A Case Study of Steam System Evaluation in a Petroleum Refinery

ASI conducted a steam system evaluation study at a multinational petroleum Refinery located in the Eastern UK during June-July, 1999. At this refinery, Steam, Fuel and Electricity systems are inter-connected. Steam is generated from direct fuel fired boilers as well from Furnace and Kiln waste heat. Steam is also supplied from the CHP waste heat boilers. Steam generation averages 1,500,000 lbs/hr and does not change significantly between winter and summer since steam needs for process and power generation dominates way above comfort heating. To generate steam, the refinery spends about £28 million per year ($46 million). The system evaluation study identified 31 Energy & steam system cost savings measures (ECM) to save fuel, steam and condensate in the areas of: Steam generation, Steam distribution, Steam Utilization, Condensate recovery, and Combustion optimization in kilns. By implementing all the above 31 ECMs, the refinery is estimated to save $3.5 million annually. Based on our preliminary investment estimate the average payback would be within 2 years. The refinery also would reduce 5600 metric tons Carbon emission to environment. Some of the opportunities address the installation defects of the steam system components that would improve the system reliability and longevity