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In 2005 alone, the United States produced an estimated 9 million barrels of crude oil per
day and imported 13.21 million barrels per day from other countries. This oil gets
refined into gasoline, kerosene, heating oil and other products. To keep up with our
consumption, oil companies must constantly look for new sources of petroleum, as well
as improve the production of existing wells.
How does a company go about finding oil and pumping it from the ground? You may
have seen images of black crude oil gushing out of the ground, or seen an oil well in
movies and television shows like "Giant," "Oklahoma Crude," "Armageddon" and
"Beverly Hillbillies." But modern oil production is quite different from the way it's
portrayed in the movies.
In this article, we will examine how modern oil exploration and drilling works. We will
discuss how oil is formed, found and extracted from the ground.
Oil is a fossil fuel that can be found in many countries around the world. In this
section, we will discuss how oil is formed and how geologists find it.
Forming Oil
Oil is formed from the remains of tiny plants and animals (plankton) that died in
ancient seas between 10 million and 600 million years ago. After the organisms died,
they sank into the sand and mud at the bottom of the sea.
Folding - Horizontal movements press inward and move the rock layers upward
into a fold or anticline.
Faulting - The layers of rock crack, and one side shifts upward or downward.
Pinching out - A layer of impermeable rock is squeezed upward into the reservoir
rock.
Locating Oil
The task of finding oil is assigned to geologists, whether employed directly by an oil
company or under contract from a private firm. Their task is to find the right conditions
for an oil trap -- the right source rock, reservoir rock and entrapment. Many years ago,
geologists interpreted surface features, surface rock and soil types, and perhaps some
small core samples obtained by shallow drilling. Modern oil geologists also examine
surface rocks and terrain, with the additional help of satellite images. However, they
also use a variety of other methods to find oil. They can use sensitive gravity meters
to measure tiny changes in the Earth's gravitational field that could indicate flowing oil,
as well as sensitive magnetometers to measure tiny changes in the Earth's magnetic
field caused by flowing oil. They can detect the smell of hydrocarbons using sensitive
electronic noses called sniffers. Finally, and most commonly, they use seismology,
creating shock waves that pass through hidden rock layers and interpreting the waves
that are reflected back to the surface.
Compressed-air gun - shoots pulses of air into the water (for exploration over
water)
Thumper truck - slams heavy plates into the ground (for exploration over land)
Explosives - drilled into the ground (for exploration over land) or thrown
overboard (for exploration over water), and detonated
The shock waves travel beneath the surface of the Earth and are reflected back by the
various rock layers. The reflections travel at different speeds depending upon the type
or density of rock layers through which they must pass. The reflections of the shock
waves are detected by sensitive microphones or vibration detectors -- hydrophones
over water, seismometers over land. The readings are interpreted by seismologists
for signs of oil and gas traps.
Although modern oil-exploration methods are better than previous ones, they still may
have only a 10-percent success rate for finding new oil fields. Once a prospective oil
strike is found, the location is marked by GPS coordinates on land or by marker buoys
on water.
Once the site has been selected, it must be surveyed to determine its boundaries, and
environmental impact studies may be done. Lease agreements, titles and right-of way
accesses for the land must be obtained and evaluated legally. For off-shore sites, legal
jurisdiction must be determined.
Once the legal issues have been settled, the crew goes about preparing the land:
1. The land is cleared and leveled, and access roads may be built.
2. Because water is used in drilling, there must be a source of water nearby. If there
is no natural source, they drill a water well.
3. They dig a reserve pit, which is used to dispose of rock cuttings and drilling mud
during the drilling process, and line it with plastic to protect the environment. If
the site is an ecologically sensitive area, such as a marsh or wilderness, then the
cuttings and mud must be disposed offsite -- trucked away instead of placed in a
pit.
Once the land has been prepared, several holes must be dug to make way for the rig
and the main hole. A rectangular pit, called a cellar, is dug around the location of the
actual drilling hole. The cellar provides a work space around the hole, for the workers
and drilling accessories. The crew then begins drilling the main hole, often with a small
drill truck rather than the main rig. The first part of the hole is larger and shallower than
the main portion, and is lined with a large-diameter conductor pipe. Additional holes
are dug off to the side to temporarily store equipment -- when these holes are finished,
the rig equipment can be brought in and set up.
Depending upon the remoteness of the drill site and its access, equipment may be
transported to the site by truck, helicopter or barge. Some rigs are built on ships or
barges for work on inland water where there is no foundation to support a rig (as in
marshes or lakes).
In the next section, we'll look at the major systems of an oil rig.
Oil Rig Systems
Once the equipment is at the site, the rig is set up. Here are the major systems of a
land oil rig:
Power system
large diesel engines - burn diesel-fuel oil to provide the main source of
power
electrical generators - powered by the diesel engines to provide electrical
power
Mechanical system - driven by electric motors
hoisting system - used for lifting heavy loads; consists of a mechanical
winch (drawworks) with a large steel cable spool, a block-and-tackle pulley
and a receiving storage reel for the cable
turntable - part of the drilling apparatus
Rotating equipment - used for rotary drilling
swivel - large handle that holds the weight of the drill string; allows the
string to rotate and makes a pressure-tight seal on the hole
kelly - four- or six-sided pipe that transfers rotary motion to the turntable
and drill string
turntable or rotary table - drives the rotating motion using power from
electric motors
drill string - consists of drill pipe (connected sections of about 30 ft / 10
m) and drill collars (larger diameter, heavier pipe that fits around the drill
pipe and places weight on the drill bit)
drill bit(s) - end of the drill that actually cuts up the rock; comes in many
shapes and materials (tungsten carbide steel, diamond) that are specialized
for various drilling tasks and rock formations
Casing - large-diameter concrete pipe that lines the drill hole, prevents the hole
from collapsing, and allows drilling mud to circulate
The crew sets up the rig and starts the drilling operations.
