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A case study of Steam System Evaluation in a Petroleum

Refinery

Abstract:
ASI conducted a steam system evaluation study at a multinational petroleum
Refinery located in the Eastern UK during June - July, 1999. At this refinery,
Steam, Fuel and Electricity systems are inter-connected. Steam is generated
from direct fuel fired boilers as well from Furnace and Kiln waste heat. Steam is
also supplied from the CHP waste heat boilers. Steam generation averages
1,500,000 Ibs/hr and does not change significantly between winter and summer
since steam needs for process and power generation dominates way above
comfort heating.
To generate steam, the refinery spends about £28 million per year ($46 million).
The system evaluation study identified 31 Energy & steam system cost savings
measures (ECM) to save fuel, steam and condensate in the areas of; Steam
generation, Steam distribution, Steam Utilization, Condensate recovery, and
Combustion optimization in kilns.
By implementing all the above 31 ECMs, the refinery is estimated to save $3.5
million annually. Based on our preliminary investment estimate the average
payback would be within 2 years. The refinery also would reduce 5600 metric
tons Carbon emission to environment. Some of the opportunities address the
installation defects of the steam system components that would improve the
system reliability and longevity.

BRIEF OVERVIEW OF THE REFINERY'S STEAM SYSTEM

The Refinery's Steam, Fuel and Electricity systems are inter-connected. Steam
is generated from fuel fired utility boilers as well from Furnace and Kiln waste
heat. Steam is also supplied from the CHP (Combined Heat & Power) plant,
located inside the refinery. Energy is also recovered from high-pressure steam
through the backpressure turbines as electricity or as shaft power to process
drives. Fuel from the refinery is available at an approximate cost of $1.65 per
MMBtu and the CHP supplied electricity at an approximate cost of $0.02 /kWh.
The refinery spends about $46 million annually to generate steam.

Steam generation
Approximately 1.5 million Ibs/hr steam is generated from the fuel-fired boilers
and from waste heat boilers throughout the refinery. The steam flows for winter
and summer conditions do not change significantly.

The refinery generates and uses steam at 5 different pressure levels. A typical
steam system diagram representing the refinery's steam system with the steam
flows at different pressure levels at the refinery is shown in Figure 1.

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Figure 1

STEAM SYSTEM DIAGRAM OF TYPICAL REFINERY

(all numbers in 1000 #/hr steam)

1--...,...~-=r-1ir""""'"""'T--lI:...-;---..,......L...----r-...L"""~-,,,,""",,::,~..l13~50
600 psig steam
2 Losses

....z:.,.-n""r--;---L.~-..,.i-~l"'T"""_......:t.-~197 375 pslg steam

36
~-_i'T_+~1;;;.0~:...-+....:.....;t....I-F~~:...L._~-r-""';"'';'''-;-''ll''''I''::~3~67 150 psig sleam
osses

_...L-_7-;--;-..z.....,....--+--:L.-_--lI~..,.....-;..r___+.:;;...-~--.....:3:.:.6 75 psig sleam

20
25
48 0

~........
12;;:..4 ..........""-_.......L.......~--:"......z.=t.,~---=-....t----u..l

~8 Condensate

To Boilers .. 1608

Steam distribution and usage

Steam is distributed at the above-mentioned pressures through main headers
through the plant and used for power generation and process heating, and as a
motive force in more than 110 steam driven turbines. Most of them are
backpressure turbines, which supply the exhaust steam to the lower pressure
levels headers. If the steam demand requires, the steam pressure is also
reduced through Letdown Stations (PRV and Desuperheaters).

Condensate return
The Condensate from the different pressure levels is collected into cascading
Flash tanks. The flash steam from each flash tank is routed to the header of
next lower level of steam pressure and the condensate is routed to the next
lower pressure Flash tank. The process of discharging condensate to cascade
Flash tanks assures the full usage of the heat content of the condensate. The
average make-up demineralized water flow is between 620 gpm and 720 gpm.
The output through the DA to all steam generators in the plant at normal
operating conditions averages 3400 gpm. The pressure at the DA is maintained

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at 40 psig. Condensate return flows and available temperatures are shown in

the steam system diagram Figure 1.

Potential areas of System Optimization

ASI team identified 31 optimization projects in the areas of; Steam generation &
waste heat recovery, Steam distribution, Steam Utilization & Condensate
recovery. The areas where ASI team identified optimization projects are shown
in Figure 2. All the optimization projects are specific to equipment or system
component and based on engineering concepts that are proven elsewhere with
successful results. Two of the opportunities are expected to improve the Waste
heat boiler reliability, process efficiency and productivity with substantial impact
on cost.

