PTQ Q2 2024 Issue

approach meant balancing current operations with a for- ward-looking strategy. As outlined in Project Catalyst, the roadmap started with examining operations and implementing energy efficiency to provide quick wins while balancing emissions reduction with profitability. In this case, it involved reviewing existing assets and operations to ensure optimal functionality. This would achieve around a 15% emissions reduction, at best 20%. However, to reach the desired mid-30% emissions reduction target and net zero by 2050, a clear strategy, outside-the-box thinking, and alternative solutions were needed to drive organisational change. To achieve this first milestone of 30% emissions reduction, the refiner built a green hydrogen plant to replace part of the hydrogen produced at their steam methane reformer. This step required various options to be evaluated to determine the impact each alternative would have on energy, emis- sions, and economics. Besides developing a solid business case and a set of digital tools to analyse the green hydrogen plant, additional actions and opportunities were explored to achieve net zero emissions, such as electrification, carbon capture storage and utilisation, and hydrogen firing. Moreover, testing and verifying results were essential to achieve top performance. As a result, tools capable of incorporating the latest site modifications were essential for real-time energy and emissions optimisation. By incor- porating these measures, the refinery worked towards achieving its emission reduction goals and contributing to a more sustainable future. Technology leads the way. Against this backdrop, and to ensure alignment between strategy and current opera- tions, two main technologies were adopted: the Integrated Process, Energy, Emissions and Economics Model (IP3EM) and digital energy management system. The first technology implemented was the IP3EM. This tool optimises renewable power options to reduce Scope 2 emissions while incorporating future Scope 3 projects. As shown in Figure 2, this refinery-wide model compre - hensively considered energy demanded from processing,

utility production and supply, and process and utility-gen- erated emissions. Powered by a process simulator with necessary modules, it addressed present and future energy transition challenges. Moreover, the IP3EM model also assessed the economic impact of the different alternatives being evaluated and guided the refinery throughout its entire decarbonisation journey. The IP3EM revealed key benefits such as analysing refin - ery margins, return on investment using emissions reduc- tion scenarios, and accurately identifying and quantifying major sources of Scope 1 greenhouse gas (GHG) emissions. Several projects were considered. The IP3EM was key to assessing the impact of Scope 1 and 2 emissions, energy consumption, and economics regarding furnace electrifica - tion, hydrogen firing, a green hydrogen plant (electrolyser), and oxygen firing. Moreover, the analysis also included future business cases that accounted for Scope 1 and 3 emissions. These projects included carbon capture and uti- lisation (CCU) for sustainable aviation fuel, CCU urea pro - duction, and a potential renewable hydroprocessing plant. The second technology involved implementing a digital energy management system to serve as the programme’s foundation. This software optimised the energy system in terms of economics and emissions to sustain long-term value. Simultaneously cutting costs and GHG emissions started in a predominantly centralised, hydrocarbon-based energy generation setting. During the energy transition, processes improved, renewable energy vectors were introduced, and assets were decentralised. Ultimately, the goal is to achieve net zero GHG emis- sions in a largely renewable energy system by maintaining decentralised, low CO 2 emissions energy generation, trans- portation, as well as storage and utilisation. The case in Figure 3 demonstrates a utility system that blends traditional with renewable energy sources. This scenario emphasises the importance of aligning short-term scheduling with real-time operations for maintaining feasi- bility and profitability.

Renewable power

Grid

3.4 MW 4.8 MW 31.5 MW 33.5 MW

Traditional utility system

Process plant

492 Kg/h

Electrolyser

HPS

28.5 TPH

KPIs

Fuels

Emissions

MPS

85.0 TPH

LPS

Ambient temp. 10 ˚C

14.1 TPH

Figure 3 Renewable and traditional energy management system

PTQ Q2 2024