First, from the starter hole, they drill a surface hole down to a
pre-set depth, which is somewhere above where they think
the oil trap is located. There are five basic steps to drilling the
surface hole:
1. Place the drill bit, collar and drill pipe in the hole.
2. Attach the kelly and turntable and begin drilling.
3. As drilling progresses, circulate mud through the pipe
and out of the bit to float the rock cuttings out of the
hole.
4. Add new sections (joints) of drill pipes as the hole gets
deeper.
5. Remove (trip out) the drill pipe, collar and bit when the
Photo courtesy Phillips
pre-set depth (anywhere from a few hundred to a
Petroleum Co.
couple-thousand feet) is reached.
Rotary workers trip
drill pipe
Once they reach the pre-set depth, they must run and
cement the casing -- place casing-pipe sections into the hole to prevent it from
collapsing in on itself. The casing pipe has spacers around the outside to keep it
centered in the hole.
The casing crew puts the casing pipe in the hole. The cement crew pumps cement down
the casing pipe using a bottom plug, a cement slurry, a top plug and drill mud. The
pressure from the drill mud causes the cement slurry to move through the casing and fill
the space between the outside of the casing and the hole. Finally, the cement is allowed
to harden and then tested for such properties as hardness, alignment and a proper seal.
In the next section we'll find out what happens once the drill bit reaches the final depth.
Drilling continues in stages: They drill, then run and cement new casings, then drill
again. When the rock cuttings from the mud reveal the oil sand from the reservoir rock,
they may have reached the final depth. At this point, they remove the drilling apparatus
from the hole and perform several tests to confirm this finding:
Well logging - lowering electrical and gas sensors into the hole to take
measurements of the rock formations there
Drill-stem testing - lowering a device into the hole to measure the pressures,
which will reveal whether reservoir rock has been reached
Core samples - taking samples of rock to look for characteristics of reservoir rock
Once they have reached the final depth, the crew completes the Blowouts and Fires
well to allow oil to flow into the casing in a controlled manner. In the movies, you see
First, they lower a perforating gun into the well to the oil gushing (a
production depth. The gun has explosive charges to create blowout), and perhaps
holes in the casing through which oil can flow. After the casing even a fire, when
has been perforated, they run a small-diameter pipe (tubing) drillers reach the final
into the hole as a conduit for oil and gas to flow up the well. A depth. These are
device called a packer is run down the outside of the tubing. actually dangerous
When the packer is set at the production level, it is expanded to conditions, and are
form a seal around the outside of the tubing. Finally, they (hopefully) prevented
connect a multi-valved structure called a Christmas tree to by the blowout
the top of the tubing and cement it to the top of the casing. The preventer and the
Christmas tree allows them to control the flow of oil from the pressure of the drilling
well. mud. In most wells,
the oil flow must be
Once the well is completed, they must start the flow of oil into
started by acidizing or
the well. For limestone reservoir rock, acid is pumped down the
fracturing the well.
well and out the perforations. The acid dissolves channels in the
limestone that lead oil into the well. For sandstone reservoir rock, a specially blended
fluid containing proppants (sand, walnut shells, aluminum pellets) is pumped down the
well and out the perforations. The pressure from this fluid makes small fractures in the
sandstone that allow oil to flow into the well, while the proppants hold these fractures
open. Once the oil is flowing, the oil rig is removed from the site and production
equipment is set up to extract the oil from the well.
Extracting Oil
In the pump system, an electric motor drives a gear box that moves a lever. The
lever pushes and pulls a polishing rod up and down. The polishing rod is attached to a
sucker rod, which is attached to a pump. This system forces the pump up and down,
creating a suction that draws oil up through the well.
In some cases, the oil may be too heavy to flow. A second hole is then drilled into the
reservoir and steam is injected under pressure. The heat from the steam thins the oil in
the reservoir, and the pressure helps push it up the well. This process is called
enhanced oil recovery.
Photo courtesy California Department of
Conservation
Enhanced oil recovery
With all of this oil-drilling technology in use, and new methods in development, the
question remains: Will we have enough oil to meet our needs? Current estimates
suggest that we have enough oil for about 63 to 95 years to come, based on current
and future finds and present demands.
For more information on oil drilling and related topics, including oil refining, check out
the links on the next page.
How Oil Refining Works
In movies and television shows -- Giant, Oklahoma Crude, Armageddon, Beverly
Hillbillies -- we have seen images of thick, black crude oil gushing out of the ground or a
drilling platform.
But when you pump the gasoline for your car, you've probably noticed that it is clear.
And there are so many other products that come from oil, including crayons, plastics,
heating oil, jet fuel, kerosene, synthetic fibers and tires.
How is it possible to start with crude oil and end up with gasoline and all of these other
products?
In this article, we will examine the chemistry and technology involved in refining crude
oil to produce all of these different things.
Crude Oil
Carbon - 84%
Hydrogen - 14%
Sulfur - 1 to 3% (hydrogen sulfide, sulfides, disulfides,
elemental sulfur)
Nitrogen - less than 1% (basic compounds with amine
groups)
Oxygen - less than 1% (found in organic compounds
such as carbon dioxide, phenols, ketones, carboxylic
acids)
Metals - less than 1% (nickel, iron, vanadium, copper,
arsenic)
Salts - less than 1% (sodium chloride, magnesium
chloride, calcium chloride)
Crude oil is the term for "unprocessed" oil, the stuff that comes out of the ground. It is
also known as petroleum. Crude oil is a fossil fuel, meaning that it was made natural-
ly from decaying plants and animals living in ancient seas millions of years ago -- most
places you can find crude oil were once sea beds. Crude oils vary in color, from clear
to tar-black, and in viscosity, from water to almost solid.
