16 september 2015© ineosslide 1 energy management at grangemouth university of strathclyde thursday...

April 21, 2023© IneosSlide 1

Energy Management at Grangemouth

University of Strathclyde

Thursday 22nd March 2006

Colin Pritchard

21 April 2023© IneosSlide 2

Agenda

Safety Brief

Background / Introduction

Approaches to Energy Management

Legislation

Industry Benchmarking

Site Tour


Safety Brief

Safety in this Building

• Alarm – Sound / Tested

• Evacuation Routes / Muster Point / Roll-Call

Safety on Site Tour

• Do NOT carry any of the following: matches, lighters, battery operated equipment, mobile phones, cameras, or any other potential source of ignition.

• Site Alarm tested on Monday 11:45.

• Do NOT leave the vehicle, unless told to do so in an emergency.


Background - Refinery

Processes 210,000 barrels per day Crude Oil

Produces 9 million litres of Clean Fuels per day

20 process units

21 process heaters, Total 730 MW

Heaters burn Fuel Oil, Fuel Gas and Natural Gas

Consumption Figures, per month:

• Fuels = c.35,000 tonnes per month

• Electricity = 24,000 MWh

• Steam 640# = 32,000 te 200# = 105,000 tes


Background – Petrochemicals

Around 2 million tonnes of products per year

2 Ethylene Crackers

3 Polymers Units

2 Ethanol Units & 1 GTU / Benzene Unit

Consumption Figures, per month:

• Fuels = c.10,000 tonnes per month

• Electricity = 42,500 MWh

• Steam 1850# = 12,500 tes; 640# = 23,000 tes;500# = 2,000 tes; 200# = 105,000 tes


Background – Power Station

Power Station consumes about 25,000 tonnes of fuel per month: Fuel Oil, Fuel Gas or Natural Gas.

8 Boilers – Total of 1190 MW (thermal) – not all on-line at the same time.

Produce (per month):

• 290,000 tonnes of steam

• 40,000 MWh of Electricity

Also on-site 3rd Party CHP Plant, that supplies the site with:

• 150,000 tonnes of steam

• 40,000 MWh of Electricity

BP (Forties Pipeline System) use 70,000 tes MP Steam / 10 MWh per month, remained used by Ineos


Agenda


Legislation




“Good Operations”

• Heater Operations

• Insulation, Steam Traps…..

Unit Optimisation

• Optimisation of individual heaters / boilers etc

System Optimisation

• Optimisation of Loads / Selection of Fuels

Capital Projects

• Only when commercial


“Good Operations” - Issues & Checks

Equipment Checks:

• Insulation Surveys

• Steam Trap Surveys

• Steam Leak Surveys

Operational Checks:

• Use / status of pre-heat systems

• Excess Air / Oxygen

• Heater Firing

Advanced Control:

• Column reflux rates etc.


Monitoring & Targeting

Key measure = Units of Energy / Unit of Throughput

There are many reasons why this may vary:

• Pre-heat fouling

• Excess Air

• Throughput

• Grade of product

Principle of continuous improvement: Make last year’s average the current year’s worst performance.


Monitoring & Targeting - Example

y = 0.0596x + 19.878

R2 = 0.6236

0.0

50.0

100.0

150.0

200.0

250.0

0.0 500.0 1000.0 1500.0 2000.0 2500.0 3000.0

Steam /tpd

WH

RU

+ A

ux

Fu

el

Ga

s /

tpd


System Optimisation

Several commercially available packages, but with the same principles:

• Capture current performance data

• Run optimiser to derive “Perfect Solution”

• Identify actions to close gap

Caution:

• Need optimised units first

• Only as good as input data!!

• Care do not compromise main production process


Capital Projects

Retrofit costs considerably higher than including in the original design.

Often do not pay for themselves on just Energy costs alone – need to consider all Sources of Value:

• EU ETS Carbon Dioxide Permit trading

• Process improvements / de-bottlenecking – extra capacity can decrease the specific energy consumption GJ/te.


Legislation

EU Emissions Trading Scheme (EU ETS)

• Ineos Grangemouth emits 3 million tonnes of CO2 per annum.

Large Combustion Plant Directive (LCPD)

• Stack Monitoring (Continuous Emissions Monitoring >50MW)

Pollution Prevention & Control (PPC)

• Basic Energy Efficiency Requirements

• Energy as a “Reserved” subject – Cannot be an Improvement Plan condition

Air Quality Directive (AQD)

• Limits on Environmental Levels of eight Pollutants



External consultants offer services:

• Confidential information exchange

• Often require a degree of “normalisation”

• Present results by quartile / ranking

Considerations:

• Data quality / accuracy provided by respondents

• Does not necessarily explain differences



Solomon Energy Intensity Index (EII)

• Provided for a refinery as a whole

• Based on equivalent distillation capacity (EDC)

• Defined as Actual Energy Consumed / Standard Energy (%)

• Standard Energy determined using factors

Considerations:

• Does not show which unit is consuming high energy.

• Greatly influenced by capacity utilisation

• Comparison to other refineries dependent on EDC


Any Questions?


Pre-Heat Operation

Impact on Heater efficiency of poor pre-heat performance.


Stack Losses

10

12

14

16

18

20

22

24

26

28

30

0 20 40 60 80 100

Excess Air %

Flu

e G

as

Lo

ss

(%

th

erm

al i

np

ut)

150 C

200 C

250 C

300 C

350 C


Pre-Heat System

Fired HeaterPre-Heater

P-1 Feed

MainColumn

Bottoms Product


Crude Distillation Pre-Heat Exchangers


Fouled Crude / Atmospheric Residue Exchanger


Clean versus Fouled Heat Exchangers


Fouled Tubes


Heater Checks


Typical Burner Arrangement


Crude Heater


414.2°C

>898.6°C

LI01: 502.1°C

LI02: 502.7°C

LI03: 542.0°C

LI04: 538.5°C

LI05: 537.0°C

Thermography


<484.5°C

873.5°C

LI01: *488.3°CLI02: *510.5°C

LI03: *529.4°C

LI04: *571.9°C

Thermography

16 september 2015© ineosslide 1 energy management at grangemouth university of strathclyde thursday...

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