OPTIMIZING ENERGY USE IN A PETROCHEMICAL PLANT: A CASE STUDY

摘要

Optimization of Steam & Energy systems in any continuous operating process plant results in substantial reduction in purchased energy use. During periods of high price of purchased energy, this would benefit the plant in controlling their fuel budget significantly. Though optimization techniques for energy use in an operating plant is well defined, implementing them into day to day practice needs focused efforts by some champions within the operating team. Many times it is the persistent effort by a motivated team rather than large amounts of money spent on big engineering modifications. If planned well, the energy cost savings efforts could be self-funded, without any large capital approvals. This paper highlights the practical efforts taken by the management of an Petrochemical plant located in the state of Louisiana. This site has five sections of process plants within the complex. The site has storage facilities that require constant energy use for heating, mixing & pumping. In addition to purchased natural gas, the site also purchases refinery fuel gas & steam to meet its energy & utility demand. The optimization program began with a formal energy study between Feb – Mar 2006, and identified 20-project recommendations to reduce the energy cost by over $3 million annually and to improve the system's reliability. The initial estimates indicated that all recommended projects have a simple payback period of less than 2.5 years. The plant management decided to pursue 12 of the 20-recommendations and completed most of the immediate action items already. Most of the remaining project recommendations also would be pursued in the coming year according to the plant management. Due to the already completed projects, Condensate recovery has improved from 30% to about 50%. This case study is a good example & motivation for all the engineers and managers who are responsible for maintaining the efficiency & reliability of the steam systems in their plants.