPORATIVE EVAPORATIVE FOGGING / WET COMPRESSION FOGGING / WET COMPRESSION DROPLET SIZE MICRONS, VERY HIGH PRESSURE PUMP : 100 – 150 BAR DROPLET SIZE MICRONS, VERY HIGH PRESSURE PUMP : 100 – 150 BAR CHILLERS CHILLERS MECHANICAL / ABSORPTION MECHANICAL / ABSORPTION LOW LEVEL RECOVERED HEAT CAN BE GAINFULLY UTILIZED LOW LEVEL RECOVERED HEAT CAN BE GAINFULLY UTILIZED OFFERS BETTER CONTROL OF TEMPERATURE OFFERS BETTER CONTROL OF TEMPERATURE APPROX. 3 TIMES COSTLY THAN FOGGING SYSTEM APPROX. 3 TIMES COSTLY THAN FOGGING SYSTEM POWER SYSTEM PERFORMANCE IMPROVEMENT

14 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 14 Engineers India Ltd – Delivering excellence through people Efficient Heat Recovery-Gas Turbine Exhaust

15 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 15 Engineers India Ltd – Delivering excellence through people Refinery With HRU/HRSG

16 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 16 Engineers India Ltd – Delivering excellence through people Impact of HRU/HRSG On EII

17 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 17 Engineers India Ltd – Delivering excellence through people COMBINED HEAT AND POWER SYSTEM

18 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 18 Engineers India Ltd – Delivering excellence through people COMBINED HEAT & POWER NETWORK POWER GENERATION GAS TURBINE GENERATOR STEAM TURBINE GENERATOR POWER DEMAND IS LINKED TO PLANT THROUGHPUT AND AFFECTS STEAM GENERATION STEAM GENERATION UTILITIES BOILERS ( GENERATION LINKED TO PLANT THROUGHPUT AND POWER OUTPUT FROM STG / GTG ) HRSG ( STEAM GENERATION LINKED TO POWER OUTPUT ) WASTE HEAT RECOVERY STEAM GENERATION AT 2 TO 3 PRESSURE / TEMPERATURE LEVELS GNERATION LINKED TO PLANT LOAD AND FEED QUALITY HIGH H 2 S CONTENT IN ACID GAS WILL GENERATE MORE STEAM IN WHB PRDS FOR MAINTAING STEAM PRESSURE AT DIFFERENT LEVELS STEAM CONSUMPTION 3 TO 4 PRESSURE / TEMPERATURE LEVELS BPT WITH INLET STEAM AND EXHAUST STEAM AT 2 OR MORE PRESSURE LEVELS

19 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 19 Engineers India Ltd – Delivering excellence through people COMBINED HEAT & POWER NETWORK CONDENSATE RECOVERY SYSTEM CONDENSATE FLASH DRUMS OPEATING AT VARIOUS PRESSURE / TEMPERATURE LEVEL VENT STEAM CONDENSER AFFECTS DM WATER REQUIREMENT PROVIDES HEAT FOR HEATING DM WATER GOING TO DEAERATOR DE-AERATOR STEAM CONSUMPTION LINKED TO BFW REQUIREMENT AND ITS TEMPERATURE HEAT AND POWER NETWORK OF A REFINERY IS COMPLEX STEAM AND POWER GENERATION AND CONSUMPTION ARE INTELINKED NETWORK MODELING / SIMULATION PROGRAM SHALL BE USEFULL IN OPTIMIZING THE STEAM AND POWER GENERATION TO MINIMIZE FUEL COST MODELS ARE SITE SPECIFIC AND ARE DEVELOPED FROM THE OPERATING DATA USING NON-LINEAR REGRESSION METHODS

