1. 16 September 2015© IneosSlide 1 Energy Management at Grangemouth University of Strathclyde Thursday 22 nd March 2006 Colin Pritchard

2. 16 September 2015 © IneosSlide 2 Agenda Safety Brief Background / Introduction Approaches to Energy Management Legislation Industry Benchmarking Site Tour

3. 16 September 2015 © IneosSlide 3 Safety Brief Safety in this Building Alarm – Sound / Tested Evacuation Routes / Muster Point / Roll-Call Safety on Site Tour Do NOT carry any of the following: matches, lighters, battery operated equipment, mobile phones, cameras, or any other potential source of ignition. Site Alarm tested on Monday 11:45. Do NOT leave the vehicle, unless told to do so in an emergency.

4. 16 September 2015 © IneosSlide 4 Background - Refinery Processes 210,000 barrels per day Crude Oil Produces 9 million litres of Clean Fuels per day 20 process units 21 process heaters, Total 730 MW Heaters burn Fuel Oil, Fuel Gas and Natural Gas Consumption Figures, per month: Fuels = c.35,000 tonnes per month Electricity = 24,000 MWh Steam 640# = 32,000 te 200# = 105,000 tes

5. 16 September 2015 © IneosSlide 5 Background – Petrochemicals Around 2 million tonnes of products per year 2 Ethylene Crackers 3 Polymers Units 2 Ethanol Units & 1 GTU / Benzene Unit Consumption Figures, per month: Fuels = c.10,000 tonnes per month Electricity = 42,500 MWh Steam 1850# = 12,500 tes; 640# = 23,000 tes;500# = 2,000 tes; 200# = 105,000 tes

6. 16 September 2015 © IneosSlide 6 Background – Power Station Power Station consumes about 25,000 tonnes of fuel per month: Fuel Oil, Fuel Gas or Natural Gas. 8 Boilers – Total of 1190 MW (thermal) – not all on-line at the same time. Produce (per month): 290,000 tonnes of steam 40,000 MWh of Electricity Also on-site 3 rd Party CHP Plant, that supplies the site with: 150,000 tonnes of steam 40,000 MWh of Electricity BP (Forties Pipeline System) use 70,000 tes MP Steam / 10 MWh per month, remained used by Ineos

7. 16 September 2015 © IneosSlide 7

8. 16 September 2015 © IneosSlide 8 Agenda Approaches to Energy Management Legislation Industry Benchmarking

9. 16 September 2015 © IneosSlide 9 Approaches to Energy Management “ Good Operations ” Heater Operations Insulation, Steam Traps ….. Unit Optimisation Optimisation of individual heaters / boilers etc System Optimisation Optimisation of Loads / Selection of Fuels Capital Projects Only when commercial

10. 16 September 2015 © IneosSlide 10 “ Good Operations ” - Issues & Checks Equipment Checks: Insulation Surveys Steam Trap Surveys Steam Leak Surveys Operational Checks: Use / status of pre-heat systems Excess Air / Oxygen Heater Firing Advanced Control: Column reflux rates etc.

11. 16 September 2015 © IneosSlide 11 Monitoring & Targeting Key measure = Units of Energy / Unit of Throughput There are many reasons why this may vary: Pre-heat fouling Excess Air Throughput Grade of product Principle of continuous improvement: Make last year ’ s average the current year ’ s worst performance.

12. 16 September 2015 © IneosSlide 12 Monitoring & Targeting - Example

13. 16 September 2015 © IneosSlide 13 System Optimisation Several commercially available packages, but with the same principles: Capture current performance data Run optimiser to derive “ Perfect Solution ” Identify actions to close gap Caution: Need optimised units first Only as good as input data!! Care do not compromise main production process

14. 16 September 2015 © IneosSlide 14 Capital Projects Retrofit costs considerably higher than including in the original design. Often do not pay for themselves on just Energy costs alone – need to consider all Sources of Value: EU ETS Carbon Dioxide Permit trading Process improvements / de-bottlenecking – extra capacity can decrease the specific energy consumption GJ/te.

15. 16 September 2015 © IneosSlide 15 Legislation EU Emissions Trading Scheme (EU ETS) Ineos Grangemouth emits 3 million tonnes of CO 2 per annum. Large Combustion Plant Directive (LCPD) Stack Monitoring (Continuous Emissions Monitoring >50MW) Pollution Prevention & Control (PPC) Basic Energy Efficiency Requirements Energy as a “ Reserved ” subject – Cannot be an Improvement Plan condition Air Quality Directive (AQD) Limits on Environmental Levels of eight Pollutants

16. 16 September 2015 © IneosSlide 16 Industry Benchmarking External consultants offer services: Confidential information exchange Often require a degree of “ normalisation ” Present results by quartile / ranking Considerations: Data quality / accuracy provided by respondents Does not necessarily explain differences

17. 16 September 2015 © IneosSlide 17 Industry Benchmarking Solomon Energy Intensity Index (EII) Provided for a refinery as a whole Based on equivalent distillation capacity (EDC) Defined as Actual Energy Consumed / Standard Energy (%) Standard Energy determined using factors Considerations: Does not show which unit is consuming high energy. Greatly influenced by capacity utilisation Comparison to other refineries dependent on EDC

18. 16 September 2015 © IneosSlide 18 Industry Benchmarking

19. 16 September 2015© IneosSlide 19 Any Questions?

20. 16 September 2015© IneosSlide 20 Pre-Heat Operation Impact on Heater efficiency of poor pre-heat performance.

21. 16 September 2015 © IneosSlide 21 Stack Losses

22. 16 September 2015 © IneosSlide 22 Pre-Heat System

23. 16 September 2015 © IneosSlide 23 Crude Distillation Pre-Heat Exchangers

24. 16 September 2015 © IneosSlide 24 Fouled Crude / Atmospheric Residue Exchanger

25. 16 September 2015 © IneosSlide 25 Clean versus Fouled Heat Exchangers

26. 16 September 2015 © IneosSlide 26 Fouled Tubes

27. 16 September 2015© IneosSlide 27 Heater Checks

28. 16 September 2015 © IneosSlide 28 Typical Burner Arrangement

29. 16 September 2015 © IneosSlide 29 Typical Burner Arrangement

30. 16 September 2015 © IneosSlide 30 Crude Heater

31. 16 September 2015 © IneosSlide 31 Thermography

32. 16 September 2015 © IneosSlide 32 Thermography