Oil and Gas World Expo 2016

Refining and Petrochemicals 2016

Engineering Solutions

Energy Optimization of Refineries and

Petrochemical Plants
Arjun Gujar, Director of Engg.
HYDRON Engineering Solutions
Agenda

 Statistics of Energy Consumption

 How do we do it

 Introduction to Pipeline Network Analysis & Optimization(PNAO)

 Benefits to Productivity

 What is the take away from this session

 Today’s Scenario – India

Traction
2%
Commercial Other
9% 5%

Industial
44%
Domestic
22%

Agriculture
18%

Reference:
CENTRAL STATISTICS OFFICE
Total Consumption
NATIONAL STATISTICAL ORGANISATION
MINISTRY OF STATISTICS AND PROGRAMME IMPLEMENTATION
Year 2013-14: 882,592GWh
GOVERNMENT OF INDIA
www.mospi.gov.in
 Industrial Pumps Consume

15% of Total Industrial Consumption,

But which is :

Rs. 45,000 Cr. Each year

This is a huge opportunity!!

Reference:
United Nations Industrial Development Organization
https://www.unido.org/fileadmin/user_media/Services/Research_and_Statistics/WP112011_Ebook.pdf
How Much can be Saved

The Saving Opportunity is 5% to 30% of their consumption

Rs. 2,250 – 13,500 Cr. Each year

**Future Savings are Current Losses

Indian Refineries – Cooling water System

Circulation Rate 6,00,000 m3/hr

Electricity Consumption Rs. 700 Cr./yr ($116 Mn)

5% Improvement in Efficiency Rs. 35 Cr. ($ 5.8 Mn)

Cooling Water Opportunity Rs. 35 – 210 Cr/yr

For 10 years, Rs. 350 – 2,100 Cr.

(For 10 MMTPA Refinery, CW Opportunity Rs. 1.5 Cr to 9 Cr/yr)
Refinery–wide Savings
Through PNAO In 10 years,
We can save Rs. 1,000 – 6,000 Cr.
of Natural Resources
Example: Parallel Pumps

Typical Refinery - Cooling Water Network

Flow-Pressure-Energy Consumption
for Pumps In Parallel

Description No. of Pumps Running in Parallel

2 Pumps 3 Pumps 4 Pumps

5,840 (+6.3% 6,000 (+2.7%

Total Flow, m3/hr 5,490
increase) increase)

Pressure, kg/cm2(g) 4.1 4.5 4.8

Pump Efficiency, % 85% 79% 70%

913 (+28% 1,090 (+19%
Power Consumption, KW 710
increase) increase)
System Curve and Pump Performance Curve
on Reduction In Pressure drops

Existing System

10% Reduced Pressure Losses

20% Reduced Pressure Losses

20% Reduction In Pressure drops
Scenario III:
Scenario I: Scenario II:
Two Pumps with
Two Pump Three Pump 7% larger impeller
New Flow Rate, m3/hr 6,000 6,450 (+7.5%) 6,450

Earlier System Consumption, Rs. 7.6 Cr. for 6000 m3/hr

730 KW 930 KW 870 KW

Consumption on 20% reduction in
Pressure losses Rs. 6.5 Cr.
Rs. 5.1 Cr. Rs. 6.1 Cr.
(+27%)
Rs. 2.5 Cr. Rs. 1.1 Cr. Rs. 1.5 Cr.
Energy Savings
33% 14% 20%
Pump Efficiency 85% 79% 85%
Scenario I: We achieved savings of Rs. 2.5 Cr. by reducing pressure losses and bringing
Pumps to Run at Best Efficiency Point
Scenario II: He were are creating an example for further explaining optimization. See
below
Scenario II & III: The difference between II and III is that we have turned off One Pump by
increasing impeller size of two pumps. Pumps also Run at Maximum
Efficiency. This simple activity helped to achieve 6% energy savings.
Pipeline Network Analysis & Optimization

 Energy Saving Opportunities

 Validation of Revamp Projects
 Identifying Low-cost Solutions for
System Bottlenecks

Difference Between Modeling and Analysis

Unbalanced Flow Issue at Exchangers in Typical
Cooling Water Systems can be solved by Pipeline
Network Analysis
Heat Exch. Actual Flow Design Flow % Design Flow
gpm gpm
Unit 17
HE-17E-1 5,654 6,050 93%
HE-17E-2 5,639 6,050 93%
HE-17E-3 1,044 1,043 100%
HE-17E-4 1,152 757 152%
HE-17E-6 A 1,400 757 185%
HE-17E-6 B 1,084 757 143%
HE-17E-7 262 466 56%
Unit 18
HE-18E-1 A 364 743 49%
HE-18E-2 A 743 971 76%
HE-18E-3 304 352 86%
HE-18E-4 483 352 137%
HE-18E-5 56 72 78%
HE-18E-8 102 119 86%
HE-18E-11 694 836 83%
HE-18E-14 328 264 124%
HE-18E-16 749 660 114%
HE-18E-17 278 593 47%
HE-18E-22 218 154 141%
HE-18E-29 1,872 3,935 48%
Losses In THROUGHPUT

FOULING LOSSES

 A 100,000 bbl/day (5.1 MMTPA) Refinery losses more than Rs. 500 Cr. due to
Fouling(c)

 Cooling Water contributes to 35% of the Fouling Losses(b)

Energy
35%

Throughput
64%

Source :
a. Paper published by Arjun Gujar at AICHE Process Technology Conference (Year 2009).
Title of the paper : IMPROVED REFINERY ENERGY EFFICIENCY WITH A COOLING WATER FLUID FLOW STUDY
b. Bott, T.R. Heat Exchanger Fouling and Its Mitigation. [book auth.] E.A. Foumeny and P.J. Heggs. Heat Exchange Engineering Volume 2
Compact Heat Exchangers: Techniques of Size Reduction. Chichester : Ellis Horwood Limited, 1991.
c. Crittenden, B.D. Chemical Reaction Fouling of Heat Exchangers. [book auth.] L.F. Melo, T.R. Bott and C.A. Bernardo. Fouling Science
and Technology. Dordrecht : Kluwer Academic Publishers, 1988.
Performance Of Several Pumps
Running In Plant is Degraded and not
measured regularly
 HYDRON Engineering Solutions Pvt. Ltd.

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Contact:
THANK
Direct : +91-9823156611
O: +91-253-2504091
E: arjun.gujar@hydroneng.com
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