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The Petroleum Refining industry is the largest industrial consumer of energy, representing about 7% of total U.S. energy consumption. The Office of Industrial Technologies (OIT) is working with the Petroleum industry to identify opportunities to use energy more efficiently through new technology research, development and deployment. In addition to solutions for the future, OIT provides smart energy management solutions that are available TODAY. These best practices provide immediate energy and cost savings. For more on how OIT's BestPractices can help the petroleum industry to lower energy costs, review the information below. If you are interested in participating in BestPractices activities, visit our How to Get Involved.
ENERGY USE IN THE PETROLEUM INDUSTRY 
The Office of Industrial Technologies has helped develop technologies that have application in the petroleum refining industry. Some of these technologies are now in the early stages of commercialization. Those, listed below, have been demonstrated and are in operation. Click on a project title to view Adobe PDF version of the project Fact Sheet. (Download Acrobat Reader)
Waste Heat Driven Ammonia Absorption Chiller (PDF 88 KB)
Bi-phase Rotary Separator Turbine
Robotics Inspection System for Storage Tanks (PDF 79 KB)
Ultrasonic Tank Cleaning (PDF 242 KB)
Electro-optic Inspection of Heat Exchangers
High-Temperature Radiant Burner
Radiation Stabilized Burner (PDF 109 KB)
Real-time Neural Network for Utility Boilers (PDF 256 KB)
MotorMaster+ Software
The Office of Industrial Technologies has helped develop of technologies that have application in the petroleum refining industry. Some of these technologies have moved beyond the basic research and development phase and are ready for field testing. These emerging technologies are listed below. Click on a project title to view an Adobe PDF version of the project Fact Sheet.
Low Profile Catalytic Cracking
Distillation Column Flooding Predictor (PDF 121 KB)
Gas Imaging for Advanced Leak Detection (PDF 107 KB)
Low-cost Robust Ceramic Membranes for Natural Gas Upgrading
Pulsed Laser Imaging for Detecting Hydrocarbons and Volatile Organic Compound Emissions
Advanced Turbine Systems
Very Low Emissions: Forced Internal Recirculation (FIR) Burner (PDF 81 KB)
Rotary Burner (PDF 333 KB)
Thermal Imaging Control of High Temperature Furnace
Ultra Low NOx Premixed Industrial Burners
Gas Turbine Cooling Improvement
Advanced Fluid Catalytic Cracker (FCC) Model (PDF 103 KB)
Advanced Membrane Devices for Natural Gas Cleaning
The Office of Industrial Technologies has assisted refineries in conducting plant-wide energy assessments. These assessments are conducted by the engineering firm of the refinery's choice. OIT will contribute as much as half the cost of the assessment up to $100,000. Plants can receive this assistance in one of two ways:
- Preparing and submitting a successful proposal during an open solicitation, or
- Working with OIT as an Allied Partner with commitment to participate in a Showcase Demonstration.
Below is a list of refineries where assessments are either complete, near completion, or in-progress:
- Flying J Salt Lake Refinery, Utah
- Chevron Salt Lake Refinery, Utah
- Silver Eagle Salt Lake Refinery, Utah
- Paramount Petroleum, California
- Equilon Martinez Refinery, California
The Office of Industrial Technologies' BestPractices Program can assist in the following types of assessments:1. Collaborative Targeted Assessments (CTAs) - DOE experts in industrial energy management are available to provide targeted, in-plant technical assistance to identify specific system areas for improvement. CTAs are offered in motor/pumping systems, steam systems, compressed air systems, and process heating. An Allied Partner plant can receive a CTA at no cost in one of two ways: (1) commit to hosting a training session(s) at the end of the CTA and involve participants from the subject plant and other plants, or (2) commit to participating in a Showcase Demonstration. 2. Student Assessments through OIT's Industrial Assessment Centers (IAC). IACs provide no-cost assessments to small and mid-sized manufacturers. Students do the engineering measurements in auditing how each facility utilizes energy and resources. Then with the guidance of their professors, they identify opportunities to save energy, reduce waste, and improve productivity.
