4 Sbanik Eil

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 13TH NOV., 2009, DELHI
Delivering excellence through people
13/11/2009 Slide Number- 1
CONTENTS

REFINING CHALLENGES UTILITIES & OFFSITE GROUP OF PLANTS STEAM SYSTEM STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES POWER SYSTEM POWER SYSTEM ENERGY CONSERVATION OPPORTUNITIES COMBINED STEAM & POWER NETWORK OPTIMIZATION

HEAT RECOVERY & CHP SMR & COGEN INTEGRATION
UTILITIES SAVING THROUGH REFINERY & PETROCHEMICAL INTEGRATION HYDROGEN SYSTEM & HYDROGEN CONSUMPTION OPTIMIZATION CONCLUSION
Engineers India Ltd Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 2
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
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 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
UTILITIES & OFFSITE SYSTEM
UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF:

BOILERS STEAM TURBINE GENERATORS GAS TURBINE GENERATORS / HEAT RECOVERY STEAM GENERATORS HYDROGEN GENERATION UNIT NITROGEN GENERATION UNIT COOLING TOWERS INSTRUMENT AIR SYSTEM WATER TREATMENT UNITS
STEAM & POWER CONSUME BULK OF THE ENERGY IN OFFSITE & UTILITIES SYSTEM
REFINERY STEAM SYSTEM
STEAM GENERATION

STAND ALONE BOILERS HEAT RECOVERY STEAM GENERATORS PROCESS WASTE HEAT BOILERS WASTE HEAT FROM SMR RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS & TURBINE EXHAUST NORMALLY STEAM IS DISTRIBUTED AT 3 4 PRESSURE LEVELS PROCESS STREAM HEATING AS A SOURCE OF WATER ( HYDROGEN GENERATION ) COMPONENT SEPARATION SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. ) CONDENSATE RECOVERY
STEAM DISTRIBUTION
END USE

RECOVERY
REFINERY STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES
STEAM GENERATION
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
PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN EFFICIENCY OF ~ 85 86%.
EFFICIENCY CAN BE IMPROVED TO +90% AVAILABILTY OF SPACE COULD BE A LIMITATION WILL REDUCE STACK LOSS AND FUEL
LOW EXCESS AIR BURNERS
USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE RUN ON PART LOAD FOR RELIABILTY

BOILER FEED-WATER PUMPS BLOWERS
STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES
IMPROVE WATER TREATMENT TO MINIMIZE BOILER BLOW DOWN RECOVER ENERGY FROM BOILER BLOW DOWN OPTIMIZE DEAERATOR VENT RATE TO MINIMIZE AVOIDABLE LOSS MAINTAIN REFRACTORY IN GOOD CONDITION TO REDUCE SURFACE LOSS
IMPROVE STEAM DISTRIBUTION SYSTEM
AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION
IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & MAINTENANCE PROGRAM

LEAKING TRAPS SHOULD NOT EXCEED 5% OF THE TRAPS FAULTY TRAP WITH 1/8 INCH ORIFICE INSTALLED ON 6.5 KG/CM2G LINE MAY CAUSE STEAM LOSS OF 300 TPA RECOMMENDED STEAM TRAP SURVEY
STEAM LINE PRESSURE, KG/CM2G TRAP TESTING FREQ.
10.0 KG/CM2G AND ABOVE 2.0 TO 10.0 KG/CM2G < 2.0 KG/CM2G
WEEKLY TO MONTHLY MONTHLY TO QUARTERLY ANNUALLY
UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs

END USE IMPROVEMENTS
REQUIRES CASE BY CASE ASSESSMENT 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 .
STEAM R ATE, KG/KWHR 48.8 63.08 STEAM CONSUMPTION, TPH 24.0 15.0 6.0 LOSS, TPH
LOAD, KW
495 250
OPTIMIZATION OF STRIPPING STEAM MINIMIZE DEAERATOR VENT STEAM CONDENSATE RECOVERY SYSTEM
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 System
Back Pressure Turbine Extraction Condensing Steam Turbine Gas Turbine Combined Cycle
Heat to power ratio ( KWth/KWe )

4.0 14.3 2.0 10.0 1.0 2.0 1.0 1.7
Power Output ( as% of fuel input )

14 - 28 22 - 40 24 - 35 34 -40
Overall Efficiency, %
84 - 92 60 - 80 70 - 85 69 - 83
POWER GENERATION
GAS TURBINES GENERATORS
A PREFERRED CHOICE OVER STEAM TURBINE BASED POWER GENRATING SYSTEMS

LOWER CAPITAL COST MODULAR DESIGN SHORTER INSTALLATION TIME QUICK TO START HIGH EFFICIENCY LOWER EMISSIONS
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
POWER SYSTEM PERFORMANCE IMPROVEMENT
COOLING OF INLET AIR

