Transcript HSEE - US-Brazil Industrial Energy Efficiency Workshop
HSEE HSEE Health, Safety, Environment and Energy Efficiency
Energy Efficiency Case Study – PETROBRAS
Claudio Rücker
Energy Efficiency Sector
Workshop US-Brazil Binational Energy Working Group (Energy Efficiency) CEPEL – Rio de Janeiro – RJ – Brazil 10 / 08 / 2011
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Petrobras Main Figures (2009 data)
•Investments : R$ 71 billion •Net Profit: R$ 28.98 billion •Global Presence: 28 countries •Reserves: 14.90 billion barrels of oil and gas equiv.
•Net Revenue: R$ 182.71 billion •Shareholders: 463,870 •Daily Production: • 2,526,000 barrels per day
78 fixed
7,197 25,966 Km 133
55 floating
15 172 52 owned
HSEE Petrobras Main Figures (2009 data)
•Production Platforms: 133 (86 fixed; 47 floating) •Vessel Fleet:172 (52 belonging to Petrobras) •Biofuels: 5 plants •Wind Energy: 1 pilot plant •Fertilizers: 2 plants •Refineries: 15 •Yield of the Refineries: 2,034,000 bdd •Pipelines: 25,966 km •Thermoelectric Plants: 18 plants •Service Stations: Nearly 8,000 7,197 25,966 Km
78 fixed
133
55 floating
15 172 52 owned
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Petrobras Main Figures
Increased to 6.4 MM boe/d in 2020, as informed in the recent Business Plan 2011 2015
HSEE Petrobras Main Figures
HSEE Research and Development
HSEE Energy Performance Challenges Strategic Objectives
Maximize efficiency and minimize the intensity of GHG emissions, reaching levels of excellence in the Oil & Gas industry, contributing to business sustainability
Energy Efficiency • • •
Corporate Quinquennial Goals quantified Intensity Indexes and goals established for each B.A.
Board of Directors analyses results quarterly
Energy Annual Report Emissions
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Energy Efficiency and Climate Change
Source: WEO World Energy Outlook 2009 - IEA
HSEE Energy Efficiency and Climate Change
Source: BP Energy Outlook 2030 (January/2011)
HSEE Management Process
Corporate Policies and Guidelines Corporate Leadership Leaders in the Operations Units Design Guidelines Performance Indicators Measurement Goals - Benchmark Supply Chain Management Energy Critical Analysis Correction of Deviations Modeling Process Optimization - Advanced Control - "RTO"
HSEE Management Process
Corporate Policies and Guidelines Corporate Leadership Leaders in the Operations Units Design Guidelines
PRIORITY
Performance Indicators Measurement Goals - Benchmark Supply Chain Management Energy Critical Analysis Correction of Deviations Modeling Process Optimization - Advanced Control - "RTO"
PDCA Information Management Systems PRIORITY
HSEE PETROBRAS ORGANIZATION CHART Business Strategy and Performance New Businesses Human Resources Finance Corporate Financial Planning and Risk Management Finance Accounting Tax Investor Relations Audit Committee Board of Directors Ombudsman’s Office Business Committee Senior Management CEO CEO’s Office Internal Audit Petrobras Secretary Office Management Systems Development Legal Department Corporate Communication Gas and Energy Corporate Marketing and Trade Logistics and Part. in Natural Gas Operations and Part. in Energy Energy Development Gas Chemicals and Liquefaction Exploration and Production Corporate Production Engineering Services Exploration North-Northeast South-Southwest Pre-salt Downstream Corporate Logistics Refining Marketing and Commercialization Petrochemicals Major Projects Program International Corporate Technical Support to Businesses Business Development South Cone LA Americas, Africa and Eurasia Services Health, Safety, Environment and Energy Efficiency Materials Research and Development (Cenpes) Engineering Information Technology Shared Services
Energy consumption in Petrobras totalizes 259,000 b/d and
HSEE
represents about 10% of its total production Consumption per activity (thousands b/d, year 2009) Thousands b/d, year 2009 Consumption represents ~10% of production
(236 boed) (363 boed) Energy Efficiency can result in substantial outcome increases for the Company
Source: 2009 Petrobras Consumption Report
HSEE What ´s Energy Efficiency?