Crude oils are such a useful starting point for so many different substances because
they contain hydrocarbons. Hydrocarbons are molecules that contain hydrogen and
carbon and come in various lengths and structures, from straight chains to branching
chains to rings.
Hydrocarbons contain a lot of energy. Many of the things derived from crude oil
like gasoline, diesel fuel, paraffin wax and so on take advantage of this energy.
Hydrocarbons can take on many different forms. The smallest hydrocarbon is
methane (CH4), which is a gas that is a lighter than air. Longer chains with 5 or
more carbons are liquids. Very long chains are solids like wax or tar. By chemically
cross-linking hydrocarbon chains you can get everything from synthetic rubber to
nylon to the plastic in tupperware. Hydrocarbon chains are very versatile!
Paraffins
general formula: CnH2n+2 (n is a whole number, usually from 1 to 20)
straight- or branched-chain molecules
can be gasses or liquids at room temperature depending upon the molecule
examples: methane, ethane, propane, butane, isobutane, pentane, hexane
Aromatics
general formula: C6H5 - Y (Y is a longer, straight molecule that connects to
the benzene ring)
ringed structures with one or more rings
rings contain six carbon atoms, with alternating double and single bonds
between the carbons
typically liquids
examples: benzene, napthalene
Napthenes or Cycloalkanes
general formula: CnH2n (n is a whole number usually from 1 to 20)
ringed structures with one or more rings
rings contain only single bonds between the carbon atoms
typically liquids at room temperature
examples: cyclohexane, methyl cyclopentane
Other hydrocarbons
Alkenes
general formula: CnH2n (n is a whole number, usually from 1 to 20)
linear or branched chain molecules containing one carbon-carbon
double-bond
can be liquid or gas
examples: ethylene, butene, isobutene
Dienes and Alkynes
general formula: CnH2n-2 (n is a whole number, usually from 1 to 20)
linear or branched chain molecules containing two carbon-carbon
double-bonds
can be liquid or gas
examples: acetylene, butadienes
To see examples of the structures of these types of hydrocarbons, see the OSHA
Technical Manual and this page on the Refining of Petroleum.
Now that we know what's in crude oil, let's see what we can make from it.
The problem with crude oil is that it contains hundreds of different types of
hydrocarbons all mixed together. You have to separate the different types of
hydrocarbons to have anything useful. Fortunately there is an easy way to separate
things, and this is what oil refining is all about.
Different hydrocarbon chain lengths all have progressively higher boiling points, so they
can all be separated by distillation. This is what happens in an oil refinery - in one part
of the process, crude oil is heated and the different chains are pulled out by their
vaporization temperatures. Each different chain length has a different property that
makes it useful in a different way.
To understand the diversity contained in crude oil, and to understand why refining crude
oil is so important in our society, look through the following list of products that come
from crude oil:
You may have noticed that all of these products have different sizes and boiling ranges.
Chemists take advantage of these properties when refining oil. Look at the next section
to find out the details of this fascinating process.
The Refining Process
As mentioned previously, a barrel of crude oil has a mixture of all sorts of hydrocarbons
in it. Oil refining separates everything into useful substances. Chemists use the following
steps:
1. The oldest and most common way to separate things into various components
(called fractions), is to do it using the differences in boiling temperature. This
process is called fractional distillation. You basically heat crude oil up, let it
vaporize and then condense the vapor.
2. Newer techniques use Chemical processing on some of the fractions to make
others, in a process called conversion. Chemical processing, for example, can
break longer chains into shorter ones. This allows a refinery to turn diesel fuel into
gasoline depending on the demand for gasoline.
3. Refineries must treat the fractions to remove impurities.
4. Refineries combine the various fractions (processed, unprocessed) into mixtures
to make desired products. For example, different mixtures of chains can create
gasolines with different octane ratings.
The products are stored on-site until they can be delivered to various markets such as
gas stations, airports and chemical plants. In addition to making the oil-based products,
refineries must also treat the wastes involved in the processes to minimize air and water
pollution.
In the next section, we will look at how we separate crude oil into its components.
Fractional Distillation
1. You heat the mixture of two or more substances (liquids) Photo courtesy Phillips
with different boiling points to a high temperature. Petroleum
Heating is usually done with high pressure steam to Distillation columns
temperatures of about 1112 degrees Fahrenheit / 600 in an oil refinery
degrees Celsius.
2. The mixture boils, forming vapor (gases); most substances go into the vapor
phase.
3. The vapor enters the bottom of a long column (fractional distillation column)
that is filled with trays or plates.
The trays have many holes or bubble caps (like a loosened cap on a soda
bottle) in them to allow the vapor to pass through.
The trays increase the contact time between the vapor and the liquids in the
column.
The trays help to collect liquids that form at various heights in the column.
There is a temperature difference across the column (hot at the bottom, cool
at the top).
4. The vapor rises in the column.
5. As the vapor rises through the trays in the column, it cools.
6. When a substance in the vapor reaches a height where the temperature of the
column is equal to that substance's boiling point, it will condense to form a liquid.
(The substance with the lowest boiling point will condense at the highest point in
the column; substances with higher boiling points will condense lower in the
column.).
7. The trays collect the various liquid fractions.
8. The collected liquid fractions may:
pass to condensers, which cool them further, and then go to storage tanks
go to other areas for further chemical processing
Very few of the components come out of the fractional distillation column ready for
market. Many of them must be chemically processed to make other fractions. For
example, only 40% of distilled crude oil is gasoline; however, gasoline is one of the
major products made by oil companies. Rather than continually distilling large quantities
of crude oil, oil companies chemically process some other fractions from the distillation
column to make gasoline; this processing increases the yield of gasoline from each
barrel of crude oil.
