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KBC IoE Webinar - Achieving Energy Efficiency in Your Downstream Operations

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An average site consumes 50% more energy than it would if built today with all up-to-date, economically justifiable measures of energy efficiency incorporated. With the cost of energy increasing, such …

An average site consumes 50% more energy than it would if built today with all up-to-date, economically justifiable measures of energy efficiency incorporated. With the cost of energy increasing, such "poor" energy performance is making many sites uncompetitive in the current economic environment. Increasing energy taxes and tightening environmental legislation means that operators now need to refocus on how to make significant reductions in their energy consumption and energy related emissions. By applying a systematic and "Total Site" approach across a site utilizing leading industry tools and technologies, operators can realise very significant cost reductions with the implementation of energy efficiency measures. This webinar will explore innovative energy efficiency solutions and their cost/benefit impacts for refineries and petrochemical sites.

To ensure energy efficiency projects are identified, implemented and sustained it is necessary to include all aspects of energy management. As with any change management task, energy management needs to address 3 strands:

- Who performs the task (people)
- What they use to perform the task (technology & tools)
- How the tools are applied to perform the task (methodology)

This free 45-minute webinar covers the organisational aspects, the leading tools and technologies required, and the methods and procedures that sites will require to achieve best practice energy performance. Key areas explored:

- Methodology and technologies that can be applied to both grassroots and revamp projects in order to improve energy efficiency
- How to combine energy conservation within and across the site
- The importance of having a robust energy management system supported by an energy-focused organisation to ensure sustainment and continuous improvement

Allan Rudman is Vice President of Energy Services with KBC. During his 20-year career with KBC, he has advised refining and petrochemical clients in a number of European, Russian, Asia, South and North American countries on improving energy efficiency. Utilising his engineering background, Allan has played a leading role in the development of energy services technology, including training, development and methodology guidelines.