Fuel-fired process heaters are often the largest consumers of energy within a refinery. The Office of Industrial Technologies' BestPractices program offers the following opportunities for plants wanting to learn more about energy efficiency and NOx reduction in the process heating area:
Collaborative Targeted Assessments
Training
Software (soon to be available)
Technical Fact Sheets and Handbooks
Process Heating Roadmap to Help U.S. industry be competitive
Seminars
Texas Industries of the Future NOx Reduction Seminar,
Houston http://texasiof.ces.utexas.edu/07-18agenda.htm
Texas Industries of the Future NOx Reduction Seminar, Corpus Christi (Oct.26,2001)
Oil refineries utilize combined heat and power systems to varying degrees. For example, steam is often generated by boilers at high pressure (i.e., 600 psig). This high-pressure steam is utilized for process heating as well as powering pumps and compressors via steam turbines. Other examples of combined heat and power systems utilize gas turbines to drive either an electric generator or process drive (i.e., a large compressor), and the waste heat is utilized to either produce steam and/or heat oil (for hot oil belt). The Department of Energy's Combined Cooling, Heating, and Power (CHP) Initiative is a coordinated effort of the Office of Energy Efficiency and Renewable Energy (EERE), the U.S. Environmental Protection Agency, the district energy community, and a diverse group of industry stakeholders. The mission of this Initiative is to raise awareness of the energy, economic, and environmental benefits of CHP and to encourage and enhance its use on a widespread basis throughout the United States and around the world. The CHP Initiatives are being coordinated by the Office of Power Technologies (OPT) in partnership with the new Distributed Energy Resources (DER) Taskforce. The Taskforce has been formed by DOE to capitalize on the synergy generated by bringing all clean, distributed energy programs together within OPT. http://www.eren.doe.gov/der/chp/
Process heating that is not done with fired-heaters is accomplished heat exchangers utilizing steam. In addition to process heating, steam is used to drive mechanical equipment and generate electricity (via steam turbines). Steam system reliability is critical since production will halt should the steam system fail. Steam can be generated by fired-boilers, process waste-heat boilers, or gas-turbine waste heat boilers (also referred to as Heat Recovery Steam Generators or HRSGs). Small improvements to steam system equipment and operation can often result in large energy savings (through fuel and water savings). The Office of Industrial Technologies' BestPractices Program offers the following opportunities for plant managers and operators who want to learn more about energy efficiency and NOx reduction in the steam system area:
Collaborative Targeted Assessments
Training
Software
3E Plus (Insulation)
Steam System Scoping Tool
Technical Fact Sheets and Handbooks - Publications with "how-to" technical detail on increasing steam system efficiencies.
Review of Orifice Plate Steam Traps
Publication Date: 2001
Length: 35 pp.
(PDF 1.09 MB)
Steam Systems Energy Efficiency Handbook
Publication Date: 1998
Length: 64 pp.
(PDF 1.16 MB)
Tip Sheets - These two-page tip sheets provide quick advice on how to keep your systems running at maximum efficiency. They include energy- and money-savings scenarios and a fax-back request form for other BestPractices publications.