In the next section, we'll look at how we chemically process one fraction into another.
Chemical Processing
You can change one fraction into another by one of three methods:
Cracking
Cracking takes large hydrocarbons and breaks them into smaller ones.
Unification
Sometimes, you need to combine smaller hydrocarbons to make larger ones -- this
process is called unification. The major unification process is called catalytic
reforming and uses a catalyst (platinum, platinum-rhenium mix) to combine low weight
naphtha into aromatics, which are used in making chemicals and in blending gasoline. A
significant by-product of this reaction is hydrogen gas, which is then either used for
hydrocracking or sold.
Alteration
Sometimes, the structures of molecules in one fraction are rearranged to produce
another. Commonly, this is done using a process called alkylation. In alkylation, low
molecular weight compounds, such as propylene and butylene, are mixed in the
presence of a catalyst such as hydrofluoric acid or sulfuric acid (a by-product from
removing impurities from many oil products). The products of alkylation are high
octane hydrocarbons, which are used in gasoline blends to reduce knocking (see
"What does octane mean?" for details).
Rearranging chains.
Now that we have seen how various fractions are changed, we will discuss the how the
fractions are treated and blended to make commercial products.
An oil refinery is a combination of all of these units.
Distillated and chemically processed fractions are treated to remove impurities, such as
organic compounds containing sulfur, nitrogen, oxygen, water, dissolved metals and
inorganic salts. Treating is usually done by passing the fractions through the following:
After the fractions have been treated, they are cooled and
then blended together to make various products, such as:
The boiling points of organic compounds can give important clues to other physical
properties. A liquid boils when its vapor pressure is equal to the atmospheric pressure.
Vapor pressure is determined by the kinetic energy of molecules. Kinetic energy is
related to temperature and the mass and velocity of the molecules. When the
temperature reaches the boiling point, the average kinetic energy of the liquid particles
is sufficient to overcome the forces of attraction that hold molecules in the liquid state.
Then these molecules break away from the liquid forming the gas state.
Vapor pressure is caused by an equilibrium between molecules in the gaseous state and
molecules in the liquid state. When molecules in the liquid state have sufficient kinetic
energy, they may escape from the surface and turn into a gas. Molecules with the most
independence in individual motions achieve sufficient kinetic energy (velocities) to
escape at lower temperatures. The vapor pressure will be higher and therefore the
compound will boil at a lower temperature.
Molecules which strongly interact or bond with each other through a variety of
intermolecular forces can not move easily or rapidly and therefore, do not achieve the
kinetic energy necessary to escape the liquid state. Therefore, molecules with strong
intermolecular forces will have higher boiling points. This is a consequence of the
increased kinetic energy needed to break the intermolecular bonds so that individual
molecules may escape the liquid as gases.
A series of alkanes demonstrates the general principle that boiling points increase as
molecular weight or chain length increases (table 1.).
Normal State
Boiling Point
Formula Name at Room
C
Temp. +20 C
CH3CH3 Ethane - 89
CH3CH2CH3 Propane - 42
QUES. State whether the compounds above will be a gas or liquid state at room
temperature (20 C). Hint: If the boiling point is below 20 C, then the liquid has already
boiled andthe compound is a gas.
The reason that longer chain molecules have higher boiling points is that longer chain
molecules become wrapped around and enmeshed in each other much like the strands
of spaghetti. More energy is needed to separate them than short molecules which have
only weak forces of attraction for each other.
FOCUS ON FOSSIL FUELS
Petroleum refining is the process of separating the many compounds present in crude
petroleum. The principle which is used is that the longer the carbon chain, the higher
the temperature at which the compounds will boil. The crude petroleum is heated and
changed into a gas. The gases are passed through a distillation column which becomes
cooler as the height increases. When a compound in the gaseous state cools below its
boiling point, it condenses into a liquid. The liquids may be drawn off the distilling
column at various heights.
Although all fractions of petroleum find uses, the greatest demand is for gasoline. One
barrel of crude petroleum contains only 30-40% gasoline. Transportation demands
require that over 50% of the crude oil be converted into gasoline. To meet this demand
some petroleum fractions must be converted to gasoline. This may be done by
"cracking" - breaking down large molecules of heavy heating oil; "reforming" - changing
molecular structures of low quality gasoline molecules; or "polymerization" - forming
longer molecules from smaller ones.
For example if pentane is heated to about 500 C the covalent carbon-carbon bonds
begin to break during the cracking process. Many kinds of compounds including alkenes
are made during the cracking process. Alkenes are formed because there are not
enough hydrogens to saturate all bonding positions after the carbon-carbon bonds are
broken.
MOTORS AND DRIVES USED IN OIL REFINERIES.
CAT CRACKER:
A catalytic cracker, or "cat cracker," is the basic gasoline-making process in a
refinery. The cat cracker uses high temperatures, low pressure, and a catalyst to
create a chemical reaction that breaks heavy gas oil into smaller gasoline
molecules. With a cat cracker, more of each barrel of oil can be turned into
gasoline.
Corro duty- Used for the regenerator’s compressors and other severe duties.
IEEE841- Used for driving air at constant speed into the catalytic reactor and the
regenerator.
hazardous location motor- Used for pumps, fans, compressors, conveyors in a
cracking unit.
DISTILLER:
Distillation is a method of separating mixtures based on differences in their
volatilities in a boiling liquid mixture. Distillation is a unit operation, or a physical
separation process, and not a chemical reaction. It is used to separate crude oil
into more fractions for specific uses such as transport, power generation and
heating.