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  • 1. Achieving Energy Efficiency inYour Downstream Operations:Lean and Green Refineries & Petrochemicals 23 October 2012 © 2012 KBC Advanced Technologies plc. All Rights Reserved.
  • 2. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 2
  • 3. KBC Corporate ProfileLeading Consultancy with World-class Technology KBC Office Locations KBC Why KBC? • Leading technical, commercial & • Independent, Objective Advice environmental consultancy with world- class technology • Deliver competitive advantage to owners, • Enhance capital & asset operators and investors in the refining, effectiveness, Improve operational petrochemical & other process industries performance and Increase industry through risk management and competitive advantage improvements in business performance • Net Revenues: £55 million in 2011. • Meet Individual Client Needs with Listed on UK Stock Exchange. ~300 Consulting, Implemented Solutions, employees worldwide. Human Performance & Technology KBC Approach KBC Solutions Capital Solutions: Operating Solutions: • Market Analysis and Forecasting • Supply Chain Management • Business Strategy Development • Process Optimization • Merger, Acquisition, Divestment & • Energy Efficiency Improvements post-transaction Integration support • Technical, Commercial, Environmental • Health, Safety and Environment • Due Diligence & Feasibility Studies • Reliability & Maintenance • Supply & off-take agreement support • Organizational Effectiveness • Environmental Impact Assessments • Technical Seminars, Training • Capital Project Support • Software Solutions • Pre-Start up Support • Technical Support 23 October 2012 PROPRIETARY INFORMATION 3
  • 4. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 4
  • 5. Impact of Energy Costs on Refining MarginOperating Cost Breakdown • Energy on Crude is 5% to 10% Other People 16% • Costs $250 to $500 Million pa (200,000 bpd refinery) 13% Energy 50% • 10% Savings Worth up to $50 Million pa C&C 6% Maintain • Increases Current Refinery Margins by 20% 15%• Costs Can Vary from Region to Region• 50% Energy Based on Internal and Purchased Power & Fuel• Other Includes: – Finance – 3rd party services – Insurance – Depreciation – Interest 23 October 2012 PROPRIETARY INFORMATION 5
  • 6. Impact of Energy Costs on Petrochemical MarginOperating Cost Breakdown • Energy Costs ~$300 Million pa (900,000 Other 20% tpa ethylene) People 10% Energy • 10% Savings Worth up to $30 Million pa 50% C&C 10% Maint- • Increases Current Margins by 15% to 20% enance 10% 1000 100.0% 900 90.0% 800 80.0%• Costs Can Vary from 700 70.0% Region to Region 600 60.0%• 50% Energy Based on $/t 500 50.0% Internal and Purchased 400 40.0% 300 30.0% Power & Fuel 200 20.0%• Other Includes: 100 10.0% – Finance 0 0.0% – 3rd party services 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020 2022 2024 2026 2028 2030 – Insurance Margin (cash margin - finance) Margin improvement (10% energy saving) – Depreciation – Interest 23 October 2012 PROPRIETARY INFORMATION 6
  • 7. Challenges for Our Industry> Increased Energy Prices> Reduced Margins> Stricter Governmental and Environmental Legislation> Improve Corporate Image: – Lean and Green 23 October 2012 PROPRIETARY INFORMATION 7
  • 8. Rising Fuel Prices Make Investment in Saving EnergyHighly Attractive > Fuel prices have increased Energy Costs Versus Capital faster than plant capital 700 costs 600 – A 5 year payback in 1995 3% Fuel Oil 500 Plant Costs is now a 2 year payback Cost Index 400 – Incentive to invest in capital projects & revisit 300 older “uneconomic” 200 projects 100 – Novel schemes could be attractive (heat pumps, 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 divided wall columns, etc.) Year > Also attractive to invest in Data: Q2 2011 engineering capabilities (manpower, tools, training) 23 October 2012 PROPRIETARY INFORMATION 8
  • 9. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 9
  • 10. ENgage Programme - The Main Tasks1. Identify what needs to be ENgage done Human Performance Improvement Human Performance Improvement  Benchmark, find performance Strategic Strategic Energy Energy gaps and recommend Road Map Energy Energy Review Review Management Management System System for closure SER EMS2. Ensure it is done Software and Technical Solutions Software and Technical Solutions  Implementation of gap closure projects3. Sustain the Effect  Build Energy Management and organisational structure enabling continuous improvement 23 October 2012 PROPRIETARY INFORMATION 10
  • 11. Achieving best practice energy performance meansaddressing all areas of energy management People Technology & Tools Energy focused organisation Energy RoadMap Defined roles & responsibilities • Project packages Organisational alignment • Investment plan ProSteam Active communication • Steam, fuel and power system Operator awareness scenario planning Training & mentoring • On-line utilities optimisation Methodology ENgage Energy Metric Management • Performance monitoring Benchmarking & Gap Analysis • Fouling monitoring Opportunity identification & evaluation SuperTarget Project implementation • Energy efficient design Performance monitoring & reporting Petro-SIM Target setting • Yield / Energy Trade-off Maintenance programmes CarbonManager • Monitoring CO2 emissions 23 October 2012 PROPRIETARY INFORMATION 11
