Identifying Potential - in Offsites and Utilities Including Steam & Power

13/11/2009
Slide Number- 1

Delivering excellence through people
IDENTIFYING POTENTIAL - IN OFFSITES AND
UTILITIES INCLUDING STEA ! PO"E#
Dr S $ANI%
&n'
r A % (O)#A
ENGINEE#S INDIA LTD
*"O#%S)OP ON ENE#GY ANAGEENT ! EFFICIENCY
IP#O(EENT IN OIL ! GAS SECTO#+
,-
T)
NO(./ 0112/ DEL)I
POTENTIAL- ENE#GY CONSE#(ATION
UTILITY! OFFSITE
13/11/2009
Slide Number - 2
Engineer3 In'i& Lt' 4 Delivering excellence through people
REFINING CHALLENGES REFINING CHALLENGES
UTILITIES & OFFSITE GROU OF LANTS UTILITIES & OFFSITE GROU OF LANTS
STEA! S"STE! STEA! S"STE!
STEA! S"STE! ENERG" CONSER#ATION OORTUNITIES STEA! S"STE! ENERG" CONSER#ATION OORTUNITIES
O$ER S"STE! O$ER S"STE!
O$ER S"STE! ENERG" CONSER#ATION OORTUNITIES O$ER S"STE! ENERG" CONSER#ATION OORTUNITIES
CO!%INE& STEA! & O$ER NET$OR' OTI!I(ATION CO!%INE& STEA! & O$ER NET$OR' OTI!I(ATION
HEAT RECO#ER" & CH HEAT RECO#ER" & CH
S!R & COGEN INTEGRATION S!R & COGEN INTEGRATION
UTILITIES SA#ING THROUGH REFINER" & ETROCHE!ICAL UTILITIES SA#ING THROUGH REFINER" & ETROCHE!ICAL
INTEGRATION INTEGRATION
H"&ROGEN S"STE! & H"&ROGEN CONSU!TION OTI!I(ATION H"&ROGEN S"STE! & H"&ROGEN CONSU!TION OTI!I(ATION
CONCLUSION CONCLUSION
CONTENTS
CONTENTS
UTILITY! OFFSITE
13/11/2009
Slide Number - 3
#EFINING C)ALLENGES
&i)*ill+*e "ield Im,r-.eme/*)
Fuel 0u+li*1 U,-2r+d+*i-/
O,*imi3e E/er21 er4-rm+/5e
S*ri5* E/.ir-/me/*+l N-rm)
!+6imi3e !+r2i/)
r-5e)) Hi27 Sul4ur Crude)
r-5e)) Hi27 TAN/ He+.1 Crude)
S1/er21- Re4i/er1 +/d e*r-57emi5+l

UTILITY! OFFSITE
13/11/2009
Slide Number - 8
Energ5 Per6or7&nce Ch&llenge
REFINER" CONSU!ES A%OUT 9 : ;< OF THE CRU&E

ROCESSE& AS FUEL
REFINERIES ARE CONTINUOUSL" !A'ING EFFORTS TO %RING REFINERIES ARE CONTINUOUSL" !A'ING EFFORTS TO %RING
&O$N THE ENERG" CONSU!TIONS &O$N THE ENERG" CONSU!TIONS
SECIFIC FUEL CONSU!TION HAS RE&UCE& %" A%OUT 20<

-FRO! ;9=0 TO 91=0 !!%TU/%%L/NRGF > O#ER THE LAST ;-10
"EARS
FUEL COST CONTRI%UTES 80-8?<

TO$AR&S THE COST OF REFINER" OERATION
30-80< OF THE FUEL COST IS ATTRI%UTE& TO GENERATION

OF UTILITIES LI'E STEA! / O$ER
FOCUS IS NO$ ON @ UTILITIESA CONSER#ATION

UTILITY! OFFSITE
13/11/2009
Slide Number - ?
UTILITIES & OFFSITE S"STE!
UTILITIES & OFFSITE S"STE!
UTILITIES AN& OFFSITE GROU OF LANTS CONSIST OFB UTILITIES AN& OFFSITE GROU OF LANTS CONSIST OFB
%OILERS %OILERS
STEA! TUR%INE GENERATORS STEA! TUR%INE GENERATORS
GAS TUR%INE GENERATORS / HEAT RECO#ER" STEA! GAS TUR%INE GENERATORS / HEAT RECO#ER" STEA!
GENERATORS GENERATORS
H"&ROGEN GENERATION UNIT H"&ROGEN GENERATION UNIT
NITROGEN GENERATION UNIT NITROGEN GENERATION UNIT
COOLING TO$ERS COOLING TO$ERS
INSTRU!ENT AIR S"STE! INSTRU!ENT AIR S"STE!
$ATER TREAT!ENT UNITS $ATER TREAT!ENT UNITS
STEA! & O$ER CONSU!E %UL' OF THE ENERG" IN OFFSITE STEA! & O$ER CONSU!E %UL' OF THE ENERG" IN OFFSITE
& UTILITIES S"STE! & UTILITIES S"STE!
UTILITY! OFFSITE
13/11/2009
Slide Number - C
#EFINE#Y STEA SYSTE
#EFINE#Y STEA SYSTE
STEA! GENERATION STEA! GENERATION
STAN& ALONE %OILERS STAN& ALONE %OILERS
HEAT RECO#ER" STEA! GENERATORS HEAT RECO#ER" STEA! GENERATORS
ROCESS $ASTE HEAT %OILERS ROCESS $ASTE HEAT %OILERS
$ASTE HEAT FRO! S!R $ASTE HEAT FRO! S!R
STEA! &ISTRI%UTION STEA! &ISTRI%UTION
RECEI#ES STEA! AT &IFFERENT LE#ELS FRO! GENERATORS & RECEI#ES STEA! AT &IFFERENT LE#ELS FRO! GENERATORS &
TUR%INE EDHAUST TUR%INE EDHAUST
NOR!ALL" STEA! IS &ISTRI%UTE& AT 3 : 8 RESSURE LE#ELS NOR!ALL" STEA! IS &ISTRI%UTE& AT 3 : 8 RESSURE LE#ELS
EN& USE EN& USE
ROCESS STREA! HEATING ROCESS STREA! HEATING
AS A SOURCE OF $ATER E H"&ROGEN GENERATION F AS A SOURCE OF $ATER E H"&ROGEN GENERATION F
CO!ONENT SEARATION CO!ONENT SEARATION
SHAFT $OR' E &RI#E FOR U!S> CO!RESSOR %LO$ERS ETC= F SHAFT $OR' E &RI#E FOR U!S> CO!RESSOR %LO$ERS ETC= F
RECO#ER" RECO#ER"
CON&ENSATE RECO#ER" CON&ENSATE RECO#ER"

