integrating CCS/CCUS into their strategies. However, refin - eries face challenges due to dispersed, lower concentra- tion emission sources and the need for desulphurisation. Despite this, their expertise in separation technologies, such as absorption, can enable approximately 90% capture. Steam methane reformers (SMRs) are prime candidates for CCS due to high CO 2 output. High costs remain a major barrier to widespread CCUS deployment, often exceeding renewables, making feasibility dependent on high carbon prices. Carbon capture ‘hubs’ and ‘clusters’ (for example, the proposed US Gulf Coast project) offer a potential solu- tion by sharing infrastructure among multiple emitters and storage sites, reducing costs and risks. However, strong policy support and collaboration are crucial for developing these vital decarbonisation networks. Environmental control in flue gas releases/flaring/ GHG emissions and wastewater treatment The refining industry faces increasing scrutiny over its environmental footprint. Proactive management of envi- ronmental controls, particularly in flue gas releases, flaring, GHG emissions, and wastewater treatment, is now crit- ical for both operational stability and long-term viability. By embracing innovative technologies and best practices, refiners can navigate stringent regulations, manage geopo - litical uncertainties, and position themselves as responsible energy providers in the ongoing transition. Investments in minimising emissions and optimising wastewater treat- ment yield benefits, including reduced operational costs, enhanced stakeholder trust, improved access to capital, and a stronger foundation for a lower-carbon future. Commercial technologies and best practices mitigate flue gas releases, flaring, and general GHG emissions. For flue gas releases, this includes commercial mitigation processes and hardware, as well as advanced FCC emission catalysts and additive technologies. Operational practices encom- pass maintaining SCR catalyst systems and upgrading to low- or ultra-low NOx burners, along with precise emission calculation methods. Regarding refinery gas flaring, proper operations are essential. This involves treating and recovering volatile organic compounds (VOCs), reducing emissions from coke drums and closed blowdown systems, minimising flaring during unit start-ups, and optimising flare system design temperatures. Flare gas analysis, combustion effi - ciency measurement, and flare-pilot monitoring are crucial. End-to-end emissions reduction strategies, considering flare gas recovery systems for greenfield refineries, using refrigerated condensers, and optimising existing systems, are also vital, alongside accurate flare gas flow measure - ment. For GHG emissions, operational experiences focus on CO 2 emissions considerations, methane leak detection and repair, GHG emissions from wastewater treatment and associated abatement measures, and managing emissions from other auxiliary units. For refinery wastewater management, the growing importance of resource recovery and circular economy inte- gration is evident. This includes advancements in treatment technologies and the role of digitalisation and optimisation
in enhancing wastewater processes. A specific challenge addressed is adapting to the unique characteristics of renewable diesel wastewater, an emerging stream. These approaches underscore how environmental excellence is becoming a key differentiator, enabling refiners to flourish in the evolving energy landscape. Integrating renewable energy into refinery operations Refineries are highly energy-intensive operations with significant CO2 emissions, primarily from fired heaters and hydrogen production. Integrating renewable energy (RE) offers opportunities but also challenges due to the inter- mittency of sources like wind and solar, which require sub- stantial land and backup. While electrification of process heating and renewable-powered electric boilers can reduce emissions, large-scale implementation requires significant infrastructure upgrades, especially for replacing older CHP plants. The economic viability of intermittent RE depends on low electricity prices and improved grid infrastructure. A key focus for RE integration is hydrogen production. Green hydrogen, produced via renewable electricity-pow- ered electrolysis, offers a near-zero-emission alternative to steam methane reforming. Major refiners are investing heavily in this: TotalEnergies is securing green hydro- gen from offshore wind farms for its European refineries (Leuna, Zeeland, Antwerp, Normandy), and Shell is building Europe’s largest green hydrogen plant (Holland Hydrogen I) for its Rotterdam refinery. OMV has also commissioned a 10 MW green hydrogen plant at its Schwechat refinery. Blue hydrogen, derived from natural gas with carbon capture and storage (CCS), is another significant pathway for emissions reduction. ExxonMobil is pursuing a large- scale blue hydrogen project at its Baytown Complex (US) for refining and chemical operations, and Aramco is secur - ing blue hydrogen for its Jubail facilities in Saudi Arabia. Beyond hydrogen, on-site solar power is gaining trac- tion for direct electricity generation. Flint Hills Resources is installing a 27 MW solar array to power nearly a third of its Corpus Christi West refinery in the US, while Petrobras is adding 48 MW of solar capacity across three Brazilian refineries (Gabriel Passos, Abreu and Lima, Paulinia) by 2025 to reduce natural gas consumption. While nuclear small modular reactors nuclear (SMRs) and geothermal are being explored for industrial heat and power, their direct integration into operational refineries is less common in current announcements, with hydropower contributing pri- marily via the grid. Overall, RE integration necessitates grid improvements, storage, and hybrid systems to manage var- iability and enable large-scale adoption, potentially through collaborative investments. The global refining industry is actively transforming, with numerous projects demonstrating tangible progress toward the integrated fuels and energy hub model. These initiatives showcase the diverse strategies refiners are employing to pivot towards a sustainable future. This list offers a snapshot of current projects, but it is important to note it is not exhaustive. Many companies have ongoing or new initiatives that have not been publicly announced yet.
39
PTQ Q1 2026
www.digitalrefining.com
Powered by FlippingBook