20 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 20 Engineers India Ltd – Delivering excellence through people SIMULATION PROGRAM MULTIVARIABLE EQUATION -SETS FOR MASS & ENERGY BALANCE FOR EACH SUBSYSTEM ARE DEVELOPED MODEL INPUTS GAS TURBINE : AMBIENT AIR TEMP., POWER OUT PUT, HEAT RATE, FUEL CONSUMPTION BOILERS : STEAM GENERATION AND FUEL CONSUMPTION HRSG : FUEL CONSUMED IN GTG, AMBIENT AIR TEMP. STEAM TURBINES : STEAM RATE CURVES, STEAM FLOW DATA EQUATIONS ARE SOLVED USING A SOLVER SUPPORTED ON EXCEL SOLVER USES A NON-LINEAR OPTIMIZATION PROGRAM PROGRAM PROVIDES TOTAL QUANTITY AND COST OF BOTH POWER AND STEAM UTILITIES. COMBINED HEAT & POWER SYSTEM MODELING/OPTIMIZATION

21 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 21 Engineers India Ltd – Delivering excellence through people CHP SYSTEM MODELING CHP SUB-SYSTEMS BOILER CGTG STG HRSG SMR HRU PRDS DEAERATOR CONDENSATE & BFW SYSTEM

22 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 22 Engineers India Ltd – Delivering excellence through people SMR COGEN INTEGRATION

23 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 23 Engineers India Ltd – Delivering excellence through people CHP COGEN INTEGRATION

24 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 24 Engineers India Ltd – Delivering excellence through people SMR COGEN INTEGRATION

25 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 25 Engineers India Ltd – Delivering excellence through people Typical CHP SYSTEM MODELING BOILER MODEL ANNUAL FUEL / STEAM GENERATION DATA OF EACH BOILER IS PLOTTED AND NON LINEAR EQUATIONS ARE OBTAINED F = A+ B.S+ C.S 2 F : FUEL CONSUMPTION S : STEAM PRODUCED FROM BOILER A,B & C ARE CONSTANTS CALCULATED FROM THE OPERATING DATA LOWER AND UPPER LIMITS OF STEAM GENERATION CAN BE PROVIDED IN THE MODEL MODEL PROVIDE ADDITIONAL STEAM GENERATION LOAD ON BOILER HAVING HIGER EFFICIENCY SIMILAR MODEL FOR HRSG IS DEVELOPED

26 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 26 Engineers India Ltd – Delivering excellence through people COMBINED HEAT & POWER SYSTEM MODELING GAS TURBINE MODEL HEAT RATE CURVE ANNUAL POWER / FUEL CONSUMPTION DATA OF EACH TURBINE AMBIENT AIR TEMPERATURE F = A+ B.P+ C.P 2 + D.T+ E.T 2 F : FUEL CONSUMPTION P : POWER, T : AMBIENT AIR TEMP A,B,C,D & E ARE CONSTANTS CALCULATED FROM THE OPERATING DATA SIMILAR MODEL FOR STEAM TURBINE IS DEVELOPED

27 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 27 Engineers India Ltd – Delivering excellence through people ENERGY AUDIT27 TYPICAL STEAM NETWORK

28 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 28 Engineers India Ltd – Delivering excellence through people ENERGY AUDIT28 SAMPLE STEAM NETWORK

29 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 29 Engineers India Ltd – Delivering excellence through people CHP MODEL ENERGY AUDIT29

30 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 30 Engineers India Ltd – Delivering excellence through people CHP NETWORK SIMULATION / OPTIMIZATION APPLICATION OF SIMULATION PROGRAM ESTABLISH OPTIMAL GENERATION / PURCHASE / EXPORT OF POWER AND STEAM SO AS TO MINIMIZE THE SITE FUEL / UTILITIES COST EVALUATE ENERGY CONSERVATION SCHEMES FROM GLOBAL ( PLANT ) PERSPECTIVE EVALUATE STRATEGIES FOR POWER / STEAM GENERATION CAPACITY EXPANSION FOR NEW REQUIREMENTS

