Energy Efficiency A P rocess L icencor 's V iew

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


Agenda





• Conclusion


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


Agenda





• Conclusion


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

200

400

600

800

1000

1200

1400

1600

1800

2000

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


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


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


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


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


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


Agenda





• Conclusion


High efficiency Heat Exchangers

RecycleGas

H2

QuenchGas

Fuel Oil

MP Steam

Sour OilFeed

Gas OilProduct


S&TExchangers

Heater

RecycleGas

H2

QuenchGas

Fuel Oil

MP Steam

Sour OilFeed

Gas OilProduct


S&TExchangers

Heater

High efficiency HX gains

Heat Duty - 48%

Electrical power - 8%

RecycleGas

H2

QuenchGas

Fuel Oil

MP Steam

Sour OilFeed

Gas OilProduct


PackinoxExchangers


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


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


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


Agenda





• Conclusion


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


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


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


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


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


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.


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


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)


• 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


Agenda





• Conclusion


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

Thank you

Energy EfficiencyA Process Licencor 's View

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Energy Efficiency A P rocess L icencor 's V iew