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Creation of energy efficiency action plan for oil refinery with advanced energy analysis (ERTC)

The INA Group plays a major part in the exploration, refining and distribution of oil, gas and oil derivatives in Croatia, and has a number of affiliates fully or partially owned by INA d.d. INA has upstream projects in Angola and Egypt, refineries in Rijeka and Sisak, and its retail network consists of 438 petrol stations in Croatia and other regions.

Igor Šepić, INA
Kari Kunnari, Neste Jacobs Oy
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Article Summary
INA d.d. introduced its Energy Management System (EnMS) in 2015. It has since been through recertification and continuous improvement audits, and is now developing a sustainable energy platform. Based on the ISO 50001:2014 standard, the EnMS team has created a platform to raise energy performance to the next level by applying the plan–do–check–act cycle. A certified EnMS confirms that the company is committed, and working continuously and strategically to:
1. Decrease energy consumption
2. Optimise the use of energy sources
3. Introduce best available techniques in the field of energy.

The energy efficiency programme for the Rijeka refinery was based on these three objectives.

The joint Neste Jacobs and INA EnMS team carried out a study of energy efficiency improvements in 2016. The objective was to identify feasible, practical and proven energy performance improvement opportunities. The study was refinery wide, and included process units, power plant and logistics, as well as current EnMS practices and development plans. The energy performance of the refinery was benchmarked lower than average, partly because the refinery was not running at full capacity.

The energy analysis was executed using the following phases:
1. Baseline phase – site review and creation of comprehensive and presentative energy baseline.
2. Analysis phase – identification and creation of improvement opportunities.
3. Action plan – prioritisation and creation of implementation plan for improvements.

The baseline phase started with the request and review of input data. Based on these data, preliminary benchmarking was carried out by calculating energy performance indicators (EnPI) for processes and main equipment.

One of the main events of the project was the site reviews of the refinery, which included kick-off meetings, mechanical field reviews, interviews with operating staff and input data verification. Based on these site reviews, as well as DCS and laboratory data, process simulation models were created from all major energy consumers. A utility simulation model was created from energy systems and production, including comprehensive steam balance. Detailed heat and material balances from more than 95% of energy consumption were also created. To achieve a common understanding between Neste Jacobs and INA, and provide a firm basis for analysis, all relevant data were issued as a 
baseline report for commenting and verification by INA’s experts.

During the analysis phase, energy performance of the baseline was analysed 
to identify the potential for improvement. The main tools used for this were pinch analysis, best technology and practices benchmarking, as well as energy optimisation workshops.

Pinch methodology was used to evaluate the current level of heat integration and provide targets for improvement. Composite curves were created to define targets for minimum potential consumption and also to determine key areas where improvements could be achieved. Utility grand composite curves were used to define optimal energys source and utility temperature levels. This expanded to site level with the utility simulation model. All sources of excess heat were also listed systematically.

Best technology benchmarking was used to identify the performance gaps between current performance and best technology performance defined by Neste Jacobs. This was applied to process energy intensity, heat integration performance, fired heater and boiler performance, as well as pump and compressor performance. In the field of energy management, the current situation was assessed against best practices in areas of organisation, energy monitoring and energy planning.

Workshops that employed a HAZOP-style process for systematic energy optimisation of the industrial process screened every part of the process based on Neste Jacobs’ procedures to identify improvement opportunities. Energy baseline, pinch analysis and 
best technology benchmarking results formed the basis of the workshop. The result was a list of improvement opportunities that were believed to be practical, proven and feasible. Together, INA’s and Neste Jacobs’ experts decided on opportunities to be evaluated further via detailed cost-benefit analysis.

At the action plan phase, cash flows and a preliminary implementation plan were created for the most feasible improvement opportunities. This included project packages for quick wins (operations and maintenance), small and major investments, as well as preliminary responsibilities and implementation schedules.

After the establishment of INA’s EnMS, trends showed a decrease in energy costs, an optimisation in energy use, and the introduction of best technology in investment projects categorised as relevant to energy.

With the energy management practices and the investment portfolio proposed in the action plan, major energy savings could be achieved on a site scale, with a significant effect on operating costs, refining margin and the overall profitability of the Rijeka refinery. ν

Did you know: NAPCON can help you boost your energy efficiency while simultaneously reducing waste?

This short article originally appeared in the 2017 ERTC Newspaper, produced by PTQ / DigitalRefining.

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