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Energy Efficiency A P rocess L icencor 's V iew

Energy Efficiency A P rocess L icencor 's V iew. XXVI Russian National Inter-Industry Meeting September 12 th - 14 th , 2012. Agenda. Energy and CO 2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion. Agenda.

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Energy Efficiency A P rocess L icencor 's V iew

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  1. Energy EfficiencyAProcess Licencor 's View XXVI Russian National Inter-Industry Meeting September 12th - 14th, 2012

  2. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  3. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  4. Energy and GHG Challenge in Refining Energy sector represents 66.5% of the total Greenhouse Gas (GHG) emissions: GHG from Oil & Gas (O&G) industry: about 6% of the total GHG Chemicals & petrochemicals: about 4% of the total GHG • Energy costs represents on average more than 50% of total operating cost • Product specification developments and dieselization lead to an increase in energy consumption

  5. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  6. Axens as a Key Partner Cumulative Number of Licenses 2205 licenses as of 31st December 2011 Eastern Europe + CIS 8% • Axens as a licensor:Extensive know-how and experience on whole refining & petrochemical scheme. • Axens as catalyst & special equipment provider: •  Innovative solutions for OPEX reduction in existing assets Asia35% Western Europe 19% Middle East 14% Latin America8% Africa4% North America 12% Axens has set up a structured knowledge management process to capitalize on each project

  7. Methodology for Energy Audit Energy Efficiency & GHG Mitigation • Step 1: Dispatching questionnaire to site Preparation of KOM • Step 2: KOM & Energy Survey on site • Step 3: Reconciled baseline for energy balance • Step 4: Identify energy conservation opportunities Meeting with customer for projects selection • Step 5: Development of the selected projects

  8. Energy Efficiency & GHG Mitigation • Establish Referential • On-site Data collection: • - Utilities network- Process units performance- Large thermal & power equipment performance- Flare system- Emissions assessment- Maintenance & Operational good practices • Baseline setting: • KPIs, EIITM, CO2- Energy consumption / cost • Cost Estimate & Financial Analysis • Detailed study of selected projects (CAPEX, IRR, NPV) • Estimation of related saving (including Solomon EIITM • Propose Options • Screen projects options that could improve energy efficiency: • - Non-CAPEX options- Low CAPEX options- High CAPEX options • Evaluation compliance to CDM criteria • Customer selection of projects to be further developed over 80 options screened Case ranking Validation of project options to be developed during the next phase

  9. Axens / SESCombined expertise for refiners Axens & Solvay Energy Services combine their expertise to provide an integrated services to the refining industry ENERGY CONSUMPTION REDUCTION SOURCING IMPROVEMENT CO2 & Energy • Energy equipements expertise • Heat integration • Processes optimization • Refining scheme integration • Emissions capture • Peak shaving • Work organization • Energy performance management • Spot market access • Shipping/Transmission • Balancing • Renewables sourcing • CO2 Allowances ASSET OPTIMISATION • Combined Heat and Power • Load curve management • Supply / Demand Response • Renewables

  10. Use Solomon benchmark 2nd Quartile 1st Quartile • But go beyond a first level analysis • Process expertise is required to assess energy performance and identify improvements in any refinery process unit

  11. Example of High Severity CCR Reforming • Includes: • catalyst regeneration • recycle compressor • Stabilization section • H2 export compressor Aromatics yields: Heat of reaction governed by thermodynamics 80% of CCR reforming net energy consumption is directly linked to production objectives

  12. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  13. High efficiency Heat Exchangers

  14. High Efficiency Furnaces Optimising heat recovery Efficiencies above 92%? Consultation with equipment manufacturers

  15. PINCH TECHNOLOGY First: Adjust process parameters to improve heat integration. Then: Use PINCH technology to intensify process /process heat exchanges and minimizewasted heat (air coolers, trim coolers) Last: Use Licensor’s experience to define schemes that provide operability and flexibility Optimum Heat Exchanger Networks

  16. Dividing Wall Columns lower energy requirement for reboiler of the combined columnExample: Benzene-Toluene distillation column Plate heat exchangers reduce T° approach and increase heat recovery  replace several heat exchangers in seriesExample: Feed/bottom of a distillation column Non-conventional equipment

  17. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  18. Aromatics Complex Scheme Overview FG + LPG Raffinate Benzene B T B C Extractive Distillation Tol C7- Transalkylation C8+ Reforming (CCR) Hydrotreated Naphtha RS Paraxylene C8A Xylenes Isom. Eluxyl C8+ C9+C10 XC Conversion units C9+ Separation units HA Fractionation columns Heavies

  19. Aromatics Complex Scheme Overview FG + LPG Raffinate Benzene B T B C Extractive Distillation Tol C7- Transalkylation C8+ Reforming (CCR) Hydrotreated Naphtha RS Paraxylene C8A Xylenes Isom. Eluxyl C8+ X C C9+C10 C9+ HA Heavies

  20. Energy efficiency studyfor Aromatic complex project Detailed study to review potential energy efficiency improvements: Project specific (based on client requirements) Technical and economical optimisation (CAPEX & OPEX) Example of modification to Aromatics Complex design: Maximize heat conservation Minimize air coolers Produce steam and electricity when possible

  21. Steam generation studyBasis of design Several levels of steam considered from LLP to MP steam Reviewed opportunities for: For steam recompression from LLP to LP and LP to MP Pre-heating BFW Pre-heating furnace air

  22. Steam generation studyBasis of design Example of scheme modifications envisaged: Increase or lower operating pressures of columns  For heat integration with other process streams Installation of additional process exchanger on reaction sections (higher heat recovery on reactor effluent streams) Increase heat efficiency of fired heater

  23. Example of Process Heat Integration HP purge Feed 1 Feed 2 Reactor LP purge to Process stab. Comp. Recycle compressor Feed heater Effluent air cooler Distillate to stab. Cold separator Feed / Effluent exch. HPst Product 1

  24. Example of Process Heat Integration LP purge HP purge Feed 1 Feed 2 Reactor Recycle compressor Off gas from TP stab Feed heater Effluent air cooler Distillate to stab. Cold separator Feed / Effluent exch. HPst Product 1

  25. Energy efficiency versus CAPEX Gains in performances, an additional: ~ 20% Higher CAPEX: Adjusting columns operating pressure: Higher pressure to improve heat integration Lower pressure to reduce reboiler duty (offgas compressor) More equipment: large heat exchangers and steam generators Risk mitigation of water leakages (Special HX design, equipment test & inspection, S/D S/U procedures)

  26. Interfaces & Off-sites • Unit interfaces may be areas of heat losses • Storage lay-out, especially on semi-finished products, must be reviewed with the energy perspective

  27. Agenda Energy and CO2 Challenge Axens as a key partner Equipment optimisation Examples of process design optimisation Conclusion

  28. Conclusion Energy efficiency practices presented earlier can be applied to new process unit design as well as existing units However, expected gains for existing assets will be more limited than for new built. Energy efficiency improvements have to be economically viable and sustainable Axens is actively working on energy efficiency improvements: Technologies & products (process integration, equipments) Consulting services (offer can be combined with Solvay Energy Services)

  29. Energy EfficiencyAProcess Licencor 's View Thank you

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