UTILITY! OFFSITE
13/11/2009
Slide Number - 9
STEA! GENERATION STEA! GENERATION
A#OI& RUNNING EDTRA %OILER EON CONSI&ERATION OF A#OI& RUNNING EDTRA %OILER EON CONSI&ERATION OF
RELIA%ILT" OF STEA! SUL"F RELIA%ILT" OF STEA! SUL"F
LEA&S TO GENERATION OF EDTRA STEA! $HICH IS FINALL" LEA&S TO GENERATION OF EDTRA STEA! $HICH IS FINALL"
CON&ENSE& IN COOLRS AN& CON&ENSATE IS REC"CLE& CON&ENSE& IN COOLRS AN& CON&ENSATE IS REC"CLE&
RO#ISION OF AIR REHEATER ON OL& %OILERS HA#ING &ESIGN RO#ISION OF AIR REHEATER ON OL& %OILERS HA#ING &ESIGN
EFFICIENC" OF G ;? : ;C<= EFFICIENC" OF G ;? : ;C<=
EFFICIENC" CAN %E I!RO#E& TO H90< EFFICIENC" CAN %E I!RO#E& TO H90<
A#AILA%ILT" OF SACE COUL& %E A LI!ITATION A#AILA%ILT" OF SACE COUL& %E A LI!ITATION
LO$ EDCESS AIR %URNERS LO$ EDCESS AIR %URNERS
$ILL RE&UCE STAC' LOSS AN& FUEL $ILL RE&UCE STAC' LOSS AN& FUEL
USE OF #ARIA%LE SEE& &RI#ES FOR E0UI!ENTS $HICH ARE USE OF #ARIA%LE SEE& &RI#ES FOR E0UI!ENTS $HICH ARE
RUN ON ART LOA& FOR RELIA%ILT" RUN ON ART LOA& FOR RELIA%ILT"
%OILER FEE&-$ATER U!S %OILER FEE&-$ATER U!S
%LO$ERS %LO$ERS
REFINER" STEA! S"STE! : ENERG"
REFINER" STEA! S"STE! : ENERG"
CONSER#ATION OORTUNITIES
CONSER#ATION OORTUNITIES
UTILITY! OFFSITE
13/11/2009
Slide Number - ;
I!RO#E $ATER TREAT!ENT TO !INI!I(E I!RO#E $ATER TREAT!ENT TO !INI!I(E

%OILER %LO$ &O$N %OILER %LO$ &O$N
RECO#ER ENERG" FRO! %OILER %LO$ &O$N RECO#ER ENERG" FRO! %OILER %LO$ &O$N
OTI!I(E &EAERATOR #ENT RATE TO !INI!I(E OTI!I(E &EAERATOR #ENT RATE TO !INI!I(E
A#OI&A%LE LOSS A#OI&A%LE LOSS
!AINTAIN REFRACTOR" IN GOO& CON&ITION TO !AINTAIN REFRACTOR" IN GOO& CON&ITION TO

RE&UCE SURFACE LOSS RE&UCE SURFACE LOSS
STEA SYSTE 4 ENE#GY CONSE#(ATION
STEA SYSTE 4 ENE#GY CONSE#(ATION
OPPO#TUNITIES
OPPO#TUNITIES
UTILITY! OFFSITE
13/11/2009
Slide Number - 9
I!RO#E STEA! &ISTRI%UTION S"STE! I!RO#E STEA! &ISTRI%UTION S"STE!
A#OI& STEA! LEA'S AN& REAIR &A!AGE& INSULATION A#OI& STEA! LEA'S AN& REAIR &A!AGE& INSULATION
I!LE!ENT EFFECTI#E STEA! TRA SUR#E" & I!LE!ENT EFFECTI#E STEA! TRA SUR#E" &
!AINTENANCE ROGRA! !AINTENANCE ROGRA!
LEA'ING TRAS SHOUL& NOT EDCEE& ?< OF THE TRAS LEA'ING TRAS SHOUL& NOT EDCEE& ?< OF THE TRAS
FAULT" TRA $ITH 1/; INCH ORIFICE INSTALLE& ON C=? 'G/C! FAULT" TRA $ITH 1/; INCH ORIFICE INSTALLE& ON C=? 'G/C!
2 2
G LINE G LINE
!A" CAUSE STEA! LOSS OF 300 TA !A" CAUSE STEA! LOSS OF 300 TA
RECO!!EN&E& STEA! TRA SUR#E" RECO!!EN&E& STEA! TRA SUR#E"
UTILI(E %AC'RESSURE TUR%INE INSTEA& OF R#) UTILI(E %AC'RESSURE TUR%INE INSTEA& OF R#)
STEA! S"STE! : ENERG" CONSER#ATION
OORTUNITIES
OORTUNITIES
STEA LINE P#ESSU#E/ %G8C
0
G T#AP TESTING F#E9.
,1.1 %G8C
0
G AND A$O(E "EE%LY TO ONT)LY
0.1 TO ,1.1 %G8C
0
G ONT)LY TO 9UA#TE#LY
: 0.1 %G8C
0
G ANNUALLY
UTILITY! OFFSITE
13/11/2009
Slide Number - 10
EN& USE I!RO#E!ENTS EN& USE I!RO#E!ENTS
RE0UIRES CASE %" CASE ASSESS!ENT RE0UIRES CASE %" CASE ASSESS!ENT
RUNNING SINGLE TUR%INE &RI#EN U! / %LO$ER RUNNING SINGLE TUR%INE &RI#EN U! / %LO$ER
T$O TUR%INE &RI#EN 89? '$ AIR %LO$ERS $ERE RUN T$O TUR%INE &RI#EN 89? '$ AIR %LO$ERS $ERE RUN
IN SRU UNIT INSTEA& OF ONE AT ART LOA& OF 2?0 '$ = IN SRU UNIT INSTEA& OF ONE AT ART LOA& OF 2?0 '$ =
OTI!I(ATION OF STRIING STEA! OTI!I(ATION OF STRIING STEA!
!INI!I(E &EAERATOR #ENT STEA! !INI!I(E &EAERATOR #ENT STEA!
CON&ENSATE RECO#ER" S"STE! CON&ENSATE RECO#ER" S"STE!

