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1 Energy Efficiency A Process Licencor 's View XXVI Russian National Inter-Industry Meeting September 12 th - 14 th, 2012.

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Presentation on theme: "1 Energy Efficiency A Process Licencor 's View XXVI Russian National Inter-Industry Meeting September 12 th - 14 th, 2012."— Presentation transcript:

1 1 Energy Efficiency A Process Licencor 's View XXVI Russian National Inter-Industry Meeting September 12 th - 14 th, 2012

2 2 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

3 3 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

4 4 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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

5 5 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

6 6 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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 Cumulative Number of Licenses Western Europe 19% Middle East 14% Africa 4% North America 12% Latin America 8% Asia 35% Eastern Europe + CIS 8% 2205 licenses as of 31 st December 2011

7 7 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Energy Efficiency & GHG Mitigation Methodology for Energy Audit 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

8 8 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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, EII TM, CO 2 - 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 EII TM 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 ranking Validation of project options to be developed during the next phase

9 9 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 CO 2 & Energy SOURCING IMPROVEMENT ENERGY CONSUMPTION REDUCTION ASSET OPTIMISATION Axens / SES Combined 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 CO 2 Allowances Spot market access Shipping/Transmission Balancing Renewables sourcing CO 2 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

10 10 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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 1 st Quartile 2 nd Quartile

11 11 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Example of High Severity CCR Reforming Aromatics yields: Heat of reaction governed by thermodynamics Includes: catalyst regeneration recycle compressor Stabilization section H 2 export compressor 80% of CCR reforming net energy consumption is directly linked to production objectives

12 12 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

13 13 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 High efficiency Heat Exchangers High efficiency HX gains Heat Duty- 48% Electrical power- 8%

14 14 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 High Efficiency Furnaces Optimising heat recovery Efficiencies above 92%? Consultation with equipment manufacturers

15 15 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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 minimize wasted heat (air coolers, trim coolers) Last: Use Licensors experience to define schemes that provide operability and flexibility

16 16 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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

17 17 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

18 18 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Aromatics Complex Scheme Overview Benzene Paraxylene Extractive Distillation Xylenes Isom. Transalkylation Heavies Reforming (CCR) Raffinate BCBC Eluxyl BTBT Hydrotreate d Naphtha C7-C7- C8+C8+ C9+C9+ C 9 +C 10 C8AC8A HAHA XC RS C8+C8+ Tol FG + LPG Conversion units Separation units Fractionation columns

19 19 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Aromatics Complex Scheme Overview Benzene Paraxylene Extractive Distillation XCXC Xylenes Isom. Transalkylation Heavies Reforming (CCR) Raffinate BCBC Eluxyl BTBT Hydrotreate d Naphtha C7-C7- C8+C8+ C9+C9+ C 9 +C 10 C8AC8A HAHA RS C8+C8+ Tol FG + LPG

20 20 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 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) Example of modification to Aromatics Complex design: Maximize heat conservation Minimize air coolers Produce steam and electricity when possible

21 21 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Steam generation study Basis 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

22 22 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Steam generation study Basis 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

23 23 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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.

24 24 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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

25 25 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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)

26 26 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 2012 Unit interfaces may be areas of heat losses Storage lay-out, especially on semi-finished products, must be reviewed with the energy perspective Interfaces & Off-sites

27 27 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

28 28 XXVI Russian National Inter-Industry Meeting - September 12 th - 14 th, 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)

29 29 Thank you Energy Efficiency A Process Licencor 's View


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