Crude Distillation Unit (CDU) Energy Components and Guidelines | Energy Conservation

Crude Distillation Unit (CDU) Energy Components and Guidelines | Energy Conservation

Leaks

  • Does the utility operator/engineer make routine check for steam leaks around the facility?
  • Does a survey have been conducted to determine the source of “energy” leaks and valves leaks?

Flare

  • Does each individual line to the flare is being measured and/or gas analysis is made to determine source of release?
  • Does the waste gas containing combustibles such as H2S is being recycled to process furnaces?
  • Does the flare gas recovery unit been justified?
  • Can we recover flare gas, part of it, via in-process modifications such as better cooling capability and better pressure control?
  • If the compressor is not justified for flare gas recovery, do the absorption and/or adsorption technologies been investigated?
  • Are combustible waste products sent to the incinerator to reduce auxiliary fuel?

Control

  • Have the furnaces been considered for excess air control?
  • Are pumps and compressors controlled to keep recycle at the minimum possible?
  • Are all products specification controlled at the sales specification required?
  • Are heat exchanger network controlled to maximize energy recovery?
  • Are columns pressure control loop tuned to render fast response to disturbances?
  • Are tower control loops been configured to keep reflux at a minimum and consistent with escalation in energy prices?

Combined Heat and Power System

  • Is the venting of exhaust steam minimized by shutting down turbines and starting up motors, upon applicable?
  • Is the idling of standby boilers minimized?
  • Is the idling of standby turbines minimized?
  • Can we replace tank heating steam with low level heat source after insulating the tanks?
  • Have steam-driven pumps and compressors checked to see the suitability of smaller impellers, if applicable?
  • Is all clean condensate recovered and semi-clean segregated, cleaned and recovered?
  • Are there any letdown stations that can be by-passed/replaced by turbine?
  • Is boiler feed water preheated using waste process heat?
  • Does all exhaust steam recovered, in the context of the total steam balance?
  • Can we reduce blow down?
  • Does blow down flash steam add value to the total steam balance?
  • Does the power factor been improved?
  • Have single stage turbines replaced with multi-stage ones?
  • Is the use of condensing steam turbines minimized?
  • Does combustion gas turbine have air inlet cooling system?
  • Are old steam lines been replaced?
  • Is electrical heat tracing used instead of steam tracing?
  • Is steam ejector used to upgrade some exhaust steam?
  • Does the throttling of steam to match less pressure demands than the line pressure minimized?

Insulation

  • Are hot flanges, man-ways and pumps insulated with removable insulation?
  • Are the medium temperature tanks insulated?
  • Are maintenance people proactively minimizing the loss in steam lines via repairing left bare lines right away?

Distillation

  • Are all columns checked for optimal feed tray location and best tray efficiency?
  • Have all the towers use the minimum reflux that renders the exact desired specification?
  • Does steam flow is just enough to get completely condensed in the steam heater?
  • Is over-flash in crude distillation unit too high?
  • Is stripping steam minimized via working the stripper at the optimal pressure?
  • Has vacuum tower in the vacuum unit been checked for possible low pressure operation?
  • Does the light ends towers equipped with inter-cooler and inter-heaters?
  • Does the light ends towers checked for among towers integration using different operating pressures?
  • Does the vapor compression/ heat pump checked as an option?
  • Does sour water stripper checked for correct number of trays?

Furnaces and Boilers

  • Is excess air controlled and monitored to keep it as low as possible while using different fuels?
  • Have the furnaces been checked for air leaks?
  • Is high pressure waste gas available to replace atomization steam?
  • Are boilers operating at its optimum combustion conditions; exhaust temperature; CO and excess air in stack?
  • Have your furnaces and/or boilers studied for more waste heat recovery?
  • Are all draft gauges operating?
  • Are all soot blowers operating well and maintained?
  • Is fuel oil temperature high enough to insure the right viscosity?
  • Are your facility checked for reliable O2 analyzers?
  • Is your atomizing steam dry?

 

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