IEEE841, hazardous location.,AP1547- Used for the feed pumps, compressors
associated with the distillating tower and condenser.
WATER TREATMENT:
IEEE841, VHS,AP1547- Designed for use on propeller pumps and other
continuous-duty, and centrifugal loads.
REFORMER:
Catalytic reforming is a chemical process used to convert petroleum refinery
naphthas, typically having low octane ratings, into high-octane liquid products
called reformates which are components of high-octane gasoline (also known as
petrol).
IEEE841, hazardous location.,AP1547- to pump the liquid feed and pressurize it.
COKER:
A coker or coker unit is an oil refinery processing unit that converts the residual
oil from the vacuum distillation column or the atmospheric distillation column into
low molecular weight hydrocarbon gases, naphtha, light and heavy gas oils, and
petroleum coke. The process thermally cracks the long chain hydrocarbon
molecules in the residual oil feed into shorter chain molecules.
IEEE841, hazardous location.,AP1547 - to pump water to the decoking derricks
and condensers.
SULFUR RECOVERY:
The desulfurizing process, recovers elemental sulfur from gaseous hydrogen
sulfide.
Corro duty, IEEE841, hazardous location are the motors used in this unit.
COOLING FACILITY:
Cooling is the transfer of thermal energy via thermal radiation, heat conduction
or convection.
Corro duty, IEEE841- To drive the ID and FD fans.
ALKYLATION UNIT:
In a standard oil refinery process, isobutane is alkylated with low-molecular-
weight alkenes (primarily a mixture of propylene and butylene) in the presence of
a strong acid catalyst, either sulfuric acid or hydrofluoric acid. In an oil refinery it
is referred to as a sulfuric acid alkylation unit (SAAU) or a hydrofluoric alkylation
unit, (HFAU). The product is called alkylate and is composed of a mixture of high-
octane, branched-chain paraffinic hydrocarbons (mostly isopentane and
isooctane). Alkylate is a premium gasoline blending stock because it has
exceptional antiknock properties and is clean burning.
Corro duty, IEEE841, AP1547- to pump the products through the polymerization
unit.
HYDROGEN UNIT:
The function of hydrogen unit is the purification of the hydrocarbon stream from
sulfur and nitrogen hetero-atoms.
The products of this process are saturated hydrocarbons; depending on the
reaction conditions (temperature, pressure, catalyst activity) these products
range from ethane, LPG to heavier hydrocarbons comprising mostly of
isoparaffins.
AP1547, IEEE841, hazardous location- to pump the products through the
hydrogenation chamber.
The motors described above are the products of Emerson Motor Technologies. The
details of these motors are described below.
Description:
General Purpose Three Phase, Totally Enclosed Fan Cooled (TEFC)
CORRO-DUTY® Premium Efficient Motors
Product Features:
Class F Insulation, Class B Rise At Full Load
All Cast iron construction (steel frame & fan cover on 140 frame)
Corrosion resistant mill & chemical duty paint
Stainless steel nameplate (with CE Mark) & zinc plated hardware
Shaft slinger on pulley end for IP54 protection
Precision balance (< 0.08 in/sec vibration)
40C Ambient, NEMA
Regreasable bearings 180 frame & up, lifting provisions 180 frame & up
Double shielded bearings 140-360, open on 400-440
Oversized conduit box - 1 size larger than NEMA standard
Cast iron inner bearing cap (180 frame & larger)
Field convertible to F2 mounting 180 frame & larger
Condensation drains with plastic plugs
Conversion kits: C&D Flanges, Canopy Kits (except 320-360)
Applications: Designed for severe duty environments found in the process industries.
Description:
General Purpose, Three Phase, Totally Enclosed Fan Cooled
(TEFC), 841 Plus® Premium Efficient
Product Features:
Inverter Grade Insulation System(Meets NEMA MG-1 Part 31)
Class F Insulation, Class B Rise At Full Load (Sine Wave Power)
All cast iron construction (Steel mounting base on 140 frame)
Corrosion Resistant Mill & Chem Duty Paint (250 hour Salt Spray Test)
Stainless Steel Nameplate (with CE Mark) & Zinc Plated hardware
40C Ambient, NEMA Design B Performance (Sine Wave Power)
VBXX® Bearing Isolators by Inpro/Seal on both ends for IP55 Protection
Description:
General Purpose Three Phase, TEFC Explosionproof Standard &
Energy Efficient Single Label, CORRO-DUTY®
Product Features:
All cast iron construction (140 frame has steel base)
Corrosion resistant mill & chemical duty paint
Stainless steel nameplate & zinc plated hardware
Shaft slinger on pulley end for IP54 protection
Cast iron inner bearing caps (180 frame & larger)
40C Ambient, NEMA design B performance (4)
Regreasable bearings 180 frame & up, lifting provisions 180 frame & up
Sealed bearings 56-140, shielded 180-360, open 400-440 frames
Brass breather plug
Suitable for inverter use per policy statement in introduction, 2:1 CT
Class 1 (Group D), T2B Temperature Code
1.15 Service Factor On 60 Hertz Sinewave Power
Note (4): On 60 Hertz Sine Wave Power
Applications: Designed for pumps, fans, compressors, conveyors, and tools located in
hazardous locations as defined by Class and Group.
Emerson designed its Oil and Gas vertical motors for reliable outdoor use in all types of
weather on pipelines, onshore and offshore wells as well as in refineries and other
process industries. These motors are meticulously designed and built to the highest
quality standards utilizing premium materials to ensure reliability and long life.
EMERSON® Oil and Gas vertical motors are ideal for use on sine wave or inverter power
applications such as booster, transfer, secondary recovery supply, secondary recovery
injection, sump, slurry, fire and cooling tower pumps.