31 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 31 Engineers India Ltd – Delivering excellence through people GAS PLANT CAPACITY : 2600 MMSCFD GAS PLANT CAPACITY : 2600 MMSCFD GAS SWEETENING UNIT GAS SWEETENING UNIT GAS DEHYDRATION UNIT GAS DEHYDRATION UNIT NGL RCOVERY ( LOW TEMP. ) NGL RCOVERY ( LOW TEMP. ) SRU SRU COMPRESSOR STATION FOR GAS PIPELINE COMPRESSOR STATION FOR GAS PIPELINE ENERGY CONSERVATION SCHEMES IDENTIFIED ENERGY CONSERVATION SCHEMES IDENTIFIED ENHANCED PROCESS TO PROCESS COLD EXCHANGE ENHANCED PROCESS TO PROCESS COLD EXCHANGE PROVISION OF LEAN / RICH AMINE EXCHANGER PROVISION OF LEAN / RICH AMINE EXCHANGER POWER GENERATION FROM HYDRAULIC TURBINE IN DGA UNIT POWER GENERATION FROM HYDRAULIC TURBINE IN DGA UNIT OBSG ON HEATERS OBSG ON HEATERS VARIAABLE SPEED DRIVES FOR PUMPS & AIR COOLERS VARIAABLE SPEED DRIVES FOR PUMPS & AIR COOLERS ENERGY SAVED ENERGY SAVED POWER : 21 MW POWER : 21 MW STEAM GENERATION : 416 MLBH STEAM GENERATION : 416 MLBH FUEL SAVING : 100MSCFH FUEL SAVING : 100MSCFH ENERGY SAVING SCHEMES HAD GOOD PAYBACK PERIOD ENERGY SAVING SCHEMES HAD GOOD PAYBACK PERIOD CHP ANALYSIS SHOWED THAT BANEFITS OF ENERGY CONSERVATION CAN BE ACHIEVED IF CHP ANALYSIS SHOWED THAT BANEFITS OF ENERGY CONSERVATION CAN BE ACHIEVED IF POWER IS GENERATED FROM THE STEAM GENERATED IN THE ENCON SCHEME AND EXPORTED POWER IS GENERATED FROM THE STEAM GENERATED IN THE ENCON SCHEME AND EXPORTED ENERGY CONSERVATION OPPORTUNITY ASSESSMENT STUDIES AT SAUDI ARAMCO GAS PLANT

32 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 32 Engineers India Ltd – Delivering excellence through people REFINERY-PETROCHEMICAL INTEGRATION(Typical)

33 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 33 Engineers India Ltd – Delivering excellence through people VALUE Chain Integration of Refinery Products to Petrochemical Feed VALUE Chain Integration of Refinery Products to Petrochemical Feed Sharing and Efficient Use of Utilities Sharing and Efficient Use of Utilities Sharing of Offsites and Infrastructure Sharing of Offsites and Infrastructure Sharing of All Plant Resources Including Human Resources Sharing of All Plant Resources Including Human Resources Overall Reduction in CAPEX and OPEX Overall Reduction in CAPEX and OPEX REFINERY-PETROCHEMICAL INTEGRATION REFINERY-PETROCHEMICAL INTEGRATION

34 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 34 Engineers India Ltd – Delivering excellence through people Integrated Common Facilities Achieving Economies of Scale for: Integrated Common Facilities Achieving Economies of Scale for: Flare Flare Waste Water Treating Waste Water Treating Buildings Buildings Control Room Control Room Laboratory Laboratory Refinery/Petrochem –Offsite/Infrastructure Integration

35 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 35 Engineers India Ltd – Delivering excellence through people Steam System: Excess MP/LP Steam from Cracker to the Refinery for Overall Steam System Efficiency Steam System: Excess MP/LP Steam from Cracker to the Refinery for Overall Steam System Efficiency Excess Hydrogen from Petrochemical to Refinery Excess Hydrogen from Petrochemical to Refinery Integrated Common Facilities Achieving Economies of Scale for: Integrated Common Facilities Achieving Economies of Scale for: Cooling Water Cooling Water Air Air Nitrogen Nitrogen Fire Water Fire Water Fuel Fuel Refinery/Petrochemicals- Utilities Integration and Energy Efficiency

36 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 36 Engineers India Ltd – Delivering excellence through people Hydrogen System

37 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 37 Engineers India Ltd – Delivering excellence through people HYDROGEN GENERATION PROCESS SCHEMES

38 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 38 Engineers India Ltd – Delivering excellence through people MODEL BASED ASSESSMENT