OORTUNITIES
OORTUNITIES
LOAD/ %" STEA # ATE/ %G8%"-
)#
STEA
CONSUPTION/
TP)
LOSS/ TP)
;2< ;=.= 0;.1
0<1 >-.1= ,<.1 >.1
UTILITY! OFFSITE
13/11/2009
Slide Number - 11
PO"E# SYSTES
CO-GENERATION OR CO!%INE& HEAT AN& O$ER LANTS

ARE $I&EL" E!LO"E& FOR RO&UCTION OF O$ER & HEAT
E STEA! F IN REFINERIES AN& ETROCHE!ICAL LANTS
30< LUS !ORE EFFICIENT THAN SEARATE RO&UCTION
E0UI!ENTS $ITH #AR"ING O$ER TO HEAT RATIO ARE

A#AILA%LE
Cogener&tion S53te7 )e&t 4 to 4 po?er
r&tio @ %"
th
8%"
e
A
Po?er Output @ &3B
o6 6uel input A
Over&ll E66icienc5/
B
%+5I re))ure Turbi/e 8=0 : 18=3 18 - 2; ;8 - 92
E6*r+5*i-/ C-/de/)i/2
S*e+m Turbi/e
2=0 : 10=0 22 - 80 C0 - ;0
G+) Turbi/e 1=0 : 2=0 28 - 3? 90 - ;?
C-mbi/ed C15le 1=0 : 1=9 38 -80 C9 - ;3
UTILITY! OFFSITE
13/11/2009
Slide Number - 12
GAS TUR%INES GENERATORS GAS TUR%INES GENERATORS
A REFERRE& CHOICE O#ER STEA! TUR%INE %ASE& A REFERRE& CHOICE O#ER STEA! TUR%INE %ASE&
O$ER GENRATING S"STE!S O$ER GENRATING S"STE!S
LO$ER CAITAL COST LO$ER CAITAL COST
!O&ULAR &ESIGN : SHORTER INSTALLATION TI!E !O&ULAR &ESIGN : SHORTER INSTALLATION TI!E
0UIC' TO START 0UIC' TO START
HIGH EFFICIENC" HIGH EFFICIENC"
LO$ER E!ISSIONS LO$ER E!ISSIONS
USE& IN CO!%INATION $ITH HEAT RECO#ER" STEA! USE& IN CO!%INATION $ITH HEAT RECO#ER" STEA!
GENERATOR EHRSGF GENERATOR EHRSGF
STEA! RO&UCE& IN HRSG CAN %E USE& TO !EET SITE STEA! RO&UCE& IN HRSG CAN %E USE& TO !EET SITE
HEATING RE0UIRE!ENT OF FOR O$ER GENERATION HEATING RE0UIRE!ENT OF FOR O$ER GENERATION
THROUGH STG THROUGH STG
PO"E# GENE#ATION
UTILITY! OFFSITE
13/11/2009
Slide Number - 13
COOLING OF INLET AIR COOLING OF INLET AIR
LO$ COST AN& LO$ A"%AC' ERIO& LO$ COST AN& LO$ A"%AC' ERIO&
EAS" TO INSTALL EAS" TO INSTALL
CHANGES ARE EDTERNAL TO GAS TUR%INE CHANGES ARE EDTERNAL TO GAS TUR%INE
O#ER 900 $ORL&$I&E INSTALLATIONS O#ER 900 $ORL&$I&E INSTALLATIONS
SUCH A S"STE! IS $OR'ING SATISFACTORIL" IN A !EGA SUCH A S"STE! IS $OR'ING SATISFACTORIL" IN A !EGA
REFINER" IN THE COUNTR" REFINER" IN THE COUNTR"
!ETHO&OLOG" CO!!ONL" ALIE& !ETHO&OLOG" CO!!ONL" ALIE&
E#AORATI#E E#AORATI#E
FOGGING / $ET CO!RESSION FOGGING / $ET CO!RESSION
&ROLET SI(E 2? -3? !ICRONS> #ER" HIGH RESSURE U! B 100 : &ROLET SI(E 2? -3? !ICRONS> #ER" HIGH RESSURE U! B 100 :
1?0 %AR 1?0 %AR
CHILLERS CHILLERS
!ECHANICAL / A%SORTION !ECHANICAL / A%SORTION
LO$ LE#EL RECO#ERE& HEAT CAN %E GAINFULL" UTILI(E& LO$ LE#EL RECO#ERE& HEAT CAN %E GAINFULL" UTILI(E&
OFFERS %ETTER CONTROL OF TE!ERATURE OFFERS %ETTER CONTROL OF TE!ERATURE
APP#OC. - TIES COSTLY T)AN FOGGING SYSTE APP#OC. - TIES COSTLY T)AN FOGGING SYSTE
PO"E# SYSTE PE#FO#ANCE IP#O(EENT
PO"E# SYSTE PE#FO#ANCE IP#O(EENT
UTILITY! OFFSITE
13/11/2009
Slide Number - 18
E66icient )e&t #ecover5-G&3 TurDine Exh&u3t
E66icient )e&t #ecover5-G&3 TurDine Exh&u3t
C)P ODELING ! OPTIISATION
28/0?/2009
Slide Number - 1?
#e6iner5 "ith )#U8)#SG
#e6iner5 "ith )#U8)#SG
28/0?/2009
Slide Number - 1C
I7p&ct o6 )#U8)#SG On EII
I7p&ct o6 )#U8)#SG On EII
UTILITY! OFFSITE
13/11/2009
Slide Number - 19
CO$INED )EAT AND PO"E# SYSTE
CO$INED )EAT AND PO"E# SYSTE
UTILITY! OFFSITE
13/11/2009
Slide Number - 1;
CO$INED )EAT ! PO"E# NET"O#%
O$ER GENERATION
GAS TUR%INE GENERATOR
STEA! TUR%INE GENERATOR
O$ER &E!AN& IS LIN'E& TO LANT THROUGHUT AN& AFFECTS STEA!

