Top Ten Ways to Increase Site Energy Efficiency
By Albert Galgut
Assuming operational efficiency improvements have been realized to a large
extent, further increases in site energy efficiency are accomplished via
implementation of modest, incremental capital investment opportunities. An
energy loss analysis is conducted to quantify energy lost to air / water
cooling followed by Process Flow Diagram brainstorming reviews to identify
potential capital projects that will reduce fired heater and boiler fuel
consumption. Top 10 opportunities include:
- Install additional heat exchangers in various feed preheat circuit
configurations (e.g., crude, hydrotreater, reformer, light ends, amine
rich / lean preheat circuits).
- Replace existing bare tube heat exchanger bundles with finned
tubes to allow utilizing lower pressure steam in reboilers /
- Replace existing bare tube heat exchanger bundles with twisted
tube bundles to take advantage of higher surface area available in
- Recover energy in various steam utility system streams (e.g.,
steam vents / letdowns, boiler blowdown, condensate, etc.).
- Maximize deaerator feed temperature to reduce deaerator steam
- Maximize boiler feedwater temperature to reduce boiler firing.
- Install waste heat boiler to generate steam and reduce boiler
- Reduce / replace steam utilized in reboilers / feed preheaters
with waste heat.
- Install mid-reboilers in light ends towers to utilize lower level
/ waste heat.
- Install additional surface in fired heater convection sections to
reduce stack temperature / furnace firing.