refining india 2022
Comprehensive energy efficiency improvement and benchmarking studies
G Srivardhan And Vijay Yalaga Engineers India Ltd
Climate change due to global warming has made it obligatory for all nations to reduce their carbon emissions to save the Earth and environment and undertake various ini- tiatives towards achieving net-zero carbon emission targets. It is well established that fuel consump- tion by industries that include upstream (E&P) and downstream sectors, includ- ing oil refineries and petrochemicals, con- tribute substantially to carbon emissions. In this regard, the energy industry world- wide is mandated to achieve substantial emission reduction voluntarily or by adopt- ing various schemes like carbon credit and energy certificates. While carbon capture, sequestration, and utilisation are gaining momentum, reducing energy use through comprehen- sive energy efficiency improvement and benchmarking studies will directly con- tribute to maximising benefits with availa- ble assets or through minor modifications. EIL has significant experience in conduct- ing energy audits and various benchmark- ing studies in refinery and petrochemical studies for domestic and International cli- ents over the years. Energy studies involve various activities, namely the collection of design and oper- ating data/documents, data analysis and reconciliation using in-house tools, tech- nical interactions and refinery site visits, identification and development of EnCon schemes and their broad-based feasibility for shortlisting of opportunities. The opportunities can be categorised into quick-wins (QW), short-term (ST) schemes, medium-term (MT) schemes, and long-term (LT) schemes with reference to ease of implementation and capital invest- ment. Based on preliminary feasibility studies, the short/medium-term schemes are being considered for implementation after detailed research, whereas the long- term schemes will become part of strate- gic initiatives. The major potential energy-saving areas
refinery in Abu Dhabi (ADNOC). Based on comprehensive energy studies, savings have been categorised as typical unit-wise energy savings or area-wise, as shown in Figures 1 and 2 , respectively. Further, conducting energy efficiency studies along with benchmarking and tar- geting strategies is another approach for identifying energy conservation potential within the constraints of operating plants. The benchmarking studies can be taken up for any key performance indexes (KPI), namely capacity utilisation, product quality upgradation, energy consumption reduc- tion, or profit maximisation. The bench- marking further requires normalisation in some cases to neutralise the impact of fac- tors not under the control of the operating plant. EIL has carried out the benchmark- ing exercise for various refineries in the past and recently conducted a benchmark- ing study for eight petrochemical plants in India. As a total solutions company, EIL pro- vides design, engineering, procurement, construction, and integrated project man- agement services from ‘concept to com- missioning’ and has developed capabilities in energy optimisation studies and bench- marking of industries covering the entire hydrocarbon value chain. It also provides specialist services such as heat and mass transfer equipment design, environmental engineering, specialist materials and main- tenance, and plant ope rations and safety services. Also, as part of its R&D endeavours, EIL has developed va rious in-house tools/ software and process models (EngRAGE for data analysis and reconciliation, and EngCHP for steam and power optimisa- tion), which are extensively used in the studies. Further, EIL is constantly devel- oping new technologies and implement- ing them in projects to help improve energy efficiency.
Implement quick wins
Reconciliation/ anaylsis of data
Commencement of energy study
Collection of data
Identifying energy savings
Save energy, money & environment
Detailed study- ST/MT/LT schemes
Implementation
Approach for EEIS projects
Primary units 20%
Utilities and o sites 16%
MS block 4%
Steam and power network 26%
Secondary processing units 13%
Bottom processing units 3%
Hydrogen management 4%
Sulphur block 8%
Treating units 6%
Figure 1 Typical unit-wise energy savings
Heat integration 12%
Low level heat recovery 6%
Optimi s ing the operating parameters 2% Fired heaters e ciency improvement 5%
Intervention of new technologies 17%
Steam and power
network 14%
Rationali s ation and upgrading of facilities 44%
Figure 2 Typical area-wise energy savings
and power network optimisation, and fired heater efficiency improvement. Using the above approach, EIL has car- ried out various studies over the years and recently conducted a comprehensive study of 15 Indian PSU refineries and the Ruwais
include optimising the operating parame- ters for feed and product slates, inter/intra unit heat integration, low-level heat recov- ery, the intervention of new technologies, rationalisation and upgradation of facilities with the best available technologies, steam
Contact: technology@eil.co.in
Managing Director Richard Watts
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