GENERATION
STEA! GENERATION
UTILITIES %OILERS E GENERATION LIN'E& TO LANT THROUGHUT AN& O$ER

OUTUT FRO! STG / GTGF
HRSG E STEA! GENERATION LIN'E& TO O$ER OUTUT F
$ASTE HEAT RECO#ER" STEA! GENERATION AT 2 TO 3 RESSURE /

TE!ERATURE LE#ELS
GNERATION LIN'E& TO LANT LOA& AN& FEE& 0UALIT"
HIGH H
2
S CONTENT IN ACI& GAS $ILL GENERATE !ORE STEA! IN $H%
R&S FOR !AINTAING STEA! RESSURE AT &IFFERENT LE#ELS
STEA! CONSU!TION
3 TO 8 RESSURE / TE!ERATURE LE#ELS
%T $ITH INLET STEA! AN& EDHAUST STEA! AT 2 OR !ORE RESSURE

LE#ELS
UTILITY! OFFSITE
13/11/2009
Slide Number - 19
CO$INED )EAT ! PO"E# NET"O#%
CON&ENSATE RECO#ER" S"STE!
CON&ENSATE FLASH &RU!S OEATING AT #ARIOUS RESSURE /

TE!ERATURE LE#EL
#ENT STEA! CON&ENSER
AFFECTS &! $ATER RE0UIRE!ENT
RO#I&ES HEAT FOR HEATING &! $ATER GOING TO &EAERATOR
&E-AERATOR
STEA! CONSU!TION LIN'E& TO %F$ RE0UIRE!ENT AN& ITS

TE!ERATURE
HEAT AN& O$ER NET$OR' OF A REFINER" IS

CO!LED
STEA! AN& O$ER GENERATION AN& CONSU!TION ARE INTELIN'E&
NET$OR' !O&ELING / SI!ULATION ROGRA! SHALL %E USEFULL IN

OTI!I(ING THE STEA! AN& O$ER GENERATION TO !INI!I(E FUEL
COST
!O&ELS ARE SITE SECIFIC AN& ARE &E#ELOE& FRO! THE OERATING &ATA
USING NON-LINEAR REGRESSION !ETHO&S
UTILITY! OFFSITE
13/11/2009
Slide Number - 20
SI!ULATION ROGRA!
!ULTI#ARIA%LE E0UATION -SETS FOR !ASS & ENERG"

%ALANCE FOR EACH SU%S"STE! ARE &E#ELOE&
!O&EL INUTS
GAS TUR%INE B A!%IENT AIR TE!=> O$ER OUT UT> HEAT RATE>
FUEL CONSU!TION
%OILERS B STEA! GENERATION AN& FUEL CONSU!TION
HRSG B FUEL CONSU!E& IN GTG> A!%IENT AIR TE!=
STEA! TUR%INES B STEA! RATE CUR#ES> STEA! FLO$ &ATA
E0UATIONS ARE SOL#E& USING A SOL#ER SUORTE& ON EDCEL
SOL#ER USES A NON-LINEAR OTI!I(ATION ROGRA!
ROGRA! RO#I&ES TOTAL 0UANTIT" AN& COST OF %OTH O$ER AN&

STEA! UTILITIES=
CO!%INE& HEAT & O$ER S"STE!
!O&ELING/OTI!I(ATION
UTILITY! OFFSITE
13/11/2009
Slide Number - 21
C)P SYSTE ODELING
CH SU%-S"STE!S
%OILER
CGTG
STG
HRSG
S!R HRU
R&S
&EAERATOR
CON&ENSATE & %F$ S"STE!

28/0?/2009
Slide Number - 22
S# COGEN INTEG#ATION
28/0?/2009
Slide Number - 23
C)P COGEN INTEG#ATION
C)P COGEN INTEG#ATION
28/0?/2009
Slide Number - 28
UTILITY! OFFSITE
13/11/2009
Slide Number - 2?
T5pic&l C)P SYSTE ODELING
%OILER !O&EL
ANNUAL FUEL / STEA! GENERATION &ATA OF EACH %OILER

IS LOTTE& AN& NON LINEAR E0UATIONS ARE O%TAINE&
F = A+ B.S+ C.S
2
F B FUEL CONSU!TION
S B STEA! RO&UCE& FRO! %OILER
A>% & C ARE CONSTANTS CALCULATE& FRO! THE

