An Investigation of the Techno-Economic and Environmental Aspects of Process Heat Source Change in a Refinery

Abstract

This study of process heat source change in industrial conditions has been developed to aid engineers and energy managers with working towards sustainable production. It allows for an objective assessment from energetic, environmental, and economic points of view, thereby filling the gap in the systematic approach to this problem. This novel site-wide approach substantially broadens the traditional approach, which is based mostly on “cheaper” and “cleaner” process heat sources’ application and only takes into account local changes, while neglecting the synergic effect on the whole facility’s operations. The mathematical model employed assesses the performance change of all the affected refinery parts. The four proposed aromatic splitting process layouts, serving as a case study, indicate feasible heat and condensate conservation possibilities. Although the estimated investment needed for the most viable layout is over €4.5 million, its implementation could generate benefits of €0.5–1.5 million/year, depending on the fuel and energy prices as well as on the carbon dioxide emissions cost. Its economics is most sensitive to the steam to refinery fuel gas cost ratio, as a 10% change alters the resulting benefit by more than €0.5 million. The pollutant emissions generated in the external power production process contribute significantly to the total emissions balance.