LOW COST AND LOW PAYBACK PERIOD EASY TO INSTALL CHANGES ARE EXTERNAL TO GAS TURBINE OVER 700 WORLDWIDE INSTALLATIONS SUCH A SYSTEM IS WORKING SATISFACTORILY IN A MEGA REFINERY IN THE COUNTRY
METHODOLOGY COMMONLY APPLIED EVAPORATIVE
FOGGING / WET COMPRESSION
DROPLET SIZE 25 -35 MICRONS, VERY HIGH PRESSURE PUMP : 100 150 BAR
CHILLERS
MECHANICAL / ABSORPTION

LOW LEVEL RECOVERED HEAT CAN BE GAINFULLY UTILIZED OFFERS BETTER CONTROL OF TEMPERATURE APPROX. 3 TIMES COSTLY THAN FOGGING SYSTEM
Efficient Heat Recovery-Gas Turbine Exhaust
Refinery With HRU/HRSG
CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 15
Impact of HRU/HRSG On EII
COMBINED HEAT AND POWER SYSTEM
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 H2S 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
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
COMBINED HEAT & POWER SYSTEM MODELING/OPTIMIZATION
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
HRSG FUEL CONSUMED IN GTG, AMBIENT AIR TEMP. STEAM TURBINES : STEAM RATE CURVES, STEAM FLOW DATA
: :
STEAM GENERATION AND FUEL CONSUMPTION
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.
CHP SYSTEM MODELING
CHP SUB-SYSTEMS

BOILER CGTG STG HRSG SMR HRU PRDS DEAERATOR CONDENSATE & BFW SYSTEM
SMR COGEN INTEGRATION
CHP COGEN INTEGRATION
SMR COGEN INTEGRATION
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.S2

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

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.P2+ D.T+ E.T2

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

TYPICAL STEAM NETWORK

Boiler 182 215 Steam Genera Kg/cm2a 17 45 41 215 Steam User 21 133 24 Alternator Turbine 96 0 0 238.8 Process Users 8.4 Compressor Aux Turbines 8.4 11 Blow Down Blow Down flash drum 3 Treated FW pump Turbine 3 15 Boiler Fan 15 24 Deaerator 0 Kg/cm2a 5 12 0.5 291 151.8 Compressor Turbine 3 Boiler atomizing steam 0 0 Kg/cm2a 20 20 BFW pump Turbine 20 13.7 Process Users 0.0 HRSG atomizing HRSG 0 Process steam generator 68 External steam source. 0 92.4 Kg/cm2a 50
148.1
Treated makeup water 168
Condensate quench drum
98.3

ENERGY AUDIT
POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 27 Slide Number - 27
SAMPLE STEAM NETWORK

ENERGY AUDIT
POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 28 Slide Number - 28
CHP MODEL
ENERGY AUDIT
29
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
ENERGY CONSERVATION OPPORTUNITY ASSESSMENT STUDIES AT SAUDI ARAMCO GAS PLANT
GAS PLANT CAPACITY : 2600 MMSCFD

GAS SWEETENING UNIT GAS DEHYDRATION UNIT NGL RCOVERY ( LOW TEMP. ) SRU COMPRESSOR STATION FOR GAS PIPELINE ENHANCED PROCESS TO PROCESS COLD EXCHANGE PROVISION OF LEAN / RICH AMINE EXCHANGER POWER GENERATION FROM HYDRAULIC TURBINE IN DGA UNIT OBSG ON HEATERS VARIAABLE SPEED DRIVES FOR PUMPS & AIR COOLERS POWER STEAM GENERATION FUEL SAVING : 21 MW : 416 MLBH : 100MSCFH
ENERGY CONSERVATION SCHEMES IDENTIFIED

ENERGY SAVED

ENERGY SAVING SCHEMES HAD GOOD PAYBACK PERIOD 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
REFINERY-PETROCHEMICAL INTEGRATION(Typical)
REFINERY-PETROCHEMICAL INTEGRATION
VALUE Chain Integration of Refinery Products to Petrochemical Feed Sharing and Efficient Use of Utilities Sharing of Offsites and Infrastructure Sharing of All Plant Resources Including Human Resources Overall Reduction in CAPEX and OPEX
Refinery/Petrochem Offsite/Infrastructure Integration
Integrated Common Facilities Achieving Economies of Scale for:

Flare Waste Water Treating Buildings Control Room Laboratory
Refinery/PetrochemicalsUtilities Integration and Energy Efficiency
Steam System: Excess MP/LP Steam from Cracker to the Refinery for Overall Steam System Efficiency Excess Hydrogen from Petrochemical to Refinery Integrated Common Facilities Achieving Economies of Scale for:
Cooling Water Air Nitrogen Fire Water Fuel

