Dual Refinery Operator Identifies 18M USD per Year in Savings

CASE STUDY

Dual Refinery Operator Identifies 18M USD per Year in Savings with Solomon's Performance Excellence Process

Solomon Applies Performance Excellence Process™ (PEP™) Methodology to Map Improvements in Yield and Performance at Operator’s Two Refineries

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CHALLENGE

The owner of two refineries wanted to improve yield and performance at both plants individually and across all operations.

SOLUTION

Refinery management brought Solomon in to apply its Performance Excellence Process™ (PEP™) and analytical tools toward identifying gaps and opportunities.

RESULTS

The operator quickly achieved 2M USD in savings.

UNDERSTANDING THE LANDSCAPE

A manager of two refineries wanted to improve yield and energy performance at the individual refineries and across the combined operating complex. The refineries were moderately complex, with a combined crude capacity of more than 325,000 barrels per stream day. They produced low-sulfur transportation fuels, lubricants, and a variety of specialty chemicals and derivatives used as feedstocks for the chemical, petrochemical, plastic, textile, fertilizer, rubber, paint, and solvent industries.

ESTABLISHING TARGETS

Having invested in process and linear program (LP) models, the refineries exhibited significant opportunities to improve yield and energy performance (see Table 1). The project goal was to close at least 10% of the energy gap (6M USD per year) at the largest refinery without capital investment by the conclusion of the engagement and 20% of the overall energy gap (12M USD).

Table 1. Performance Gaps and Opportunities

EVALUATING PROCESSES

The team’s assessment utilized analytical tools that measured and evaluated planning and optimization, process unit yields, and energy efficiency.

Proprietary tools such as Deep Drill-Down (3D) Data Analysis, Energy Diagnostics, Best Practices Assessment, Process and LP Model Audits, and the Developing Initiatives Workshop were used to diagnose the root causes behind the gaps and develop an immediate response.

REALIZING RESULTS

These assessments uncovered more than 100 initiatives to undertake, including 16 quick hits — measures that can be implemented right away to start improving processes. In the first 3 months, the refinery achieved documented savings valued at 2M USD. Ongoing recommendations from Solomon included:

Improving stripping steam effectiveness
Optimizing steam generation throughout the refinery
Improving the effectiveness of the crude unit preheat train
Developing a program to emphasize furnace efficiencies through gap monetization
Optimizing the temperature profiles of several distillation columns

The refinery has made very good progress and has plans for further implementation that should result in achievement of its target within another year.

Solomon’s team of subject matter experts started from the ground up, using Solomon’s Performance Excellence Process™ methodology to evaluate yield and energy gaps at each refinery.

Learn More about our Performance Excellence Process™