Description:
Vertical A.C. Motors
Hollow Shaft
High & Low Thrust
WPI, WPII, TEFC & Explosionproof Enclosures
Product Features:
Class F Insulation, Class B Rise At Full Load (Sine Wave Power)
1.15 Service Factor (Sine Wave Power)(typical) – for WPI & WPII enclosures
1.00 Service Factor (Sine Wave Power) – for TEFC & Explosionproof enclosures
Maximum 40°C Ambient, 3,300 Feet Altitude
NEMA®† Design “B” · 3 Phase 60 Hz
NRR = Non-Reverse Ratchet SRC = Self Release Coupling
Applications: Designed for use on turbine, mix flow, and propeller pumps
WPI enclosures are constructed to minimize the entrance of rain, snow and airborne
contaminants found in outdoor applications while providing optimal cooling to the thrust
bearing and electrical components.
WPII enclosures are constructed for hostile outdoor atmospheres. The WPII ventilation
circuit is arranged with a minimum of three abrupt changes in airflow direction of at
least 90° each. This results in an area of reduced velocity in the air intake that
provides protection against high velocity air, moisture and airborne particles reaching
the cooling passages of the motor. Emerson has approved its vertical WPII motors for
use in customer-defined Division 2 environments per the requirements of NEC article
500 and NFPA-70.
TEFC enclosures prevent the free exchange of air between the outside and inside of the
motor, but are not airtight. Each TEFC motor is cooled by a fan that is within the
machine, but external to the enclosing parts. Emerson has approved its vertical TEFC
motors for use in customer-defined Division 2 environments per the requirements of
NEC article 500 and NFPA-70. EMERSON® vertical TEFC motors are available up to 700
hp.
Explosionproof enclosures are built to contain explosions inside the motor casing as
well as to prevent ignition outside the motor by containing sparks, flashing and
explosions. EMERSON® vertical Hazardous Location motors are UL®† Recognized and
CSA®† Certified to meet UL Class 1 Group D. EMERSON® vertical Hazardous Location
motors are available up to 700 hp.
Description:
Vertical A.C. Motors
Solid Shaft
High & Low Thrust
WPI, WPII, TEFC & Explosionproof Enclosures
Product Features:
Class F Insulation, Class B Rise At Full Load (Sine Maximum 40°C Ambient,
Wave Power) 3,300 Feet Altitude
1.15 Service Factor (Sine Wave Power)(typical) – NEMA®† Design “B” · 3
for WPI & WPII enclosures Phase 60 Hz
1.00 Service Factor (Sine Wave Power) – for TEFC
& Explosionproof enclosures NRR = Non-Reverse Ratchet
Applications: Designed for use on turbine, mix flow, and propeller pumps
Description:
Vertical A.C. Motors
Solid Shaft
Medium Thrust
TEFC & Explosionproof Enclosures
Product Features:
Class F Insulation, Class B Rise at Full Load (Sine Wave Power)
1.00 Service Factor (Sine Wave Power)
Maximum 40°C Ambient, 3,300 Feet Altitud
NEMA® Design “B”
3 Phase 60 Hz
Description:
Emerson has the first motors specifically designed to the rigorous
API®† 547 Standard for severe-duty horizontal motors and the shortest delivery time
available.
Product Features: Fully meets the stringent API 547 electrical and mechanical
requirements that build in quality, reliability and longevity; 250-700 horsepower; totally
enclosed fan cooled enclosures; sleeve or anti-friction bearings.
Product Features:
Class F Insulation, Class B Rise At Full Load (4)
Cast Iron Frame & End Shields
Corrosion Resistant Mill & Chemical Duty Paint
Stainless Steel Nameplate & Zinc Plated Hardware
Insulife 5000 Insulation Treatment (2 Cycles Epoxy VPI)
Thermostats - One Per Phase
40°C Ambient, NEMA Design B Performance (4)
Applications: Designed for pulp & paper, mill & chemical and any other severe duty
environments found in the process industries.
Description:
General Purpose Three Phase TITAN® II WPI Ball Bearing
2300/4000 Volt Motors
Product Features:
Cast Iron & Fabricated Steel Construction
Insulife 5000 Insulation Treatment (2 Cycles Epoxy VPI)
Class F Insulation, 40°C Ambient
F1 Assembly Position (Extra Long Leads For F2 Factory Conversion)
Same Size 6200 or 6300 Series Ball Bearings
Qty-2 Accessory Conduit Boxes With Terminal Strips
3400 Cubic Inch Main conduit Box With Drip Lid
Single Phase 115V Space Heaters
Provisions For Bearing RTD’s, Dowel Pins & Vertical Jack Screws
Dual Stator RTD’s – 100 Ohm & 120 Ohm
Form Wound All Copper Windings
Applications: Designed for compressors, fans, blowers, pumps, and indoor or
relatively clean outdoor installations.
Description:
General Purpose Three Phase TITAN® II WPII Ball Bearing
2300/4000 Volt Motors
Product Features:
Cast Iron & Fabricated Steel Construction
Insulife 5000 Insulation Treatment (2 Cycles Epoxy VPI)
Class F Insulation, 40°C Ambient
F1 Assembly Position (Extra Long Leads For F2 Factory Conversion)
Same Size 6200 or 6300 Series Ball Bearings
Qty-2 Accessory Conduit Boxes With Terminal Strips
3400 Cubic Inch Main conduit Box With Drip Lid
Single Phase 115V Space Heaters
Provisions For Bearing RTD’s, Dowel Pins & Vertical Jack Screws
Dual Stator RTD’s – 100 Ohm & 120 Ohm
Provisions For Air Filters & Air Pressure Differential Switch
Form Wound All Copper Windings
Applications: Designed for compressors, fans, blowers, and pumps in wet corrosive
and contaminated environments found in heavy industries such as pulp & paper,
mining, petro-chemical, and municipal installations
Description:
Three Phase Modifiable Motors - Vertical Solid Shaft – “P” Base -
American Petroleum Institute (API) 610 Specification.
