Implementing an Energy Management Strategy for a Houston Refinery

Intense competition and environmental regulation of industries utilizing combustion equipment have motivated many owners and operators to seek ways to reduce costs, improve performance, and minimize emissions. Energy management programs are being implemented throughout industry to improve equipment operating efficiencies, profitability, extend equipment life, prevent forced shutdowns, generate substantial fuel savings, track valuable information, and enhance compliance margins. A well designed and maintained energy management program translates to PROFIT added directly to the BOTTOM LINE. Woodward-Clyde Consultants (WCC) recently implemented and energy management program at the Lyondell-Citgo Refinery in Houston, Texas. The basis of the program is the 80/20 rule where 80% of the total potential savings are derived from optimizing the energy utilization from 20% of the combustion equipment. In this case, 11 out of 55 heaters were targeted for inclusion in the program. The fuel savings potential alone exceeded $1,250,000. In addition to the fuel savings, there were reduced costs from improved operation, as well as reduction in maintenance requirements and forced shutdowns. The remainder of this paper discusses the technical approach, the benefits, and the results of the program implemented at the Lyondell-Citgo Refinery