Clean Boiler Waterside Heat Transfer Surfaces (PDF 82 KB)
Benchmark the Fuel Cost of Steam Generation (PDF 562 KB)
Deaerators in Industrial Steam Systems (PDF 561 KB)
Inspect and Repair Steam Traps (PDF 80 KB)
Install Removable Insulation on Uninsulated Valves and Fittings (PDF 562 KB)
Insulate Steam Distribution and Condensate Return Lines (PDF 80 KB)
Improve Your Boiler's Combustion Efficiency (PDF 80 KB)
Minimize Boiler Blowdown (PDF 85 KB)
Minimize Boiler Short Cycling Losses (PDF 561 KB)
Recover Heat from Boiler Blowdown (PDF 81 KB)
Return Condensate to the Boiler (PDF 83 KB)
Use Feedwater Economizers for Waste Heat Recovery (PDF 80 KB)
Industrial Insulation for Systems Operating above Ambient
Use a vent condenser to recover flash steam energy
Flash HP Condensate to Regenerate LP Steam
Use Vapor Recompression to recover LP Waste Steam
Use Low Grade waste steam to power absorption chillers
Installation of a reverse osmosis unit reduces refinery energy consumption
Helping Industry to be Steam Smart
Newsletter
Steaming Ahead
Seminars
Texas Industries of the Future NOx Reduction Seminar, Houston http://texasiof.ces.utexas.edu/07-18agenda.htm
Texas Industries of the Future NOx Reduction Seminar, Corpus Christi (Oct 26,2001)
Motor and Pumping Systems are often the largest consumers of electricity in an oil refinery. Pumps and compressors are responsible for "moving" the feedstock and products through the refinery. They can either be driven by an electric motor or a steam turbine (large compressors are sometimes driven by a gas turbine). The Office of Industrial Technologies' BestPractices program offers the following opportunities for plant managers and operators who want to learn more about reducing the operating costs associated with motor and pumping systems:
Motor system Upgrades Save $700 at Refinery (PDF 74 KB)
Collaborative Targeted Assessments
Training
Software
Pumping System Assessment Tool
MotorMaster+
ASD Master
Technical Fact Sheets and Handbooks - Publications with "how-to" technical detail on increasing steam system efficiencies. The following documents can be downloaded using Adobe Acrobat Reader.
Buying an Energy-Efficient Electric Motor
Publication Date: September 1996
Length: 8 pp.
(PDF 106 KB)
Replacing an Oversized and Underloaded Electric Motor
Length: 6 pp.
(PDF 162 KB)
Optimizing Your Motor Drive System
Publication Date: September 1996
Length: 8 pp.
(PDF 87 KB)
Reducing Power Factor Cost
Publication Date: September 1996
Length: 4 pp.
(PDF 98 KB)
Determining Electric Motor Load and Efficiency
Length: 16 pp.
(PDF 191 KB)
Tip Sheets - These two-page tip sheets provide quick advice on how to keep your systems running at their maximum efficiency. They include energy- and money-savings scenarios and a fax-back request form for other BestPractices publications.
Eliminate Voltage Unbalance (PDF 445 KB)
Reduce Pumping Costs through Optimum Pipe Sizing (PDF 86 KB)
Replace V-Belts with Cogged or Synchronous Belt Drives (PDF 647 KB)
Pump Life Cycle Costs: A Guide to LCC Analysis for Pumping Systems,
Executive Summary (PDF 820 KB)
Energy Efficient Electric Motor Selection Handbook
Improving Pumping System Performance: A Sourcebook for Industry
Reduce Pumping Costs through Optimum Pump Sizing
Like the refinery steam system, compressed air systems are critical to refinery operations. Compressed air is used to operate / modulate instruments and valves that control the operation of refinery process systems. Compressed air failure will often lead to process systems operating in a safe, but inefficient mode. Air compressors are usually driven by either large motors or steam turbines. Optimizing the operation of a compressed air system will often yield savings of either electricity or fuel. The Office of Industrial Technologies' BestPractices program offers the following opportunities for plant managers and operators who want to learn more about reducing the operating costs associated with compressed air systems:
Collaborative Targeted Assessments
Training
Software
Pumping System Assessment Tool
MotorMaster+
Tip Sheets - These two-page tip sheets provide quick advice on how to keep your systems running at their maximum efficiency. They include energy and money savings scenarios and a fax-back request form for other BestPractices publications. The following documents can be downloaded using Adobe Acrobat Reader.
Determine the Cost of Compressed Air for Your Plant (PDF 569 KB)
Eliminate Inappropriate Uses of Compressed Air (PDF 539 KB)
Minimize Compressed Air Leaks (PDF 542 KB)
Improving Compressed Air System Performance: A Sourcebook for Industry
Compressed Air System Market Assessment
Compressed Air Challenge Sponsors Introduce New Training Workshop
Optimum Compressed Air System Performance at Solutia Plant
Implementing a Compressed Air System Leak Management Program at an Automotive Plant
(Download Acrobat Reader)
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Commercial Technologies