  • 12. ENgage Implementation Overview Traditional Implementation Process Energy 5 Management 1 System PEOPLE Best Human Capital Practices 4 & Procedures Organisational Energy MASTER METHODOLOGY AlignmentAssessment PLAN Strategic Review ROADMAP 5 Definition of Work TECHNOLOGY Processes Tools & TOOLS Tool Online Utility Development Optimiser Training Energy Metric Tracker Check Point to focus 2 3 Design Tools 2 1 Planning Tools efforts in optimum area Discover Develop Deliver 23 October 2012 PROPRIETARY INFORMATION 12
  • 13. The Strategic Energy Review Identifies All Opportunitiesfor Improving Energy Performance Benchmarking Benchmarking and gap analysis KBC determine the most profitable areas for Gap Analysis improvement Utility System Modelling Project identification using pinch Project Ownership Detailed analysis, Total Site analysis, process Analysis simulation, PFD reviews and Mechanical Walkthrough Project Ideas Project review to select projects for detailed development Project Development of project packages Development Modelling of utility systems to identify performance gaps and to evaluate project Client Energy ideas RoadMap Evaluation of project combinations and development of investment RoadMap 23 October 2012 PROPRIETARY INFORMATION 13
  • 14. KBC’s Proprietary “Best Technology” [BT]Energy Benchmarking Methodology KBC’s Development WorkBT Configuration Development CorrelationsAll economically justifiable ENCON Developmentbuilt in (4 years payback on last - BT process modelledpiece of equipment): - Parameters affecting- Furnaces 92% eff. energy performance- Optimised heat integration varied (pinch) and process features - Sensitivity found- Efficient Steam&Power system - Correlations using- All power generated at 80% eff. important parameters- Yield efficient developedCalculate BT Calculate Apply KBC Collect Process index for Total energy Energy Costing Calculate data:each process consumption methodology BT Target - BT parameters and whole for each - PEE for power for all units - Energy Balances site process - Steam costing Application 23 October 2012 PROPRIETARY INFORMATION 14
  • 15. BT Benchmarking and Gap Analysis> Best Technology (BT) benchmarking compares actual energy usage to a BT energy usage> 100% BT represents the best performance that could be expected from a modern plant designed with high efficiency components and features> Performance gaps identified: – Steam and power – Heater performance – Heat Integration effectiveness – Process 23 October 2012 PROPRIETARY INFORMATION 15
  • 16. Gap Analysis Steam&Power 55% Heaters 11% Heat Integration 13% Gap Process 21%BT Index, %BT 100 Base Case Areas of Improvement % of Gap Unit 1 Unit 2 Unit 3 Attributable to Steam and Power 55 32 67 Fired Heaters 11 24 12 Heat Integrations 13 12 10 Process 21 32 11 100 100 100 23 October 2012 PROPRIETARY INFORMATION 16
  • 17. Process Unit Optimisation PFD Review Meetings Supported by………… SIMULATION  Comprehensive analysis  Rigorous and systematic approach PINCH  Practical project ANALYSIS development  Proven results from 1000’s of successful applications PROCESS EXPERTISE 23 October 2012 PROPRIETARY INFORMATION 17
  • 18. Optimising Crude Distillation Unit Pressure 55 Reflux Pumparound Duty TPA 6 1 LP steam MPA KERO Preheat train: 6- Design Heater 1 LP steam- Performance O2, Eff. BPA LGO 6- Fouling 1 LP steam DESALTER HGO Overflash 7 HEAT RECOVERY TO 20°C ∆T AT PINCH FLASH DRUM 6 Steam LP steam Inlet T Outlet T RESIDUE 23 October 2012 PROPRIETARY INFORMATION 18
  • 19. Process Unit Optimisation - Pinch F Pinch Modelling in SuperTarget Composite Curves T Grand Composite Curve Steam Steam Generation Cooling Water Q Hot & Cold Targets + Utility Targets = Saving Scope 23 October 2012 PROPRIETARY INFORMATION 19
  • 20. Case Study - Topping Unit Revamp> Contractor Design – 8 New Exchangers, 12 Shells – Furnace for stabiliser reboiler> KBC Design – 5 New exchangers, 8 Shells, 2 Twisted tubes – No separate furnace – Additional 3.4 Gcal/h energy savings> Economic Benefits – Operating cost saving US$ 0.57M per year – Reduced capital US$ 5.94M (55%) 23 October 2012 PROPRIETARY INFORMATION 20
  • 21. Steam & Power Efficiency> Model of Site Steam and Power System in ProSteam Software – Utility balances – Equipment / system constraints – Real cost of utilities – Emissions calculations> Compare with Best Practice Design and Operation> Target Cycle Efficiency Determined by R-Curve – Individually – System-wide – Optimal import strategy 23 October 2012 PROPRIETARY INFORMATION 21
  • 22. Roadmap Development Project Development 60 40 31 28 Ideas Project Full RoadMap Generation Screening Costing > 60 project ideas were generated during the analysis phase > Screening for practicality and cost/benefits reduces the number > Final RoadMap contains 28 projects compatible with each other and the utility system 23 October 2012 PROPRIETARY INFORMATION 22
  • 23. Sample Implementation Roadmap Payback years 0 1 2 3 you are here Add New 0 3 4 5 6 7 8 9 11 12 Turbogen 2 6 1 4 5 7 10 9 8 boiler Spare Steam Capacity Select 6, 7 or 9 For Limited Expansion operation to Save LP Steam (Replaces 3 & 8) SASOL East Plant 13 Initial Roadmap Add New Boxes Represent Projects on Payback Time Scale - Size Proportional to savings Process 23 October 2012 PROPRIETARY INFORMATION 23
  • 24. Technology: Energy System Modelling and Optimisation KBC CarbonManager™ - EmissionsProSteam™ – Utility System WaterTracker™ and WaterPinch™Modelling & Optimisation Petro-SIM™ SuperTarget™ – Heat Integration of HX Monitor™ – Fouling Monitoring Processes and Utilities 23 October 2012 PROPRIETARY INFORMATION 24