Applications: Commonly used for centrifugal pumps, turbines and mix flow on
pipelines as well as off-shore and on-shore rigs.
Description:
VARIDYNE® 2 variable speed drives is a new, rugged, yet simple
to setup, range of Sensorless Vector Drives developed by Emerson
Motor Technologies.
Product Features:
Open Loop Vector Control - Speed or Torque
Switching Frequency range: 3kHz - 18kHz -quiet motor operation
Built-in EMC filter
Output Frequency: 0-1500 Hz
Easy Setup - all parameters for basic usage on front panel
Program just ten parameters for 80% of applications
RS485, Modbus-RTU comm. port standard (RJ45 connector)
8 Preset Speeds
Dynamic Braking Transistor standard
Fan and Pump optimization with quadratic motor flux V/Hz
Wide range of options for easy system integration: Communication modules,
LogicStick for small PLC functionality, I/O options, SmartStick for configuration
cloning, and much more
Free configuration software on CD with each driveQuick installation with convenient
cable management
Applications: Ideal for Pumps, Blowers, Conveyors, Mixers, and much more.
Energy Efficiency Improvement and Cost Saving Opportunities for
Petroleum Refineries
Contents
1. Introduction
3. Energy Recovery
6. Process Heaters
7. Distillation
9. Equipments
1. Introduction
Uncertain energy prices in today’s marketplace negatively affect predictable earnings, which are a
concern, particularly for the publicly traded companies in the petroleum industry. Improving energy
efficiency reduces the bottom line of any refinery. For public and private companies alike, increasing
energy prices are driving up costs and decreasing their value added. Successful, cost-effective
investment into energy efficiency technologies and practices meets the challenge of maintaining the
output of a high quality product while reducing production costs. This is especially important, as
energy efficient technologies often include “additional” benefits , such as increasing the productivity of
the company.
Energy use is also a major source of emissions in the refinery industry, making energy efficiency
improvement an attractive opportunity to reduce emissions and operating costs. Energy efficiency
should be an important component of a company’s environmental strategy. End-of-pipe solutions can
be expensive and inefficient while energy efficiency can be an inexpensive opportunity to reduce
criteria and other pollutant emissions. Energy efficiency can be an efficient and effective strategy to
work towards the so-called “triple bottom line” that focuses on the social, economic, and
environmental aspects of a business. In short, energy efficiency investment is sound business
strategy in today's manufacturing environment.
In cracking the severity and in hydrotreating the treated feed may affect energy use. An average
severity is assumed for both factors. Furthermore, energy intensity assumptions are based on a
variety of sources, and balanced on the basis of available data. The different literature sources
provide varying assumptions for some processes, especially for electricity consumption.
Although the vast majority of greenhouse gas (GHG) emissions in the petroleum fuel cycle occur at
the final consumer of the petroleum products, refineries are still a substantial source of GHG
emissions. The high energy consumption in refineries also leads to substantial GHG emissions. This
Energy Guide focuses on CO2 emissions due to the combustion of fossil fuels, although process
emissions of methane and other GHGs may occur at refineries. The estimate in this Energy Guide is
based on the fuel consumption as reported in the Petroleum Supply Annual of the Energy Information.
3. Energy Recovery
3.1 Flare Gas Recovery:
Flare gas recovery (or zero flaring) is a strategy evolving from the need to improve environmental
performance. Conventional flaring practice has been to operate at some flow greater than the
manufacturer’s minimum flow rate to avoid damage to the flare. Typically, flared gas consists of
background flaring (including planned intermittent and planned continuous flaring) and ups et-
blowdown flaring. In offshore flaring, background flaring can be as much as 50% of all flared gases
(Miles, 2001). In refineries, background flaring will generally be less than 50%, depending on
practices in the individual refinery.
Emissions can be further reduced by improved process control equipment and new flaring technology.
Development of gas- recovery systems, development of new ignition systems with low-pilot-gas
consumption, or elimination of pilots altogether with the use of new ballistic ignition systems can
reduce the amount of flared gas considerably. Development and demonstration of new ignition
systems without a pilot may result in increased energy efficiency and reduced emissions.
Reduction of flaring can be achieved by improved recovery systems, including installing recovery
compressors and collection and storage tanks. This technology is commercially available. The refinery
will install new recovery compressors and storage tanks to reduce flaring. No specific costs were
available for the flare gas recovery project, as it is part of a large package of measures for the
refinery. The overall project has projected annual savings of $52 million and a payback period of 2
years.
4.1 Boilers
Boiler Feed Water Preparation: Depending on the quality of incoming water, the boiler feed water
(BFW) needs to be pre-treated to a varying degree. Various technologies may be used to clean the
water. A new technology is based on the use of membranes. In reverse osmosis (RO), the pre-filtered
water is pressed at increased pressure through a semi-permeable membrane. Reverse osmosis and
other membrane technologies are used more and more in water treatment (Marti n et al., 2000).
Membrane processes are very reliable, but need semi-annual cleaning and periodic re placement to
maintain performance.
Improved Process Control: Flue gas monitors are used to maintain optimum flame temperature, and
to monitor CO, oxygen and smoke. The oxygen content of the exhaust gas is a combination of excess
air (which is deliberately introduced to improve safety or reduce emissions) and air infiltration (air
leaking into the boiler). By combining an oxygen monitor with an intake airflow monitor, it is possible to
detect (small) leaks. Using a combination of CO and oxygen readings, it is possible to optimize the
fuel/air mixture for high flame temperature (and thus the best energy efficiency) and low emissions.