OERATING &ATA
LO$ER AN& UER LI!ITS OF STEA! GENERATION CAN

%E RO#I&E& IN THE !O&EL
!O&EL RO#I&E A&&ITIONAL STEA! GENERATION LOA&

ON %OILER HA#ING HIGER EFFICIENC"
SI!ILAR !O&EL FOR HRSG IS &E#ELOE&

UTILITY! OFFSITE
13/11/2009
Slide Number - 2C
CO$INED )EAT ! PO"E# SYSTE ODELING
GAS TUR%INE !O&EL
HEAT RATE CUR#E
ANNUAL O$ER / FUEL CONSU!TION &ATA OF

EACH TUR%INE
A!%IENT AIR TE!ERATURE
F = A+ B.P+ C.P
2
+ D.T+ E.T
2
F B FUEL CONSU!TION
B O$ER > T B A!%IENT AIR TE!
A>%>C>& & E ARE CONSTANTS CALCULATE& FRO! THE

OERATING &ATA
SI!ILAR !O&EL FOR STEA! TUR%INE IS

&E#ELOE&
UTILITY! OFFSITE
13/11/2009
Slide Number - 29
ENERGY AUDIT 27
TYPICAL STEA NET"O#% TYPICAL STEA NET"O#%
UTILITY! OFFSITE
13/11/2009
Slide Number - 2;
ENERGY AUDIT 28
SAPLE STEA NET"O#% SAPLE STEA NET"O#%
28/0?/2009
Slide Number - 29
C)P ODEL
C)P ODEL
ENERGY AUDIT 29
UTILITY! OFFSITE
13/11/2009
Slide Number - 30
C)P NET"O#% SIULATION 8 OPTIIEATION
ALICATION OF SI!ULATION ROGRA!
ESTA%LISH OTI!AL GENERATION / URCHASE / EDORT OF

O$ER AN& STEA! SO AS TO !INI!I(E THE SITE FUEL / UTILITIES
COST
E#ALUATE ENERG" CONSER#ATION SCHE!ES FRO! GLO%AL

E LANT F ERSECTI#E
E#ALUATE STRATEGIES FOR O$ER / STEA! GENERATION

CAACIT" EDANSION FOR NE$ RE0UIRE!ENTS
UTILITY! OFFSITE
13/11/2009
Slide Number - 31
GAS LANT CAACIT" B 2C00 !!SCF& GAS LANT CAACIT" B 2C00 !!SCF&
GAS S$EETENING UNIT GAS S$EETENING UNIT
GAS &EH"&RATION UNIT GAS &EH"&RATION UNIT
NGL RCO#ER" E LO$ TE!= F NGL RCO#ER" E LO$ TE!= F
SRU SRU
CO!RESSOR STATION FOR GAS IELINE CO!RESSOR STATION FOR GAS IELINE
ENERG" CONSER#ATION SCHE!ES I&ENTIFIE& ENERG" CONSER#ATION SCHE!ES I&ENTIFIE&
ENHANCE& ROCESS TO ROCESS COL& EDCHANGE ENHANCE& ROCESS TO ROCESS COL& EDCHANGE
RO#ISION OF LEAN / RICH A!INE EDCHANGER RO#ISION OF LEAN / RICH A!INE EDCHANGER
O$ER GENERATION FRO! H"&RAULIC TUR%INE IN &GA UNIT O$ER GENERATION FRO! H"&RAULIC TUR%INE IN &GA UNIT
O%SG ON HEATERS O%SG ON HEATERS
#ARIAA%LE SEE& &RI#ES FOR U!S & AIR COOLERS #ARIAA%LE SEE& &RI#ES FOR U!S & AIR COOLERS
ENERG" SA#E& ENERG" SA#E&
O$ER O$ER B 21 !$ B 21 !$
STEA! GENERATION STEA! GENERATION B 81C !L%H B 81C !L%H
FUEL SA#ING FUEL SA#ING B 100!SCFH B 100!SCFH
ENERG" SA#ING SCHE!ES HA& GOO& A"%AC' ERIO& ENERG" SA#ING SCHE!ES HA& GOO& A"%AC' ERIO&
CH ANAL"SIS SHO$E& THAT %ANEFITS OF ENERG" CONSER#ATION CAN %E ACHIE#E& IF CH ANAL"SIS SHO$E& THAT %ANEFITS OF ENERG" CONSER#ATION CAN %E ACHIE#E& IF
O$ER IS GENERATE& FRO! THE STEA! GENERATE& IN THE ENCON SCHE!E AN& EDORTE& O$ER IS GENERATE& FRO! THE STEA! GENERATE& IN THE ENCON SCHE!E AN& EDORTE&
ENE#GY CONSE#(ATION OPPO#TUNITY ASSESSENT ENE#GY CONSE#(ATION OPPO#TUNITY ASSESSENT
STUDIES AT SAUDI A#ACO GAS PLANT STUDIES AT SAUDI A#ACO GAS PLANT
28/0?/2009
Slide Number - 32
#EFINE#Y-PET#OC)EICAL INTEG#ATION@T5pic&lA
#EFINE#Y-PET#OC)EICAL INTEG#ATION@T5pic&lA
UTILITY! OFFSITE
13/11/2009
Slide Number - 33
#ALUE C7+i/ I/*e2r+*i-/ -4 Re4i/er1 r-du5*) *-

#ALUE C7+i/ I/*e2r+*i-/ -4 Re4i/er1 r-du5*) *-
e*r-57emi5+l Feed
e*r-57emi5+l Feed
S7+ri/2 +/d E44i5ie/* U)e -4 U*ili*ie)

S7+ri/2 +/d E44i5ie/* U)e -4 U*ili*ie)
S7+ri/2 -4 O44)i*e) +/d I/4r+)*ru5*ure

S7+ri/2 -4 O44)i*e) +/d I/4r+)*ru5*ure
S7+ri/2 -4 All l+/* Re)-ur5e) I/5ludi/2 Hum+/