Ratio between a produced good or an accomplished service and the quantity of energy consumed for that •In case of Petrobras:
Produce more with less energy intensity
HSEE Petrobras Energy Efficiency Goals
– Reduce 10% and 5% the energy intensity , between 2009 and 2015, in its Downstream and Thermal Plants , respectively – Reduce 65% the natural gas flaring , between 2009 and 2015, in its Upstream operations – Considering R&D and projects of energy efficiency, Petrobras will invest US$ 1.2 billion until 2015
HSEE Main Projects
– –
Thermal Plants
: Convertion symple cycle in combined cycle thermal plants –
Downstream
: Motorization of large condensate turbines, energy integration, process units optimization, modernization of thermoelectric systems
Upstream
: natural gas compression and logistics investments
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Example of energy efficiency projects Example of Advanced Control in a Gas Process Unit
• Investiment: US$ 270,000 • Results: – Earnings: US$ 14 million (in energy efficiency and production) – Extra production: 16,410,000 m³ LGN/year (increase of 9%) – Energy economy: 2 to 10%
HSEE Example of energy efficiency projects Furnaces and Boilers Soot Blowing Modernization Projects
•
Refinery Case Example:
– Investment: US$ 1.74 million – Energy economy: 305 b/d – Carbon emission avoided: 38,000 tons CO2/year
HSEE Example of energy efficiency projects Condensate and Steam Modernization Projects
•
Fertilizer Plant Example Case :
– Investiment: US$ 1.5 million – Condensate recuperated: 20 t/h – Natural gas economy: 4,920 m CO 2 /year 3 /day – Carbon emissions avoided: 3,700 ton
HSEE Example of energy efficiency projects Fluid Catalytic Cracking (FCC) Turboexpanders
• • •
Recovery energy by substituting pressure reducing valves by a turbine coupled to an electric generator 5 refineries 98 MW of total installed capacity
HSEE Example of energy efficiency projects
Variable Speed Driver Projects
•
Refinery Example Case (6 pumps)
– Investiment: US$ 1.7 million – Energy Economy: 800 MWh/year – Carbon emissions avoided: 83 ton CO2/year Fonte: WEG
HSEE Example of energy efficiency projects Dessalinization Units Projects
• • • • • •
Offshore Platforms Dessalinization Example Case :
3 production units Reducing of potable water transportation by ships Dessalinization water capacity: 255 m³/day Investment: US$ 1.7 million Energy economy: 5.2 b/d Carbon emissions avoided: 829 ton CO 2 /year
HSEE Example of energy efficiency projects
Heat Recovery Projects
• • • •
Process Unit Example Case :
Reduce 70% of furnace thermal demand Investments: US$ 15 million Energy economy: 55,000 m³/day of natural gas Carbon emissions avoided: 40,000 tCO 2 /year
HSEE Example of energy efficiency projects Thermal Solar Energy Projects
• • •
Onshore Oil Well Case Example:
To take the paraffin off from the well column Energy economy: 0.35 b/d Carbon emissions avoided: 35 ton CO 2 /year
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE EZR Cogeneration Plant
• This project consists of an integration of two different Business Areas of Petrobras (Downstream and Gas & Energy):
– The RPBC Refinery old boilers were with low energy efficiency – The Gas & Energy was looking for new thermal plants business opportunties
HSEE EZR Cogeneration Plant – Main Equipments
• 1 Gas Turbine: 171.7 MW (ISO) • 1 HRSG (120 bar; 42 bar; 12 bar) • 1 Condensate Steam Turbine: 55 MW • 2 Auxiliary Boilers • Startup in 2010 • 2011 in pre-operation
HSEE EZR Cogeneration Plant – Energy Economy
RPBC Boilers EZR Cogeneration Plant Fuel 12,953 TJ/year Efficiency = 77,5% Steam 415 t/h 196 MW Electricity Combined Cycle Thermal Plant 196 MW Electricity Fuel 19,541 TJ/year Efficiency = 82% Steam 415 t/h Fuel 10,407 TJ/year Efficiency = 60% Without integration Fuel = 23,360 TJ/a Global Efficiency = 69%
Energy Economy 3,819 TJ/year 1,771 b/d
With integration - cogen Fuel = 19,541 TJ/year Global Efficiency = 82%
HSEE EZR Cogeneration Plant – Carbon Emissions
RPBC Boilers EZR Cogeneration Plant Fuel 85% FO 15% NG 951,500 tCO 2 /year Efficiency = 77,5% Steam 415 t/h 196 MW Electricity Combined Cycle Thermal Plant 196 MW Electricity Fuel 78% NG 22% RG 1,136,500 tCO 2 /year Efficiency = 82% Steam 415 t/h Fuel 100% NG 581,000tCO 2 /year Efficiency = 60% Without integration 1,532,500 tCO 2 /year CO 2 Index = 0,34 tCO 2 /MWh
CO 2 Avoided 396,000 tCO 2 /year
With integration - cogen 1,136,500 tCO 2 /year CO 2 Index = 0,26 tCO 2 /MWh
HSEE EZR Cogeneration Plant – Conclusion
• Results:
– Energy economy: 1,771 b/d – Carbon emisisons avoided: 396,000 ton CO 2 /year – Lower carbon intensity in Petrobras energy profile – Lower NOx emissions
HSEE Agenda
1. Petrobras Main Figures 2. Petrobras 2020 Strategic Plan 3. Energy Efficiency Context in Petrobras 4. Energy Efficiency Example Cases 5. EZR Cogeneration Case 6. Challenges for Petrobras
HSEE Energy Efficiency Challenges in Petrobras Implement a new management model for Energy Efficiency
Future vision KPIs and goals New corporative standards
Insertion of Energy Efficiency requirements in Petrobras new design models
More efficient designs Consider the carbon emission
Projects of energy efficiency in the actual plants
Priorize energy efficiency projects in the Company portfolio Profitability Increases Operational Efficiency Increases Company Image Prepare to Future Scenarios
HSEE