1. Energy Efficiency A Process Licencor 's View
XXVI Russian National
Inter-Industry Meeting
September 12th - 14th, 2012

2. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

3. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

4. Energy and GHG Challenge in Refining
Energy sector represents 66.5% of the total Greenhouse Gas (GHG) emissions:
GHG from Oil & Gas (O&G) industry: about 6% of the total GHG
Chemicals & petrochemicals: about 4% of the total GHG
Energy costs represents on average more than 50% of total operating cost
Product specification developments and dieselization lead to an increase in energy consumption

5. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

6. Axens as a Key Partner
Cumulative Number of Licenses
2205 licenses
as of 31st December 2011
Axens as a licensor: Extensive know-how and experience on whole refining & petrochemical scheme.
Axens as catalyst & special equipment provider:
 Innovative solutions for OPEX reduction in existing assets
Eastern Europe + CIS 8%
Asia 35%
Western Europe 19%
Middle East 14%
Latin America 8%
Africa 4%
North America 12%
Axens has set up a structured knowledge management process to capitalize on each project 6

7. Energy Efficiency & GHG Mitigation
Methodology for Energy Audit
Step 1: Dispatching questionnaire to site Preparation of KOM
Step 2: KOM & Energy Survey on site
Step 3: Reconciled baseline for energy balance
Step 4: Identify energy conservation opportunities Meeting with customer for projects selection
Step 5: Development of the selected projects

8. Energy Efficiency & GHG Mitigation
Establish Referential
On-site Data collection:
- Utilities network - Process units performance - Large thermal & power equipment performance - Flare system - Emissions assessment - Maintenance & Operational good practices
Baseline setting:
KPIs, EIITM, CO2 - Energy consumption / cost
Cost Estimate & Financial Analysis
Detailed study of selected projects (CAPEX, IRR, NPV)
Estimation of related saving (including Solomon EIITM
Propose Options
Screen projects options that could improve energy efficiency:
- Non-CAPEX options - Low CAPEX options - High CAPEX options
Evaluation compliance to CDM criteria
Customer selection of projects to be further developed
over 80 options screened
Case ranking
Validation of project options to be developed during the next phase 8

9. Axens / SES Combined expertise for refiners
Axens & Solvay Energy Services combine their expertise to provide an integrated services to the refining industry
ENERGY
CONSUMPTION
REDUCTION
SOURCING
IMPROVEMENT
CO2
&
Energy
Energy equipements expertise
Heat integration
Processes optimization
Refining scheme integration
Emissions capture
Peak shaving
Work organization
Energy performance management
Spot market access
Shipping/Transmission
Balancing
Renewables sourcing
CO2 Allowances
ASSET
OPTIMISATION
Combined Heat and Power
Load curve management
Supply / Demand Response
Renewables

10. Use Solomon benchmark But go beyond a first level analysis
2nd Quartile
1st Quartile
But go beyond a first level analysis
Process expertise is required to assess energy performance and identify improvements in any refinery process unit

11. Example of High Severity CCR Reforming
Includes:
catalyst regeneration
recycle compressor
Stabilization section
H2 export compressor
Aromatics yields: Heat of reaction governed by thermodynamics
80% of CCR reforming net energy consumption is directly linked to production objectives

12. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

13. High efficiency Heat Exchangers
High efficiency HX gains
Heat Duty
- 48%
Electrical power
- 8% 13

14. High Efficiency Furnaces
Optimising heat recovery
Efficiencies above 92%?
Consultation with equipment manufacturers

15. Optimum Heat Exchanger Networks
PINCH TECHNOLOGY
First: Adjust process parameters to improve heat integration.
Then: Use PINCH technology to intensify process /process heat exchanges and minimize wasted heat (air coolers, trim coolers)
Last: Use Licensor’s experience to define schemes that provide operability and flexibility

16. Non-conventional equipment
Dividing Wall Columns  lower energy requirement for reboiler of the combined column Example: Benzene-Toluene distillation column
Plate heat exchangers  reduce T° approach and increase heat recovery  replace several heat exchangers in series Example: Feed/bottom of a distillation column

17. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

18. Aromatics Complex Scheme Overview
FG + LPG
Raffinate
Benzene B T
Extractive Distillation B C
Tol
C7-
Transalkylation
C8+
Reforming
(CCR)
Hydrotreated Naphtha RS
Paraxylene
C8A
Eluxyl
Xylenes
Isom.
C8+
C9+C10 XC
Conversion units
C9+
Separation units HA
Fractionation columns
Heavies

19. Aromatics Complex Scheme Overview
FG + LPG
Raffinate
Benzene B T
Extractive Distillation B C
Tol
C7-
Transalkylation
C8+
Reforming
(CCR)
Hydrotreated Naphtha RS
Paraxylene
C8A
Eluxyl
Xylenes
Isom.
C8+ X C
C9+C10
C9+ HA
Heavies

20. Energy efficiency study for Aromatic complex project
Detailed study to review potential energy efficiency improvements:
Project specific (based on client requirements)
Technical and economical optimisation (CAPEX & OPEX)
Example of modification to Aromatics Complex design:
Maximize heat conservation
Minimize air coolers
Produce steam and electricity when possible

21. Steam generation study Basis of design
Several levels of steam considered from LLP to MP steam
Reviewed opportunities for:
For steam recompression from LLP to LP and LP to MP
Pre-heating BFW
Pre-heating furnace air

22. Steam generation study Basis of design
Example of scheme modifications envisaged:
Increase or lower operating pressures of columns
 For heat integration with other process streams
Installation of additional process exchanger on reaction sections (higher heat recovery on reactor effluent streams)
Increase heat efficiency of fired heater

23. Example of Process Heat Integration
Feed 1
HP purge
Feed 2
Reactor
LP purge to Process stab. Comp.
Recycle compressor
Feed heater
Effluent air cooler
Distillate to stab.
Cold separator
Feed / Effluent exch.
HPst
Product 1

24. Example of Process Heat Integration
LP purge
Feed 1
HP purge
Feed 2
Reactor
Recycle compressor
Off gas from TP stab
Feed heater
Effluent air cooler
Distillate to stab.
Cold separator
Feed / Effluent exch.
HPst
Product 1

25. Energy efficiency versus CAPEX
Gains in performances, an additional: ~ 20%
Higher CAPEX:
Adjusting columns operating pressure:
Higher pressure to improve heat integration
Lower pressure to reduce reboiler duty (offgas compressor)
More equipment: large heat exchangers and steam generators
Risk mitigation of water leakages (Special HX design, equipment test & inspection, S/D S/U procedures)

26. Interfaces & Off-sites
Unit interfaces may be areas of heat losses
Storage lay-out, especially on semi-finished products, must be reviewed with the energy perspective 26

27. Agenda Energy and CO2 Challenge Axens as a key partner
Equipment optimisation
Examples of process design optimisation
Conclusion

28. Conclusion
Energy efficiency practices presented earlier can be applied to new process unit design as well as existing units
However, expected gains for existing assets will be more limited than for new built.
Energy efficiency improvements have to be economically viable and sustainable
Axens is actively working on energy efficiency improvements:
Technologies & products (process integration, equipments)
Consulting services (offer can be combined with Solvay Energy Services)

29. Energy Efficiency A Process Licencor 's View
Thank you