S7+ri/2 -4 All l+/* Re)-ur5e) I/5ludi/2 Hum+/
Re)-ur5e)
Re)-ur5e)
O.er+ll Redu5*i-/ i/ CAED +/d OED

O.er+ll Redu5*i-/ i/ CAED +/d OED

#EFINE#Y-PET#OC)EICAL INTEG#ATION
#EFINE#Y-PET#OC)EICAL INTEG#ATION
UTILITY! OFFSITE
13/11/2009
Slide Number - 38
I/*e2r+*ed C-mm-/ F+5ili*ie) A57ie.i/2 E5-/-mie)

-4 S5+le 4-rB
-4 S5+le 4-rB
Fl+re Fl+re
$+)*e $+*er Tre+*i/2 $+)*e $+*er Tre+*i/2
%uildi/2) %uildi/2)
C-/*r-l R--m C-/*r-l R--m
L+b-r+*-r1 L+b-r+*-r1
#e6iner58Petroche7 4O663ite8In6r&3tructure
#e6iner58Petroche7 4O663ite8In6r&3tructure
Integr&tion
Integr&tion
UTILITY! OFFSITE
13/11/2009
Slide Number - 3?
S*e+m S1)*emB E65e)) !/L S*e+m 4r-m Cr+5Ier

S*e+m S1)*emB E65e)) !/L S*e+m 4r-m Cr+5Ier
*- *7e Re4i/er1 4-r O.er+ll S*e+m S1)*em E44i5ie/51
*- *7e Re4i/er1 4-r O.er+ll S*e+m S1)*em E44i5ie/51
E65e)) H1dr-2e/ 4r-m e*r-57emi5+l *- Re4i/er1

E65e)) H1dr-2e/ 4r-m e*r-57emi5+l *- Re4i/er1

-4 S5+le 4-rB
-4 S5+le 4-rB
C--li/2 $+*er C--li/2 $+*er
Air Air
Ni*r-2e/ Ni*r-2e/
Fire $+*er Fire $+*er
Fuel Fuel
#e6iner58Petroche7ic&l3-
#e6iner58Petroche7ic&l3-
Utilitie3 Integr&tion &n' Energ5 E66icienc5
Utilitie3 Integr&tion &n' Energ5 E66icienc5
28/0?/2009
Slide Number - 3C
)5'rogen S53te7
)5'rogen S53te7
28/0?/2009
Slide Number - 39
H"&ROGEN GENERATION ROCESS SCHE!ES
H"&ROGEN GENERATION ROCESS SCHE!ES
28/0?/2009
Slide Number - 3;
!O&EL %ASE& ASSESS!ENT
!O&EL %ASE& ASSESS!ENT
UTILITY! OFFSITE
13/11/2009
Slide Number - 39
H
H
2 2
i/*er/+l -,*imi3+*i-/
i/*er/+l -,*imi3+*i-/
O,*imi3ed ,er4-rm+/5e -4 *7e /eJ -/-,ur,-)e H O,*imi3ed ,er4-rm+/5e -4 *7e /eJ -/-,ur,-)e H
2 2

4+5ili*1> J7ile be)* )+*i)41i/2 *7e re4i/er1-Jide u*ili*ie) 4+5ili*1> J7ile be)* )+*i)41i/2 *7e re4i/er1-Jide u*ili*ie)
+/d -,er+*i-/+l reKuireme/*)> e),e5i+ll1 i/ *erm) -4 +/d -,er+*i-/+l reKuireme/*)> e),e5i+ll1 i/ *erm) -4
reli+bili*1 +/d 4le6ibili*1= reli+bili*1 +/d 4le6ibili*1=
&e2ree -4 ROG u*ili3+*i-/> H &e2ree -4 ROG u*ili3+*i-/> H

2 2
re5-.er1 +/d mul*i,le re5-.er1 +/d mul*i,le
4eed 4le6ibili*1 4eed 4le6ibili*1
Re4-rmi/2 )e.eri*1 Re4-rmi/2 )e.eri*1
!i/imi3+*i-/ -4 i/.-lu/*+r1 H )*e+m e6,-r* !i/imi3+*i-/ -4 i/.-lu/*+r1 H )*e+m e6,-r*
Le.el -4 CO Le.el -4 CO
2 2
5+,*ure 5+,*ure
)0 Net?orF Opti7iG&tion
)0 Net?orF Opti7iG&tion
UTILITY! OFFSITE
13/11/2009
Slide Number - 80
H H
2 2
e6*er/+l -,*imi3+*i-/ e6*er/+l -,*imi3+*i-/
&e.el-,i/2 -4 H &e.el-,i/2 -4 H
2 2
b+l+/5e m-del b+l+/5e m-del
Ide/*i4i5+*i-/ -4 limi*+*i-/) +/d/-r 4le6ibili*1 -4 *7e H Ide/*i4i5+*i-/ -4 limi*+*i-/) +/d/-r 4le6ibili*1 -4 *7e H
2 2
u)+2e u)+2e
H H
2 2
/e*J-rI L m-delli/2 -r H /e*J-rI L m-delli/2 -r H
2 2
-44-li/e +/+l1)i) -44-li/e +/+l1)i)
Ide/*i4i5+*i-/ -4 *7e Ie1 i/e44i5ie/51 -4 *7e H Ide/*i4i5+*i-/ -4 *7e Ie1 i/e44i5ie/51 -4 *7e H
2 2
/e*J-rI /e*J-rI
I/*e2r+*i-/ -4 ,-))ible +l*er/+*i.e) 4-r H I/*e2r+*i-/ -4 ,-))ible +l*er/+*i.e) 4-r H

2 2
re-u)e +/d re-u)e +/d
re2e/er+*i-/ re2e/er+*i-/
Ide/*i4i5+*i-/ -4 *7e -,*imum )i3e 4-r + /eJ L-/-,ur,-)eM Ide/*i4i5+*i-/ -4 *7e -,*imum )i3e 4-r + /eJ L-/-,ur,-)eM
H H
2 2
2e/er+*i-/ U/i* 2e/er+*i-/ U/i*

