Olefin Site Energy Performance Excellence Analysis Identifies up to 30M USD in Annual Energy Savings
The operator realized a 23 Energy Intensity Index™, EII® point reduction, and electricity savings and a reduction in carbon emissions for their aromatics units, ethylene plants, and utilities.
An international ethylene producer desired a reduction in carbon emissions and to address previously identified significant energy consumption gaps of 34M USD for ethylene plants and 29M USD for aromatics units.
Solomon’s used its Performance Excellence Process™ (PEP™) to assess the current energy performance and recommend energy reduction items for aromatics units, ethylene plants, and utilities.
30M USD in annual savings in utility systems opportunities were identified which would result in a potential net reduction in EII of 23 and corresponding lower carbon emissions.
ENERGY EFFICIENCY PEER COMPARISON METRICS CONCERNED AN OLEFIN PLANT OPERATOR
An international olefin plant operator and participant in Solomon’s Worldwide Olefin Plant Performance Analysis (Olefin Study) realized their energy efficiency improvement journey was not progressing as well as industry peers and chose to take action to improve their competitiveness. In addition, the organization desired to take steps to reduce carbon emissions for aromatics units, ethylene plants, and utilities. The operator’s past study results revealed EII gaps of 25 EII for ethylene facilities and 43 EII for aromatics units. These significant energy consumption gaps reported were equivalent to disadvantages of 34M USD and 29M USD, respectively. Solomon proposed using its PEP methodology to analyze and create a realistic plan close the operator’s energy consumption gap.
OPERATOR DESIRED A DETAILED ANALYSIS
The operator requested the following details for their engagement with Solomon:
- Energy data diagnostics along with a review of internal client data and analysis of specific operating equipment.
- On-site, industry best practice assessments.
- Key personnel interviews and prioritization workshops.
- Specific recommendations developed.
- Ongoing tracking of KPIs to sustain improvement.
TAKING A DEEPER DIVE INTO ENERGY PERFORMANCE
Solomon started by assessing the operators “baseline” energy performance. This assessment consisted of personnel interviews, benchmarking study results, and current energy related data. After assessing the energy profile of the operator Solomon conducted a Best Practice Assessment to understand the root causes of the gaps and compare the operators work practice to the industry’s best. Figure 1 depicts the scoring distribution for the energy related practices of Solomon’s Best Practice Assessment.
The evaluation identified that majority of the inefficiencies were found in the utility system. For example, ethylene plants use super high-pressure and high-pressure steam to drive turbines and compressors for gas cracking and refrigeration purposes. Compared to other high performing plants, this plant suboptimized its utility generation, distribution, and consumption.
Figure 1. Scoring Distribution for Energy Related Practices
To improve energy efficiency and consumption performance gaps, Solomon provided the following recommendations:
- Monetize energy performance and share throughout organization
- Improve efficiencies of key rotating equipment
- Improve monitoring of the “older” pyrolysis furnaces for tighter control
- Optimize pressures of the aromatic’s distillation columns
- Develop a monitoring program for the ethylene plant’s preheat network
OPPORTUNITIES IDENTIFIED
Solomon advisors identified over 11 energy savings opportunities, totaling 30M USD saved annually, in the Aromatics Units, Ethylene Plant and Utility systems. These opportunities resulted in an estimated a net reduction in EII of 23 and lower carbon emissions. The opportunities included a combination of quick-hit, no-to-low-cost recommendations, and longer-term recommendations to sustain improvements. These projects put the company on a path to save fuel gas and electricity, positively impacting the site’s carbon emissions and improving the operator’s competitive position.
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