Figure 2.
STEAM SYSTEM OPTIMISATION PROJECTS AT THE REFINERY
(Areas of optimization projects are circled in green dots)

.,---I.....L,,;T-1UI2~;;;!~r-..,..~_;;:;:;::r~L.-,---:13-2i'~1;"'35~0600 psig sleam

2 Losses

-~--;-;---;---L..,...._:--...L- __~---r_.....;.;--+::.:..::..._...:.- 36:::. 75 psig steam

20
25

Six of the 31 identified savings projects are highlighted in the following sections
of this paper.

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Steam System Savings Projects

1. Preheat the secondary air in Calciner Kilns #1 & #2

Volatile matter in the 'green coke' is removed by the Calcining process at a
temperature of approximately 2500 0 F in the Kilns. The product then needs to be
cooled rapidly to approximately 215°F. This cooling is currently achieved by
water quenching to below the oxidation temperature of the product, prior to the
'final cooling by contact with ambient air.

Approximately 35 million Btu/hr of heat energy is removed from the coke during
this rapid cooling process. At present this energy is rejected to the atmosphere.
In newer refineries various techniques of dry quenching of the coke are used as
alternatives to water quenching. A technology already used in cement kilns is to
use the cooler exhaust air as the combustion air. For a coke-calcining kiln, the
cooler exhaust air cannot be directly used as combustion air due to its moisture
content, but could be used to pre-heat the combustion air.

The project proposes to install an air pre-heater to utilize the hot exhaust gases
to pre-heat the combustion air (secondary air) for the Kiln. The temperature of
the exhaust gases will be reduced from 477°F to approximately 250°F and will
pre-heat the combustion air by approximately 120°F. The concept of the
proposal is shown in Figure 3 below;
Figure 3

Preheat the secondary air in Calciner Kilns #1 & #2

Secondary Air
Cooler gas
to Stack

477°F

Cooler gas
Cyclone

Product ­
r.<lldnpn r.nl<p

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Preheating the combustion air using cooler exhaust air would result in an annual
savings of $92,000. A preliminary investment estimate to install an air pre­
heater for the combustion air indicates a straight pay back period of less than
2.2 years.

2. Optimize heat recovery from FCC Waste Heat Boiler

In the FCC area, waste Heat Boiler X3412 generates superheated steam that
recover heat from the flue gases at 1025°F, coming from the Turbo Expander.
At present the economizer for the WHB is installed prior to the Electro Static
Precipitator (ESP). However the temperature of the flue gases entering the ESP
is limited to a minimum of 530°F hence imposing restrictions on the heat
recovery from the flue gases. This results in a large amount of recoverable heat
being released to atmosphere. Figure 4, shows the existing arrangement.

Figure 4
Existing arrangement at FCC Waste Heat Boiler

High Pressure Super

Heated Steam @ 600

Electro
Static
Precipitatol----~
Flue-gas after '---';';';;;""'...-.!-Flue-gas Flue-gas
Turbo-expander @ 5300F to Stack
@. 1022°F

This proposal relocates the existing economizer after the Electro Static
Precipitator with additional heat recovery surface. The additional heat recovery
surface would reduce the Waste Heat Boiler exhaust temperature by 210°F,
without violating the ESP temperature limitations. Figure 5, shows the proposed
arrangement.

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Figure 5

Proposed arrangement at FCC Waste Heat Boiler

High Pressure Super

Heated Steam @ 600 psig

BFW@
?AQ°i=

Flue Gas
to
Higher Temperatures Stack
@330°F
Before the ESP

Electro
Static
PreciDitato

The resulting annual savings would be $210,000. A preliminary investment

estimate to remove the economizer from its existing position and install a new
large economizer in the new position indicates a straight pay back period of less
than 2.0 years.

3. Heat recovery from # 1 Vacuum Distillation Unit (VDU) Heater

VDU #1 is the first vacuum unit built among three vacuum distillation units in the
refinery. Originally VDU#1 furnace was designed to operate with natural
draught and had no heat recovery system from the hot furnace exhaust gases.
VDU #2 and VDU #3 furnaces were built later with FD and 10 fans and air pre­
heaters recovering heat from the furnace exhaust gases. The exhaust gas from
VDU #2 has a separate stack, and VDU #1 and VDU #3 are routed to a
common stack. Later, VDU #1 furnace also has been equipped with an 10 fan
to overcome the back-pressure in the flue gas path assuring higher reliability of
the unit. However the stack temperature of VDU #1 furnace is 830°F, while the
stack temperatures of VDU #2 & #3 are in the range of 360 - 390°F. The
existing furnace stack gas routings are shown in Figure 6.

To improve the efficiency of VDU #1 furnace also matching similar to VDU #2 &
#3 furnaces, an Air to Air Pre-heater to heat the combustion air using the waste
heat in the exhaust gases of the same furnace. The proposed pre-heater will
reduce the temperature of the exhaust flue gases by approximately 470°F. An
additional FD fan will be required and the burner will be changed from natural
draught to forced draft type. The conceptual scheme of the proposed
modifications is shown in Figure 7.