)5'rogen Net?orF Opti7iG&tion
UTILITY! OFFSITE
13/11/2009
Slide Number - 81
Re4i/er1-Jide ,+r+me*er)
Re4i/er1-Jide ,+r+me*er)
Crude e.+lu+*i-//)ub)*i*u*i-/ Crude e.+lu+*i-//)ub)*i*u*i-/
O.er+ll re4i/er1 )57eme +/d u/i* -,er+*i-/ i/*er+5*i-/) O.er+ll re4i/er1 )57eme +/d u/i* -,er+*i-/ i/*er+5*i-/)
Re)idue u,2r+di/2 -,*i-/) +))e))me/* Re)idue u,2r+di/2 -,*i-/) +))e))me/*
Fuel )ub)*i*u*i-/ Fuel )ub)*i*u*i-/
C+rb-/ )e,+r+*i-//)eKue)*r+*i-/ )-lu*i-/) C+rb-/ )e,+r+*i-//)eKue)*r+*i-/ )-lu*i-/)
U*ili*ie) L m-delli/2 U*ili*ie) L m-delli/2
CO CO
2 2
L m-delli/2 L m-delli/2
28/0?/2009
Slide Number - 82
T5pic&l #e6iner5 )5'rogen Net?orF
T5pic&l #e6iner5 )5'rogen Net?orF
UTILITY! OFFSITE
13/11/2009
Slide Number - 83
O,*imi3+*i-/ -4 H1dr-2e/ U)+2e O,*imi3+*i-/ -4 H1dr-2e/ U)+2e
Te57/-l-21 U,-2r+d+*i-/ Te57/-l-21 U,-2r+d+*i-/
Feed H Fuel E NG 5+)eF i) 9< l-Jer 4-r SA b+)ed Feed H Fuel E NG 5+)eF i) 9< l-Jer 4-r SA b+)ed
l+/* l+/*
Fuel ReKuired i) 39< l-Jer 4-r SA b+)ed ,l+/* Fuel ReKuired i) 39< l-Jer 4-r SA b+)ed ,l+/*
SJi*57i/2 *- L-Jer !-l $* H1dr-5+rb-/ )+.e) u*ili*1 SJi*57i/2 *- L-Jer !-l $* H1dr-5+rb-/ )+.e) u*ili*1
%e/e4i*) -4 SJi*57i/2 -4 Feed 4r-m N+,7*7+ *- e/*+/e %e/e4i*) -4 SJi*57i/2 -4 Feed 4r-m N+,7*7+ *- e/*+/e
re-de)ul,7uri)+*i-/ i) -mi**ed re-de)ul,7uri)+*i-/ i) -mi**ed
S*e+m Fl-J +* !i6i/2 ,-i/* Redu5ed b1 12< S*e+m Fl-J +* !i6i/2 ,-i/* Redu5ed b1 12<
Fuel ReKuireme/* Redu5ed b1 18=2< Fuel ReKuireme/* Redu5ed b1 18=2<
H2 "ield I/5re+)ed b1 1 < H2 "ield I/5re+)ed b1 1 <
CO2 Emi))i-/) Redu5ed %1 1=?< CO2 Emi))i-/) Redu5ed %1 1=?<

H"&ROGEN GENERATION-S+.i/2 i/ U*ili*1
H"&ROGEN GENERATION-S+.i/2 i/ U*ili*1
UTILITY! OFFSITE
13/11/2009
Slide Number - 88
OFFSITES AN& UTILITIES CONSU!E A%OUT 80

OFFSITES AN& UTILITIES CONSU!E A%OUT 80
< OF ENERG"
< OF ENERG"
STEA!> O$ER ARE !ANOR UTILITIES

STEA!> O$ER ARE !ANOR UTILITIES
CONSI&ERE&
CONSI&ERE&
SCOE FOR RE&UCTION IN ENERG"

SCOE FOR RE&UCTION IN ENERG"
CONSU!TIO I&ENTIFIE&
CONSU!TIO I&ENTIFIE&
INTEGRATION OF REFINER"/ETROCHE!ICAL
INTEGRATION OF REFINER"/ETROCHE!ICAL
LANT SA#ES COST AN& ENERG"
LANT SA#ES COST AN& ENERG"
H"&ROGEN S"STE! !ANAGE!ENT CAN HEL

H"&ROGEN S"STE! !ANAGE!ENT CAN HEL
TO I&ENTIF" OORTUNIT" FOR UTILIT" SA#INGS
TO I&ENTIF" OORTUNIT" FOR UTILIT" SA#INGS
CONCLUSIONS
CONCLUSIONS
???.engineer3in'i&.co7
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You

Identifying Potential - in Offsites and Utilities Including Steam & Power

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Identifying Potential - in Offsites and Utilities Including Steam & Power

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13/11/2009

REFINING CHALLENGES REFINING CHALLENGES

STEA! S"STE! STEA! S"STE!

O$ER S"STE! O$ER S"STE!

HEAT RECO#ER" & CH HEAT RECO#ER" & CH

S!R & COGEN INTEGRATION S!R & COGEN INTEGRATION

&i)*ill+*e "ield Im,r-.eme/*)

Fuel 0u+li*1 U,-2r+d+*i-/

O,*imi3e E/er21 er4-rm+/5e

S*ri5* E/.ir-/me/*+l N-rm)

r-5e)) Hi27 Sul4ur Crude)

r-5e)) Hi27 TAN/ He+.1 Crude)

S1/er21- Re4i/er1 +/d e*r-57emi5+l

REFINER" CONSU!ES A%OUT 9 : ;< OF THE CRU&E

SECIFIC FUEL CONSU!TION HAS RE&UCE& %" A%OUT 20<

FUEL COST CONTRI%UTES 80-8?<

30-80< OF THE FUEL COST IS ATTRI%UTE& TO GENERATION

FOCUS IS NO$ ON @ UTILITIESA CONSER#ATION

STEA! TUR%INE GENERATORS STEA! TUR%INE GENERATORS

H"&ROGEN GENERATION UNIT H"&ROGEN GENERATION UNIT

NITROGEN GENERATION UNIT NITROGEN GENERATION UNIT

COOLING TO$ERS COOLING TO$ERS

INSTRU!ENT AIR S"STE! INSTRU!ENT AIR S"STE!

