Energy Management: Back to the Basics

In 2005, Texas Petrochemicals LP achieved a reduction in energy usage of 6.2 percent when compared to 2004. This is based on the but per pound of plant-wide production. Also, halfway through 2006, the company has achieved a reduction in energy usage of 11.6 percent when compared to 2005. This was accomplished in spite of the fact that market conditions forced plant-wide production to be reduced by 2.5 percent. The following projects and procedures were implemented to achieve these results: • Overall energy management system with “top-down” support • Conversion of 2 boilers to a CO control strategy • Using combustion analysis metrics to drive boiler pre-heater cleanings • Deaerator optimization • Utility leak repair program • Steam trap management program • Insulation program • Distillation targets assessment and optimization • Advanced and regulatory process control improvements • Conversion of steam turbines (vented to atmosphere) to high-efficiency motors • Diversity of natural gas suppliers The company is initially targeting an energy reduction goal of 5 percent year over year