Hydrogen System
HYDROGEN GENERATION PROCESS SCHEMES
MODEL BASED ASSESSMENT
H2 Network Optimization
H2 internal optimization
Optimized performance of the new on-purpose H2 facility, while best satisfying the refinery-wide utilities and operational requirements, especially in terms of reliability and flexibility. Degree of ROG utilization, H2 recovery and multiple feed flexibility Reforming severity Minimization of involuntary HP steam export Level of CO2 capture
Hydrogen Network Optimization
H2 external optimization
Developing of H2 balance model Identification of limitations and/or flexibility of the H2 usage H2 network LP modelling or H2 off-line analysis Identification of the key inefficiency of the H2 network Integration of possible alternatives for H2 re-use and regeneration Identification of the optimum size for a new onpurpose H2 generation Unit
Hydrogen Network Optimization
Refinery-wide parameters
Crude evaluation/substitution Overall refinery scheme and unit operation interactions Residue upgrading options assessment Fuel substitution Carbon separation/sequestration solutions Utilities LP modelling CO2 LP modelling
Typical Refinery Hydrogen Network
HYDROGEN GENERATION-Saving in Utility

Optimization of Hydrogen Usage Technology Up-gradation

Feed + Fuel ( NG case) is 7% lower for PSA based Plant Fuel Required is 37% lower for PSA based plant
Switching to Lower Mol Wt Hydrocarbon saves utility
Benefits of Switching of Feed from Naphtha to Pentane

Pre-desulphurisation is omitted Steam Flow at Mixing point Reduced by 12% Fuel Requirement Reduced by 14.2% H2 Yield Increased by 1 % CO2 Emissions Reduced By 1.5%
CONCLUSIONS
OFFSITES AND UTILITIES CONSUME ABOUT 40 % OF ENERGY STEAM, POWER ARE MAJOR UTILITIES CONSIDERED SCOPE FOR REDUCTION IN ENERGY CONSUMPTIO IDENTIFIED INTEGRATION OF REFINERY/PETROCHEMICAL PLANT SAVES COST AND ENERGY HYDROGEN SYSTEM MANAGEMENT CAN HELP TO IDENTIFY OPPORTUNITY FOR UTILITY SAVINGS

Thank You
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IDENTIFYING POTENTIAL - IN OFFSITES AND UTILITIES INCLUDING STEAM & POWER

Delivering excellence through people

13/11/2009 Slide Number- 1

HEAT RECOVERY & CHP SMR & COGEN INTEGRATION

Synergy- Refinery and Petrochemical

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 3

Energy Performance Challenge

REFINERY CONSUMES ABOUT 7 8% OF THE CRUDE PROCESSED AS FUEL

FOCUS IS NOW ON UTILITIES CONSERVATION

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 4

UTILITIES & OFFSITE SYSTEM

UTILITIES AND OFFSITE GROUP OF PLANTS CONSIST OF:

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 5

REFINERY STEAM SYSTEM

Engineers India Ltd Delivering excellence through people

REFINERY STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES

AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF RELIABILTY OF STEAM SUPPLY)

PROVISION OF AIR PREHEATER ON OLD BOILERS HAVING DESIGN EFFICIENCY OF ~ 85 86%.

LOW EXCESS AIR BURNERS

BOILER FEED-WATER PUMPS BLOWERS

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 7

STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 8

STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES

IMPROVE STEAM DISTRIBUTION SYSTEM

AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION

IMPLEMENT EFFECTIVE STEAM TRAP SURVEY & MAINTENANCE PROGRAM

WEEKLY TO MONTHLY MONTHLY TO QUARTERLY ANNUALLY

UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs

Engineers India Ltd Delivering excellence through people

STEAM SYSTEM ENERGY CONSERVATION OPPORTUNITIES

END USE IMPROVEMENTS

Engineers India Ltd Delivering excellence through people

Heat to power ratio ( KWth/KWe )

Power Output ( as% of fuel input )

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 11

GAS TURBINES GENERATORS

A PREFERRED CHOICE OVER STEAM TURBINE BASED POWER GENRATING SYSTEMS

USED IN COMBINATION WITH HEAT RECOVERY STEAM GENERATOR (HRSG)

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 12

POWER SYSTEM PERFORMANCE IMPROVEMENT

COOLING OF INLET AIR

METHODOLOGY COMMONLY APPLIED EVAPORATIVE

FOGGING / WET COMPRESSION

Engineers India Ltd Delivering excellence through people

Efficient Heat Recovery-Gas Turbine Exhaust

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 14

Refinery With HRU/HRSG

Engineers India Ltd Delivering excellence through people

CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 15

Impact of HRU/HRSG On EII

Engineers India Ltd Delivering excellence through people

CHP MODELING & OPTIMISATION 24/05/2007 Slide Number - 16

COMBINED HEAT AND POWER SYSTEM

Engineers India Ltd Delivering excellence through people

POTENTIAL- ENERGY CONSERVATION UTILITY& OFFSITE 13/11/2009 Slide Number - 17