Transcript IDENTIFYING POTENTIAL - IN OFFSITES AND

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
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

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
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:









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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 5
REFINERY STEAM SYSTEM

STEAM GENERATION





STEAM DISTRIBUTION



RECEIVES STEAM AT DIFFERENT LEVELS FROM GENERATORS &
TURBINE EXHAUST
NORMALLY STEAM IS DISTRIBUTED AT 3 – 4 PRESSURE LEVELS
END USE





STAND ALONE BOILERS
HEAT RECOVERY STEAM GENERATORS
PROCESS WASTE HEAT BOILERS
WASTE HEAT FROM SMR
PROCESS STREAM HEATING
AS A SOURCE OF WATER ( HYDROGEN GENERATION )
COMPONENT SEPARATION
SHAFT WORK ( DRIVE FOR PUMPS, COMPRESSOR BLOWERS ETC. )
RECOVERY

CONDENSATE RECOVERY
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 6
REFINERY STEAM SYSTEM – ENERGY
CONSERVATION OPPORTUNITIES

STEAM GENERATION

AVOID RUNNING EXTRA BOILER (ON CONSIDERATION OF
RELIABILTY OF STEAM SUPPLY)


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
LOW EXCESS AIR BURNERS


LEADS TO GENERATION OF EXTRA STEAM WHICH IS FINALLY
CONDENSED IN COOLRS AND CONDENSATE IS RECYCLED
WILL REDUCE STACK LOSS AND FUEL
USE OF VARIABLE SPEED DRIVES FOR EQUIPMENTS WHICH ARE
RUN ON PART LOAD FOR RELIABILTY


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

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
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


IMPLEMENT EFFECTIVE STEAM TRAP SURVEY &
MAINTENANCE PROGRAM




AVOID STEAM LEAKS AND REPAIR DAMAGED INSULATION
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
WEEKLY TO MONTHLY
2.0 TO 10.0 KG/CM2G
MONTHLY TO QUARTERLY
< 2.0 KG/CM2G
ANNUALLY
UTILIZE BACKPRESSURE TURBINE INSTEAD OF PRVs
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 9
STEAM SYSTEM – ENERGY CONSERVATION
OPPORTUNITIES

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 .
LOAD, KW
STEAM R ATE, KG/KWHR
STEAM
CONSUMPTION,
TPH
495
48.8
24.0
250
63.08
15.0



LOSS, TPH
6.0
OPTIMIZATION OF STRIPPING STEAM
MINIMIZE DEAERATOR VENT STEAM
CONDENSATE RECOVERY SYSTEM
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 10
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
Heat – to – power
ratio ( KWth/KWe )
Power Output ( as%
of fuel input )
Overall Efficiency,
%
Back Pressure Turbine
4.0 – 14.3
14 - 28
84 - 92
Extraction Condensing
Steam Turbine
2.0 – 10.0
22 - 40
60 - 80
Gas Turbine
1.0 – 2.0
24 - 35
70 - 85
Combined Cycle
1.0 – 1.7
34 -40
69 - 83
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 11
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
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





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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 13
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
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 18
COMBINED HEAT & POWER NETWORK

CONDENSATE RECOVERY SYSTEM


CONDENSATE FLASH DRUMS OPEATING AT VARIOUS PRESSURE /
TEMPERATURE LEVEL
VENT STEAM CONDENSER



DE-AERATOR


AFFECTS DM WATER REQUIREMENT
PROVIDES HEAT FOR HEATING DM WATER GOING TO DEAERATOR
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 19
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.


Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 20
CHP SYSTEM MODELING

CHP SUB-SYSTEMS








BOILER
CGTG
STG
HRSG
SMR HRU
PRDS
DEAERATOR
CONDENSATE & BFW SYSTEM
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 21
SMR COGEN INTEGRATION
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 22
CHP COGEN INTEGRATION
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 23
SMR COGEN INTEGRATION
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 24
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 25
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 26
TYPICAL STEAM NETWORK
Boiler
182
0
External steam
source.
0
92.4
Kg/cm2a 50
215
Steam
Genera
21
133
24
Kg/cm2a 17
45
41
215
Steam
User
Process
steam
generator
68
HRSG
Alternator
Turbine
96
151.8
3
Compressor
Turbine
20
Boiler
atomizing
steam
148.1
13.7
BFW pump
Turbine
Process
Users
0.0
HRSG
atomizing
20
0
0
0
0
238.8
Process
Users
8.4
Kg/cm2a 20
3
Compressor
Aux Turbines
8.4
Treated FW
pump
Turbine
3
15
Boiler Fan
0
Kg/cm2a 5
15
12
11
Blow
Down
24
Blow Down
flash drum
Treated makeup water
0.5
291
Deaerator
Condensate
quench drum
98.3
168
Engineers India Ltd – Delivering excellence through people
ENERGY AUDIT
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
27
Slide Number - 27
SAMPLE STEAM NETWORK
Engineers India Ltd – Delivering excellence through people
ENERGY AUDIT
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
28
Slide Number - 28
CHP MODEL
Engineers India Ltd – Delivering excellence through people
ENERGY AUDIT
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 29
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 30
ENERGY CONSERVATION OPPORTUNITY ASSESSMENT
STUDIES AT SAUDI ARAMCO GAS PLANT

GAS PLANT CAPACITY : 2600 MMSCFD






ENERGY CONSERVATION SCHEMES IDENTIFIED









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
ENERGY SAVED


GAS SWEETENING UNIT
GAS DEHYDRATION UNIT
NGL RCOVERY ( LOW TEMP. )
SRU
COMPRESSOR STATION FOR GAS PIPELINE
POWER
STEAM GENERATION
FUEL SAVING
: 21 MW
: 416 MLBH
: 100MSCFH
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 31
REFINERY-PETROCHEMICAL
INTEGRATION(Typical)
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 32
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
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 33
Refinery/Petrochem –Offsite/Infrastructure
Integration

Integrated Common Facilities Achieving Economies
of Scale for:
Flare
 Waste Water Treating
 Buildings
 Control Room
 Laboratory

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 34
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

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 35
Hydrogen System
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 36
HYDROGEN GENERATION PROCESS SCHEMES
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 37
MODEL BASED ASSESSMENT
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 38
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

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 39
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

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 40
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

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 41
Typical Refinery Hydrogen Network
Engineers India Ltd – Delivering excellence through people
CHP MODELING & OPTIMISATION
24/05/2007
Slide Number - 42
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%
Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 43
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

Engineers India Ltd – Delivering excellence through people
POTENTIAL- ENERGY CONSERVATION
UTILITY& OFFSITE
13/11/2009
Slide Number - 44
Thank You
www.engineersindia.com