Energy Efficiency Improvement in the Petroleum Refining Industry

Introduction

Refinery energy efficiency is multidisciplinary subject, involving process operations, utility system, equipment, power generation, housekeeping, process control, advanced thermodynamic concepts of heat exchanger trains (Pinch Technology) and effective management. Processes and systems, such as steam, cooling water, process heating, and electric motors, consume most of energy. In the same time, these systems offer significant opportunities for savings, based on new technologies and advanced controls This Energy Efficiency Improvement in Petroleum Refining Industry training course will provide a comprehensive review of various aspects of process plant integrity as the essential foundation for sustainable plant profitability and optimization, including energy saving program that is devised to incorporate all these disciplines with the goal of reaching the maximum of energy efficiency and profitability. 

Participants attending this training course will develop the following competencies:

• Ability to assess energy efficiency of refinery and individual processes
• Skill to calculate potential for improvement
• Familiarity with optimization of refinery utility systems (steam and power)
• Implementation of effective energy management procedures

Objectives

This training course aims to enable participants to achieve the following objectives:

• Knowledge of Energy Consumption and KPU of Refinery
• Understanding of Methods to Improve Energy Efficiency
• Ability to Perform Analysis of Equipment Efficiency
• Knowledge to implement Energy Management Program
• Understanding of Importance of Employees Involvement in Energy Program
• Implementation of Process Heat Integration: Pinch Theory and Heat Exchangers

Training Methodology

The Energy Efficiency Improvement in Petroleum Refining Industry training course will be conducted along workshop principles with formal lectures and interactive worked examples and with active contribution by all participants during workshops and team work. Real life examples and case studies will be included to illustrate the procedure for controlling operation of utilities and impact on environment. The emphasis in the course will be on the explanation of technical phenomena and providing answers to problems that are encountered in everyday practice in modern refineries There will be ample opportunities during workshops for active discussion on new technical measures and methodologies

Who Should Attend?

• Boardman and Lead Operator (BO, LO)
• Other relevant technical personnel

Course Outline

Day 1 - Introduction to Energy Efficiency: Effect of Energy Consumption

• Identifying Areas of Refinery with High Energy Consumption

• Potential for Improvement of Energy Consumption

• Importance and Benefits of Maintaining High Energy Efficiency in Refinery

• Consideration of Refinery Energy Balance

• Overview of Energy Use and Optimization in Petrochemical Industries

• Recommended Approach to Energy Saving (Benchmarking)

• Responsibility Distribution Regarding Energy Efficiency

• Common Barriers to Achieving Energy Efficiency

• Employee Behaviour and Company’s Attitude towards Energy Conservation

• Implementation of Organization-wide Energy Management Program

• Workshop: Case Studies

Day 2 - Energy Features of Refinery Key Process Units and How to Improve their Energy Efficiency

• Development of Best Practices for Energy Saving for Key Process Units

• Survey of Major Equipment and Utility Systems

• Case Study: Centrifugal Pump & Electric Motor

• Introduction of Energy Efficiency Process Controls in Key Areas

• Implementation of Successful Energy Management Program.

• Analysis of Distillation Units: Crude, Vacuum and Binary Distillation Columns

• Consideration of Hydro-Treating, Catalytic Reforming, Fluid Catalytic and Hydrocracking etc.

• Industrial Energy Management and System Standards

• Energy Use and Optimization Technologies

• Workshop: Case Studies

Day 3 - Refinery Utility System Energy Consumption

• Steam Systems, Compressed Air Systems

• Power Generation

• Power Consumption: Mechanical Systems

• Case Study: Centrifugal Pump & Electric Motor

• Reduction of Wasteful Greenhouse Gas Emissions

• Flare Network Losses Optimization

• Establishment of Integrity Operating Windows (IOW)

• Effective Management of Change (MOC) Program: Operation & Maintenance

• Workshop: Case Studies

Day 4 - Process Heat Integration

• Fired Heaters and Boilers: Methods of Improved Combustion, Waste Heat Recovery

• Efficiency of Heat Exchangers and Other Thermal Equipment

• Process Heat Integration: “Pinch Technology”

• Heat Exchanger Train Optimization

• Benefits from Synergies of Systems with Multiple Components Working Together

• Retrofitting Heat Exchanger Networks for Improved Performance

• Application of New Technology that Yields Lower Input/Output Ratio, Using Same Fuel

• Consideration of Alternative Models that Enhance Energy Efficiency.

• Workshop: Case Studies

Day 5 - Equipment Efficiency; Effective Energy Management

• Approaches to Improved Energy Efficiency and Unit Operations

• Adoption of Low-Carbon Hydrogen from Natural Gas Using Steam Methane Reformation

• Efficiency Improvement of Rotating Machinery: Machine-Driver Copupling

• Developing Internal Competence in Energy: Energy Focus

• Plant Economics

• Daily Monitoring System Guidelines:

• Historical Data and Case Studies