International Best Practices of ESO Implementation in the ... · • High efficiency heat...
Transcript of International Best Practices of ESO Implementation in the ... · • High efficiency heat...
International Best Practices of ESO Implementation in the Oil Refining Industry
Prof. V. Mahalec McMaster University
Hamilton, Ontario, Canada [email protected]
Topics
• Components of ESO Success • Overview of potential energy efficiency improvements • Improvements in the Operating Practices • Redesign of the Plant Structure
– High efficiency equipment – Maximum energy recovery
• Measurement of Performance • Management Systems • Information Systems • Summary
Components of ESO Success
Equipment
People & ManagingSystemsInformation Systems
Potential Energy Efficiency Improvements M
anag
em
en
t Sy
ste
ms
Pro
cess
Co
ntr
ol &
R
eal
Tim
e O
pt.
Dis
till
atio
n
He
at E
xch
ange
rs
Pro
cess
He
ate
rs
Ste
am D
istr
ibu
tio
n
Pro
cess
Inte
grat
ion
Co
gen
era
tio
n
Po
we
r G
en
era
tio
n
Pu
mp
s
Mo
oto
rs
Desalting x x xCrude Distillation x x x x x x x x xVacuum Distillation x x x x x x xHydrotreater x x x x x x xCatalytic Reformer x x x x x x xFCC x x x x x x xHydrocracker x x x x x x xCoker x x x x x x xAlkylation x x x x x x xLight Ends x x x x x xAromatics x x x x x x xHydrogen x x x x x xUtilities x x x x x x x
Crude Distillation 54%Vaccum Distillation 39%FCC 28%Hydrotreater 32%Catalytic Reformer 23%Alkylation 38%
Potential Energy Savings in US Refineries % of 2005 Energy Usage
Equipment
“Energy bandwidth for petroleum Refining Processes” , Energetics, 2006
Potentially 25% to 30% energy savings.
Process Control and Real Time Optimization
• Throughput increase: 5% to 10% • Energy savings: 2% to 5% • Yield of most valuable product: 1% to 5% • Value added by the unit: 5% to 10%
• APC is a standard practice • RTO will operate properly only if all other systems
function well: – Equipment operates as expected – Instruments are accurate and reliable – Advanced control applications service factor close to 100% – Competent staff to implement and maintain
Equipment Operating Practices
Equipment Maintenance – Enhances Efficiency
• Heat Exchangers: monitor fouling & clean as needed – Optimal heat exchanger cleaning schedule maintains desired
performance while some HX are off-line (MINLP problem)
• Process Heaters – target 1% to 2% excess oxygen – Eliminate air leaks – Optimize burner operation (flame monitoring)
• Distillation – Minimize operating pressure; – Clean fouled trays
• Steam distribution – minimize header pressure, maintain steam traps, repair
leaks, insulate
Equipment Operating Practices
Maximize efficiency of individual equipment
• High efficiency heat exchangers – High pressure spiral HE for fouling service – HE Plate exchangers – Packinox (for some feed/reactor effluent applications)
• Process Heaters – air preheat, efficient burners • Distillation
– Install more efficient trays – Heat integrated distillation columns – Alter separation sequence: Progressive Crude Distillation
(15%+ energy saving)
• Steam distribution - return condensate
Equipment Re-Design
Process Integration
• Energy Systems Integration – Total Site (process units, utilities, cogeneration, power generation) – Caution: must be able to start-up and shut-down after the
integration projects are implemented. – Savings: 15% to 40%+ of the energy consumed by the
units that are integrated.
• Hydrogen System Integration – Optimize usage – Decide where to install hydrogen recovery equipment
• Water System Integration
Equipment Site Re-Design
Strong Interaction Among All Decision Levels
People & Managing Systems
Plan Production
Schedule Production
Run to Targets; Optimize Operating Targets
Monitor / Analyze Operations
Plant (Re)Design
Equipment Modifications Maintenance
Visibility / access to information is vital for good decision making
Enterprise Wide Monitoring
Equipment Unit/Plant Plant/Region
People & Managing Systems
If Boss monitors it, it will be done
Region
Refinery 1
Refinery n
CDU FCC Utilities …
…
Management System – Continuous Improvement
Assess Performance Identify Opportunities
Set Goals
Create Plan
Implement
Evaluate
Reward Achievement
Sustainable, long term improvements require continuous commitment of the management team and of the employees.
From organizational viewpoint, the responsibility for energy optimization performance resides with the operating arm of the enterprise.
People & Managing Systems
Company Wide Enterprise Architecture
Federated Databases
Business Intelligence
Plan Production
Schedule Production Run to Targets;
Optimize Operating Targets
Business Applications (monitoring, APC, RTO, planning, scheduling, maintenance…)
Operating Data
Equipment Data
… Data . . .
Information Systems
Monitor / Analyze Operations
Enterprise Content
Management
Maintain Equipment Manage Business
Processes
Summary
Technical Systems
Human (Organizational)
Systems
Technical System Performance Guidelines
Managing Systems
Guidelines
• Very significant reduction in energy consumption is possible. • Energy Savings Guidelines / Standards should encompass both technical and human systems.
Scope of the Guidelines
End