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Figure 6

EXisting furnace stack gas routings

ill Fan
Flue Gas
767'F 357'F 357'F

632'F 144'F
VDU#3 Hll02

Combustion Air

Fuel

Common
FDFan
754'F 389'F Stack

570'F
VDU#2 H4102 ID Fan
Combustion Air
Fuel 60'F
FD Fan Flue Gas

83I'F

60'F
VDU#] H4101 C<:>mbustion Air
14860 sefm ID Fan
Fuel 1741 sefm

Figure 7

Proposed furnace stack gas routings

Flue Gas
767'F 357'F
357'F

632'F 144'F
VDU#3 HII02
JD Fao
Combustion Air
FliP I Common
FD Fan Slack
754'F 389'F

570'F
VDU#2 H4102 JD Fan
Combustion Air
Fuel 60°F
FD Fan
Flue Gas
831"F 360'F

VDU#I JD Fan

Combustion Air

The proposed modification would benefit the refinery $109,000 annually. A

preliminary investment estimate indicates a straight pay back period of less than
2.2 years.

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4. Heat recovery from # 1 Reformer Heater

The waste heat boiler in the Reformer #1 furnace generates high-pressure
superheated steam from the heat in its exhaust gas. The existing economizer
reduces the exhaust gas temperature from 12000 F to 483°F prior to release to
the stack. The existing arrangement is shown in Figure 8.

A considerable amount of heat energy is still wasted since the flue gases are
leaving at 483°F. It is beneficial to recover as much of this waste heat as
possible, since the refinery fuel gas has very low sulfur content. Pre-heating
returning condensate or generation of low-pressure steam are considerations in
this situation.

Since the most economical solution being the generation of LP steam, it is

proposed to install an additional economizer, downstream of the existing one to
reduce the temperature of the exhaust gases leaving the stack to 300°F. The
recovered heat energy would produce low-pressure steam. The proposed
arrangement is shown in different color on Figure 8.

The proposed heat recovery from reformer furnace would save the refinery
$140,000 annually. A preliminary investment estimate indicates a straight pay
back period of less than 2.0 years.

Figure 8
Heat recovery from # 1 Reformer Heater

To SOpsi Main

Flue gas to atm.

@300'F

Vacuum
Condensate 6,000 Ibtlu'@125"1' Flue gas @ 483"F
75,300 Ib./hr @ 297'F

BFW ----t~~=~___;:=== =t::~5~=:

494'F
Waste

Heat

Steam@604
Boiler

psig
Sarurated

HP SH @ 604 psig
69,300 Ib/hr @ 740'F
Flue Gas to
stack @ 1200'F

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5. Preheat the green coke using the waste heat of hot kiln exhaust gases
Volatile matter in the 'green coke' is removed by the Calcining process at a
temperature of approximately 2500°F in the Kilns. Due to this high temperature
processing, hot gases with volatile hydrocarbons released from coke need to be
removed continuously from the kiln at a high temperature. The volatile
hydrocarbons are oxidized completely in an incinerator and cooled down
through a waste heat boiler before it is released to atmosphere. Currently,
production of calcined coke from the rotary Kilns are limited due to the high
temperatures of the exhaust gases that could be handled by the Incinerator and
Waste Heat Boiler. The existing arrangement is shown in Figure 9.

Figure 9

Existing arrangement of Kiln. Incinerator and Waste Heat Boiler

....._ _ Green Coke Bin

Rotary IGln

INCINERATOR

ASI proposes a specially designed cyclone to preheat the green coke using the
hot kiln exhaust gases that would reduce significantly the operating temperature
in the Incinerator and Waste Heat Boiler, thus improving the overall throughput
of the kiln. The proposed feed coke preheating arrangement is shown in Figure
10.

By utilizing part of the heat energy in the kiln exhaust gases to preheat the
green coke feed the overall throughput of the kiln can be increased while
maintaining the existing operating temperature that limits the kiln throughput.
Depending upon the gross margin for the various grades of coke produced, the
increased kiln throughput would save the refinery between $675,000 and
$1,850,000 annually. No details have been worked out on the investment
estimate, but it is expected to be very attractive.

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Figure 10

Proposed arrangement of Kiln green coke feed

4--- Green Coke Bin

Cyclone Pre-he"ter

Rotarv Kiln

W.H.B. INCINERATOR

6. Preheat the combustion air using the cooler exhaust gases

The calciner kiln #3 is designed slightly different compared to Kilns #1 & #2. Air
from the kiln cooler exhaust after passing through a cyclone separator and fan is
routed to the kiln incinerator at 448°F. This is similar to the 'tertiary combustion
air' terminology used in dry process pre-calciner cement kilns. The intention is
to save fuel at the incinerator due to preheated combustion air. The existing
arrangement is shown in Figure 11.

