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ENERGY STAR Guide for Petroleum Refineries

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Energy Efficiency Improvement and Cost Saving Opportunities for Petroleum Refineries ® An ENERGY STAR Guide for Energy and Plant Managers February 2015 ENERGY STAR is a U.S. Environmental Protection Agency Program helping organizations and individuals fight climate change through superior energy efficiency. Learn more at energystar.gov/industry. Document Number 430-R-15-002 Energy Efficiency Improvement and Cost Saving Opportunities for Petroleum Refineries An ENERGY STAR® Guide for Energy and Plant Managers Ernst Worrell, Utrecht University Mariëlle Corsten, Utrecht University Christina Galitsky, Lawrence Berkeley National Laboratory February 2015 Disclaimer This document was prepared as an account of work sponsored by the United States Government. While this document is believed to contain correct information, neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Acknowledgment This report was funded by the U.S. Environmental Protection Agency’s Climate Protection Partnerships Division as part of ENERGY STAR. ENERGY STAR is a government-backed program that helps businesses protect the environment through superior energy efficiency. ii ABSTRACT The petroleum refining industry in the United States is the largest in the world, providing inputs to virtually all economic sectors, including the transportation sector and the chemical industry. The industry operates 144 domestic refineries (as of January 2012), employing over 63,000 employees. The refining industry produces a mix of products with a total value exceeding $555 billion. Although refineries typically spend 50% of cash operating costs (i.e., excluding capital costs and depreciation) on energy, recent developments in natural gas prices have reduced this to approximately 30%. Even with these savings, energy remains a major cost factor and an important opportunity for cost reduction. Energy use is also a major source of emissions in the refinery industry, making energy efficiency improvement an attractive opportunity to reduce emissions and operating costs. Voluntary government programs aim to assist industry to improve competitiveness through increased energy efficiency and reduced environmental impact. ENERGY STAR, a voluntary program managed by the U.S. Environmental Protection Agency, stresses the need for strong and strategic corporate energy management programs. ENERGY STAR provides energy management tools and strategies for successful corporate energy management programs. This Guide describes research conducted to support ENERGY STAR and its work with the petroleum refining industry. This Guide introduces energy efficiency opportunities available for petroleum refineries, beginning with descriptions of the trends, structure and production of the refining industry and the energy used in the refining and conversion processes. Specific energy savings for the energy efficiency measure are provided, based on case studies of plants and references to technical literature. If available, typical payback periods are also listed. The Guide draws upon the experiences with energy efficiency measures of petroleum refineries worldwide. The findings suggest that, given available resources and technology, there are opportunities to reduce energy consumption cost- effectively in the petroleum refining industry while maintaining the quality of the products manufactured. Further research on the economics of the measures, as well as the applicability of these measures to individual refineries, is needed to assess the feasibility of implementation of selected technologies at individual plants. iii Table of Contents 1. Introduction ................................................................................................................. 1 2. The U.S. Petroleum Refining Industry ......................................................................... 3 3. Process Description ................................................................................................... 10 4. Energy Consumption ................................................................................................. 20 5. Energy Efficiency Opportunities ................................................................................. 28 6. Energy Management and Control .............................................................................. 31 6.1 Energy Management Systems (EMS) and Programs ................................................ 31 6.2 Energy Teams ........................................................................................................... 33 6.3 Energy Monitoring and Control Systems ................................................................... 34 7. Energy Recovery ....................................................................................................... 38 7.1 Flare Gas Recovery .................................................................................................. 38 7.2 Power recovery ......................................................................................................... 39 8. Steam Generation and Distribution ............................................................................ 41 8.1 Boilers ....................................................................................................................... 42 8.2 Steam Distribution System Energy Efficiency Measures ........................................... 47 9. Heat Exchangers and Process Integration ................................................................. 51 9.1 Heat transfer - Fouling ............................................................................................... 51 9.2 Process integration.................................................................................................... 52 10. Process Heaters ...................................................................................................... 57 10.1 Maintenance ............................................................................................................ 57 10.2 Air preheating .......................................................................................................... 58 10.3 New burners ............................................................................................................ 58 11. Distillation ................................................................................................................ 60 12. Hydrogen Management and Recovery .................................................................... 63 12.1 Hydrogen integration ............................................................................................... 63 12.2 Hydrogen recovery .................................................................................................. 63 12.3 Hydrogen production ............................................................................................... 65 13. Motor Systems ........................................................................................................ 66 14. Pump Systems ........................................................................................................ 71 15. Compressors and Compressed Air .......................................................................... 79 iv 16 . Fan systems ............................................................................................................ 86 17. Lighting .................................................................................................................... 89 18. Power Generation.................................................................................................... 92 18.1 Combined heat and power generation (CHP) .......................................................... 92 18.2 Gas expansion turbines ........................................................................................... 94 18.3 Steam expansion turbines ....................................................................................... 95 18.4 Turbine pre-coupling ............................................................................................... 95 18.5 Gasification ............................................................................................................. 97 19. Other Opportunities ................................................................................................. 99 19.1 Process changes and design .................................................................................. 99 19.2 Alternative production flows ................................................................................... 100 19.3 Other opportunities ................................................................................................ 100 19.4 Innovative technologies ........................................................................................
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