$ATER TREAT!ENT UNITS $ATER TREAT!ENT UNITS

STEA! GENERATION STEA! GENERATION

STAN& ALONE %OILERS STAN& ALONE %OILERS

HEAT RECO#ER" STEA! GENERATORS HEAT RECO#ER" STEA! GENERATORS

ROCESS $ASTE HEAT %OILERS ROCESS $ASTE HEAT %OILERS

$ASTE HEAT FRO! S!R $ASTE HEAT FRO! S!R

STEA! &ISTRI%UTION STEA! &ISTRI%UTION

EN& USE EN& USE

ROCESS STREA! HEATING ROCESS STREA! HEATING

AS A SOURCE OF $ATER E H"&ROGEN GENERATION F AS A SOURCE OF $ATER E H"&ROGEN GENERATION F

CO!ONENT SEARATION CO!ONENT SEARATION

CON&ENSATE RECO#ER" CON&ENSATE RECO#ER"

STEA! GENERATION STEA! GENERATION

EFFICIENC" CAN %E I!RO#E& TO H90< EFFICIENC" CAN %E I!RO#E& TO H90<

A#AILA%ILT" OF SACE COUL& %E A LI!ITATION A#AILA%ILT" OF SACE COUL& %E A LI!ITATION

LO$ EDCESS AIR %URNERS LO$ EDCESS AIR %URNERS

%OILER FEE&-$ATER U!S %OILER FEE&-$ATER U!S

I!RO#E $ATER TREAT!ENT TO !INI!I(E I!RO#E $ATER TREAT!ENT TO !INI!I(E

!AINTAIN REFRACTOR" IN GOO& CON&ITION TO !AINTAIN REFRACTOR" IN GOO& CON&ITION TO

I!RO#E STEA! &ISTRI%UTION S"STE! I!RO#E STEA! &ISTRI%UTION S"STE!

RECO!!EN&E& STEA! TRA SUR#E" RECO!!EN&E& STEA! TRA SUR#E"

EN& USE I!RO#E!ENTS EN& USE I!RO#E!ENTS

OTI!I(ATION OF STRIING STEA! OTI!I(ATION OF STRIING STEA!

!INI!I(E &EAERATOR #ENT STEA! !INI!I(E &EAERATOR #ENT STEA!

CON&ENSATE RECO#ER" S"STE! CON&ENSATE RECO#ER" S"STE!

CO-GENERATION OR CO!%INE& HEAT AN& O$ER LANTS

30< LUS !ORE EFFICIENT THAN SEARATE RO&UCTION

E0UI!ENTS $ITH #AR"ING O$ER TO HEAT RATIO ARE

GAS TUR%INES GENERATORS GAS TUR%INES GENERATORS

LO$ER CAITAL COST LO$ER CAITAL COST

0UIC' TO START 0UIC' TO START

HIGH EFFICIENC" HIGH EFFICIENC"

LO$ER E!ISSIONS LO$ER E!ISSIONS

COOLING OF INLET AIR COOLING OF INLET AIR

EAS" TO INSTALL EAS" TO INSTALL

O#ER 900 $ORL&$I&E INSTALLATIONS O#ER 900 $ORL&$I&E INSTALLATIONS

!ETHO&OLOG" CO!!ONL" ALIE& !ETHO&OLOG" CO!!ONL" ALIE&

FOGGING / $ET CO!RESSION FOGGING / $ET CO!RESSION

!ECHANICAL / A%SORTION !ECHANICAL / A%SORTION

OFFERS %ETTER CONTROL OF TE!ERATURE OFFERS %ETTER CONTROL OF TE!ERATURE

&i)ill+e "ield Im,r-.eme/*)

Fuel 0u+li1 U,-2r+d+i-/

Sri5 E/.ir-/me/*+l N-rm)

#ALUE C7+i/ I/e2r+i-/ -4 Re4i/er1 r-du5) -

S7+ri/2 +/d E44i5ie/* U)e -4 Uiliie)

S7+ri/2 -4 O44)ie) +/d I/4r+)ru5*ure

I/e2r+ed C-mm-/ F+5ili*ie) A57ie.i/2 E5-/-mie)

$+)e $+er Tre+i/2 $+)e $+er Tre+i/2

C-/r-l R--m C-/r-l R--m

Se+m S1)emB E65e)) !/L S*e+m 4r-m Cr+5Ier

E65e)) H1dr-2e/ 4r-m er-57emi5+l - Re4i/er1

I/e2r+ed C-mm-/ F+5ili*ie) A57ie.i/2 E5-/-mie)

C--li/2 $+er C--li/2 $+er

Fire $+er Fire $+er

&e2ree -4 ROG uili3+i-/> H &e2ree -4 ROG uili3+i-/> H

Re4-rmi/2 )e.eri1 Re4-rmi/2 )e.eri1

!i/imi3+i-/ -4 i/.-lu/+r1 H )e+m e6,-r !i/imi3+i-/ -4 i/.-lu/+r1 H )e+m e6,-r

I/e2r+i-/ -4 ,-))ible +ler/+i.e) 4-r H I/e2r+i-/ -4 ,-))ible +ler/+i.e) 4-r H

Crude e.+lu+i-//)ub)iui-/ Crude e.+lu+i-//)ub)iui-/