Due to elevated combustion air temperature, the flame temperature at the

incinerator is high and therefore limits the throughput of the kiln. By reducing
the temperature in the incinerator the kiln calcining process throughput can be
increased until the incinerator reaches its limiting temperature again.

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Figure 11
Existing arrangement of calciner kiln #3

Green

Steam
Coke
Feed
o
Addi'ional
448°F Secondary
BFW Air

Kiln

Waste Incinerator
Heal
Boiler

Secondary
Air

The heat from the cooler exhaust gases still could be used to preheat the
secondary combustion air supplied to the kiln burner. Hot air from the kiln
cooler would pass through a newly installed air preheater to heat the ambient
combustion air to the kiln. A new combustion air fan would be installed to feed
ambient air to the incinerator. The proposed arrangement is shown in Figure
12.

Figure 12
Proposed arrangement of calciner kiln #3

Green
Coke
Feed

Steam New Fan

Addi'ional
Secondary Air
BFW

Waste Incinerator
Hea'
Boiler

Secondary Air

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Due to the proposed modifications, the overall throughput of the kiln would be
increased and fuel to kiln also would be reduced due to preheating of the
combustion air, utilizing the waste heat rejected to atmosphere. Implementing
t~lis changes in kiln #3 would save the refinery $866,000 annually. No details
have been worked out on the investment estimate, but it is expected to be very
attractive.

Summarized list of Energy & Steam cost saving measures:

# Brief Project Title Estimate Savings

($Near)
1 Kiln #1 & #2 Secondary Air Pre-heat 92,000
2 FCC WHB Economizer Optimization 210,000
3
Utility Boiler Economizer Optimization 173,000
4 Utility Boiler Blowdown Optimization 96,000
5 Utility Boiler #703 Fuel/Air Ratio Optimization 23,000

6
Heat Recovery from VDU #1 109,000

7 Heat Recovery from Reformer #1 141,000

8
Heat Recovery from Reformer #2 142,000
11 Condensate Recovery Through 0803 14,000
14 DA Vent Condenser 8,000
15 TA Lube Oil Exhaust Vent Condenser 19,000
25 Trap Replacement Program 209,000
29 Steam Leak Optimization 18,000
30 Utilization from X3415 - Proposal 2 22,000
31 Kiln #1 & #2 Feed Pre-heater retrofits 1,850,000
32 Kiln #3 Combustion Air Pre-heat 866,000

Total Estimated Savings 3,495,000

Reduction in annual energy cost when all proposals implemented 7.8 %

Reduction in environmental emission of Total Carbon 6160 tons/yr.

The above saving and simple payback estimates are developed according to standard
engineering practices and based on ASI's extensive experience in steam and utility
systems.
Based on Refinery's management's interest, more technical details and accurate
savings & investment estimates will be provided during the Development phase that
includes Basic Engineering Design & Detailed Engineering Design.

© Armstrong Service Inc.

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Sio-Data of Presenters:

Name: Ven V. Venkatesan,

Title: Director of Engineering Services

Company: Armstrong Service, Inc.,

8545 Commodity Circle, Orlando, FL 32819

Brief Resume:
Mr. Venkatesan has over 25 years of experience in the energy management
field. Mr. Venkatesan has both a M.Tech. degree in Chemical Engineering, with
specialization in Process Design, and a B.S. degree in Industrial Engineering.
Mr. Venkatesan obtained world-class knowledge from organizations like
DuPont, SHELL, and Armstrong International. Mr. Venkatesan utilized his skills
by managing an array of projects that reduced total energy cost by $20 million.
Mr. Venkatesan also was involved in 30 process industries in India, Europe, the
Caribbean, China, Malaysia and the United States. Mr. Venkatesan is a Certified
Energy Manager and a licensed Professional Engineer for the state of Florida.

Name: Nevena lordanova,

Title: Senior Energy Systems Engineer

Company: Armstrong Service, Inc.,

8545 Commodity Circle, Orlando, FL 32819

Brief Resume:

Mrs. lordanova has over 17 years of experience in design and optimization of

Steam and HVAC Systems, audit studies, and identification of opportunities in
energy systems and cost related optimizations, including the technical
evaluation and further project implementation of various energy savings
proposals. Mrs. lordanova conducted steam system studies in a broad
spectrum of industries (pulp and paper, chemical, petrochemical, food and other
process industries) in Eastern and Western Europe, the Caribbean, and the
USA.
Mrs. lordanova has a BS degree in Mechanical Engineering and is a Certified
Energy Manager (CEM) in the USA.

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