39 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 39 Engineers India Ltd – Delivering excellence through people H 2 internal optimization H 2 internal optimization Optimized performance of the new on-purpose H 2 facility, while best satisfying the refinery-wide utilities and operational requirements, especially in terms of reliability and flexibility. Optimized performance of the new on-purpose H 2 facility, while best satisfying the refinery-wide utilities and operational requirements, especially in terms of reliability and flexibility. Degree of ROG utilization, H 2 recovery and multiple feed flexibility Degree of ROG utilization, H 2 recovery and multiple feed flexibility Reforming severity Reforming severity Minimization of involuntary HP steam export Minimization of involuntary HP steam export Level of CO 2 capture Level of CO 2 capture H2 Network Optimization

40 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 40 Engineers India Ltd – Delivering excellence through people H 2 external optimization H 2 external optimization Developing of H 2 balance model Developing of H 2 balance model Identification of limitations and/or flexibility of the H 2 usage Identification of limitations and/or flexibility of the H 2 usage H 2 network LP modelling or H 2 off-line analysis H 2 network LP modelling or H 2 off-line analysis Identification of the key inefficiency of the H 2 network Identification of the key inefficiency of the H 2 network Integration of possible alternatives for H 2 re-use and regeneration Integration of possible alternatives for H 2 re-use and regeneration Identification of the optimum size for a new on- purpose H 2 generation Unit Identification of the optimum size for a new on- purpose H 2 generation Unit Hydrogen Network Optimization

41 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 41 Engineers India Ltd – Delivering excellence through people Refinery-wide parameters Refinery-wide parameters Crude evaluation/substitution Crude evaluation/substitution Overall refinery scheme and unit operation interactions Overall refinery scheme and unit operation interactions Residue upgrading options assessment Residue upgrading options assessment Fuel substitution Fuel substitution Carbon separation/sequestration solutions Carbon separation/sequestration solutions Utilities LP modelling Utilities LP modelling CO 2 LP modelling CO 2 LP modelling Hydrogen Network Optimization

42 CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 42 Engineers India Ltd – Delivering excellence through people Typical Refinery Hydrogen Network

43 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 43 Engineers India Ltd – Delivering excellence through people Optimization of Hydrogen Usage Optimization of Hydrogen Usage Technology Up-gradation Technology Up-gradation Feed + Fuel ( NG case) is 7% lower for PSA based Plant Feed + Fuel ( NG case) is 7% lower for PSA based Plant Fuel Required is 37% lower for PSA based plant Fuel Required is 37% lower for PSA based plant Switching to Lower Mol Wt Hydrocarbon saves utility Switching to Lower Mol Wt Hydrocarbon saves utility Benefits of Switching of Feed from Naphtha to Pentane Benefits of Switching of Feed from Naphtha to Pentane Pre-desulphurisation is omitted Pre-desulphurisation is omitted Steam Flow at Mixing point Reduced by 12% Steam Flow at Mixing point Reduced by 12% Fuel Requirement Reduced by 14.2% Fuel Requirement Reduced by 14.2% H2 Yield Increased by 1 % H2 Yield Increased by 1 % CO2 Emissions Reduced By 1.5% CO2 Emissions Reduced By 1.5% HYDROGEN GENERATION-Saving in Utility

44 POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 44 Engineers India Ltd – Delivering excellence through people OFFSITES AND UTILITIES CONSUME ABOUT 40 % OF ENERGY OFFSITES AND UTILITIES CONSUME ABOUT 40 % OF ENERGY STEAM, POWER ARE MAJOR UTILITIES CONSIDERED STEAM, POWER ARE MAJOR UTILITIES CONSIDERED SCOPE FOR REDUCTION IN ENERGY CONSUMPTIO IDENTIFIED SCOPE FOR REDUCTION IN ENERGY CONSUMPTIO IDENTIFIED INTEGRATION OF REFINERY/PETROCHEMICAL PLANT SAVES COST AND ENERGY INTEGRATION OF REFINERY/PETROCHEMICAL PLANT SAVES COST AND ENERGY HYDROGEN SYSTEM MANAGEMENT CAN HELP HYDROGEN SYSTEM MANAGEMENT CAN HELP TO IDENTIFY OPPORTUNITY FOR UTILITY SAVINGS CONCLUSIONS

45 Thank You


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