  • 25. Energy Metric Tracker> Successful energy management is built around monitoring energy metrics – Optimise energy without sacrificing yields – Continuous comparison to target  sustain performance – Optimise targets over time  continuous improvement Energy Tracker – Energy Coordinator Level Site KPIs 01/01/2008 Controlling CDU1 NHT CCR GOH1 GOH2 + Drive continuous Target BT improvement - Energy Specific Specific BT BT BT BT BT Energy Specific Energy Specific Specific Energy Energy Energy Coordinator Energy Tracker - Engineering Level Energy Tracker - Operator Level Stats CDU KPIs 01/01/2008 KPIs Stats CDU EIVs 01/01/2008 Energy Consumption Energy Consumption + + Target Target BT BT - Engineering Operator - CDU Stripping Furnace O2 Side Reboiler Q Steam Overflash % Vacuum D86 Gap HN/Kero Furnace Stack T LDO/HDO D86 Gap CIT HDO/HAGO Furnace D86 Gap Kero/LDO D86 Gap CDU KPIs EIVs Strategic High energy impact Promote Measurable investigation Controllable 23 October 2012 25
  • 26. Energy Metric Monitoring & Reporting> Defining energy metrics in itself is not enough 78 C 60.7 m3/h Vacuum System MP Steam 47 C 56.7 mmHg 62 C 5.8 t/h – Need to be implemented and then acted upon E-4164 E-4161 181 C 10.5 m3/h E-4159 4.2 Gcal/h LVGO 8 t/h to HDS-1/2 14 t/h to HDS-3 1.8 Gcal/h LP Steam 1.0 Gcal/h 192 C 139 C 160 C 291 C 122.3 t/h AR CDU2 F.F. Vacuum Column VR to VB 80 t/h Flow 151.3 t/h 82 t/h 4151 E 173 LP Steam 346 C 150 C E-4153 5.3 Gcal/h E-4163 4.4 Gcal/h 311 C 28.6 m3/h AR CDU3 4151B 0.0 t/h Quench 94.6 t/h Qf=15.2 O2 7.6 t/h 346 C 0C 245 C η=89.6% 237 C 264 C 145 C 389 C LP Steam KPI AR tank E-4151 E-4152 Spl 82.5 t/h 136 C 11.2 Gcal/h 2.9 Gcal/h E-4165 0 m3/h 80 C STM 0.8 Gcal/h 317 C 4152B 192 C 288 C 4.5 t/h Qf=4.2 LP Steam 320 C Stm E-4162 η=77.4% 1.8 Gcal/h E-4154 LP Steam Quench 9.5 Gcal/h 172 C 2.3 t/h 165 C 7.6 t/h 0.4 m3/h 94.4 t/h 366 C HVGO to U300&4300 and RCC 1.7 m3/h 13.5 t/h 1.3 m3/h Slop Wax to RCC KBC can develop a customised system or work with third-party software 23 October 2012 PROPRIETARY INFORMATION 26
  • 27. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 27
  • 28. Client Review Conversion Refinery, 100KBPD, 2nd Quartile Energy Efficiency Performance> Profit Improvement Program in 2000 Results Achieved: – Focus on non investment • PIP identified operational energy opportunities yield & energy savings worth 2.7%> Strategic Energy Review in 2005 • SER identified projects (with payback – Focus on energy efficiency < 4years) worth 11.9% improvement projects • Utility optimiser resulted in savings> Utility System Optimiser in 2007 up to 4% based on previous – On-line optimisation of utility system operation> Metric Identification study in 2009 • Improved energy metrics monitoring – Identify appropriate energy metrics to saved 1% monitor Net impact of KBC studies: EII reduced by up to 20%, client now a solid first quartile performer 23 October 2012 PROPRIETARY INFORMATION 28
  • 29. Client Review KBC Best Technology Energy Index SER Completed in 2005 Steam Optimiser on line in Process 2008 Metrics implemented in 2009 SER Projects Installed 23 October 2012 PROPRIETARY INFORMATION 29
  • 30. Summary of typical savings• KBC’s ENgage programme is designed to capture and sustain all energy improvement potential• Typical savings  10-15% reduction in energy costs  Sustained and improved upon in the longer term• Less tangible elements ensure full Typical Savings Savings identified Savings realised as % of total in stand-alone potential is achieved energy cost implementation and sustained Best Practices 3 2  Organisational Projects 6 4 aspects  Energy tools Optimiser 3 2  Training and Energy Metric Tracker 3 2 mentoring TOTAL 15% 10% 23 October 2012 PROPRIETARY INFORMATION 30
  • 31. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 31
  • 32. Summary> ENgage combines all elements of energy management to deliver a best practice EMS> Tailor made to meet site requirements – Energy focused organisation – RoadMap of improvement projects and initiatives – Optimisation tools for operational optimisation and planning – Monitoring tools – Design tools – Training and mentoring – Working procedures for delivering best practice energy management> Combining all elements can achieve and sustain savings of up to 15% of site energy bills 23 October 2012 PROPRIETARY INFORMATION 32
  • 33. Agenda> KBC Overview> Energy in the Current Context> KBC’s Approach to Sustainable Improvements> Experience and Case Studies> Summary> Q&A 23 October 2012 PROPRIETARY INFORMATION 33
  • 34. A Question and Quick Survey> Was this topic valuable? > How do you rate the – Yes webinar overall? – No – Excellent> Was the presentation – Good clear? – Fair – Yes – Poor – No Please send any further> Would you be interested questions and feedback to: in future webinars? kbc-marketing@kbcat.com – Yes – No 23 October 2012 PROPRIETARY INFORMATION 34
  • 35. Closing> Contact: Allan Rudman, Vice President Energy Services, arudman@kbcat.com> Questions?> Future webinar topics: – Market conditions – Asset optimisation – Investment support – Sustainable workforce development> We welcome suggestions for future topics – please email kbc-marketing@kbcat.com> Thank you for joining us! 23 October 2012 PROPRIETARY INFORMATION 35

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