IETC 2010 Energy Findings in a Mature Manufacturing Process

2010 ACC Energy Efficiency Award Exceptional Merit Cyclohexanone 1 Steam Optimization, Freeport Texas

3 Energy Survey Concept 80% of the savings come from 20% of the recommendations: “What are the critical few recommendations?” 20% of the plant consumes 80% of the energy: “Where are the big consumers?” Only 20% of all plant energy data is needed to make 80% of the recommendations: “What data are relevant to make decisions?”

4 Cyclohexanone 1 Steam Optimization The challenge: How to optimize steam usage in a mature plant (greater than 25 years) for a commodity product with increased energy costs? The answer: The activities included a pinch analysis as well as a design of experiments (DoE).

5 Cyclohexanone 1 Steam Optimization Pinch Analysis / Heat Integration Two existing cross exchangers were relocated to improve the cooling of the oxidation reactor overheads stream. New, high flow pumps on the cyclohexane recovery tower were installed to provide cooling on the shell side of the relocated exchangers. Large bore piping was installed to improve the heat recovery of the cyclohexane recovery tower bottoms/overheads cross exchangers.

6 Cyclohexanone 1 Steam Optimization Design of Experiments (DoE) The study was conducted to re-optimize process conditions (e.g. process flow rates, temperature set points, etc.) to further reduce steam usage. It is important to note that the DoE was not included in the justification of the pinch analysis project. Also, no capital expenditure was required to achieve this additional steam reduction.

7 Cyclohexanone 1 Steam Optimization Results 2009 vs Annualized % Energy Savings – 13.8% Annualized Energy Saved in 2009 – 303,850 x 10 6 BTU Annualized Net CO 2 Emissions Reduction – 17,623 Tons CO 2 There was also a yield improvement in the plant

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