Reduce Flue Gas Quantities: Often, excessive flue gas results from leaks in the boiler and the flue,
reducing the heat transferred to the steam, and increasing pumping requirements. These leaks are
often easily repaired. The savings from this measure and from flue gas monitoring are not cumulative,
as they both address the same losses. Reduce Excess Air. The more air is used to burn the fuel, the
more heat is wasted in heating air. Air slightly in excess of the ideal stoichometric fuel/air ratio is
required for safety, and to reduce NOx emissions, and is dependent on the type of fuel.
Improve Insulation: New materials insulate better, and have a lower heat capacity. Savings of 6-26%
can be achieved if this improved in sulation is combined with improved heater circuit controls. This
improved control is required to maintain the output temperature range of the old firebrick system. As a
result of the ceramic fiber’s lower heat capacity, the output temperature is more vulnerable to
temperature fluctuations in the heating elements. The shell losses of a well-maintain ed boiler should
be less than 1%.
Maintenance: A simple maintenance program to ensure that all components of the boiler are
operating at peak performance can result in substantial savings. In the absence of a good
maintenance system, the burners and condensate return systems can wear or get out of adjustment.
These factors can end up costing a steam system up to 20-30% of initial efficiency over 2-3 years. On
average, the possible energy savings are estimated at 10%. Improved maintenance may also reduce
the emission of criteria air pollutants.
Recover Heat From Flue Gas: Heat from flue gasses can be used to preheat boiler feed water in an
economizer. While this measure is fairly common in large boilers, there is often still potential for more
heat recovery. The limiting factor for flue gas heat recovery is the economizer wall temperature that
should not drop below the dew point of acids in the flue 38 gas. Traditionally this is done by keeping
the flue gases at a temperature significantly above the acid dew point. However, the economizer wall
temperature is more dependent on the feed water temperature than flue gas temperature because of
the high heat transfer coefficient of water. As a result, it makes more sense to preheat the feed water
to close to the acid dew point before it enters the economizer. This allows the economizer to be
designed so that the flue gas exiting the economizer is just barely above the acid dew point. One
percent of fuel use is saved for every 25 °C reduction in exhaust gas temperature.
Recover Steam From Blowdown: When the water is blown from the high-pressure boiler tank, the
pressure reduction often produces substantial amounts of steam. This steam is low grade, but can be
used for space heating and feed water preheating. For larger high-pressure boilers, the losses may be
less than 0.5%. It is estimated that this measure can save 1.3% of boiler fuel use for all boilers below
100 MMBtu/h r (approximately 5% of all boiler capacity in refineries).
Reduce Standby Losses: In refineries often one or more boilers are kept on standby in case of
failure of the operating boiler. The steam production at standby can be reduced to virtually zero by
modifying the burner, combustion air supply and boiler feedwater supply. By installing an automatic
control system the boiler can reach full capacity within 12 minutes. Installing the control system and
modifying the boiler can result in energy savings up to 85% of the standby boiler, depending on the
use pattern of the boiler.
Improve Steam Traps: Using modern thermostatic elements, steam traps can reduce energy use
while improving reliability. The main advantages offered by these traps are that they open when the
temperature is very close to that of the saturated steam (within 2 °C), purge non-condensable gases
after each opening, and are open on startup to allow a fast steam system warm-up. These traps are
also very reliable, and useable for a wide variety of steam pressures. Energy savings will vary
depending on the steam traps installed and state of maintenance.
Maintain Steam Traps: A simple program of checking steam traps to ensure that they operate
properly can save significant amounts of energy. If the steam traps are not regularly monitored, 15-
20% of the traps can be malfunctioning. In some plants, as many as 40% of the steam traps were
malfunctioning. Energy savings for a regular system of steam trap
Monitor Steam Traps Automatically: Attaching automated monitors to steam traps in conjunction
with a maintenance program can save even more energy, without significant added cost. This system
is an improvement over steam trap maintenance alone, because it gives quicker notice of steam trap
malfunctioning or failure. Using automatic monitoring is estimated to save an additional 5% over
steam trap maintenance.
Repair Leaks:. As with steam traps, the distribution pipes themselves often have leaks that go
unnoticed without a program of regular inspection and maintenance. In addition to saving up to 3% of
energy costs for steam production, having such a program can reduce the likelihood of having to
repair major leaks.
Recover Flash Steam: When a steam trap purges condensate from a pressurized steam distribution
system to ambient pressure, flash steam is produced. This steam can be used for space heating or
feed water preheating. The potential for this measure is extremely site dependent, as it is unlikely that
a producer will want to build an entirely new system of pipes to transport this low-grade st eam to
places where it can be used, unless it can be used close to the steam traps. Hence, the savings are
strongly site dependent. Many sites will use multi-pressure steam systems. In this case, flash steam
formed from high-pressure condensate can be routed to reduced pressure systems.
Return Condensate: Reusing the hot condensate in the boiler saves energy and reduces the need
for treated boiler feed water. The substantial savings in energy costs and purchased chemicals costs
makes building a return piping system attractive.
6. Process Heaters
Over 60% of all fuel used in the refinery is used in furnaces and boilers. The average thermal
efficiency of furnaces is estimated at 75-90%. Accounting for unavoidable heat losses and dewpoint
considerations, the theoretical maximum efficiency is around 92% (HHV). This suggests that on
average a 10% improvement in energy efficiency can be achieved in furnace and burner design.
6.1 Maintenance
Regular maintenance of burners, draft control and heat exchangers is essential to maintain safe and
energy efficient operation of a process heater.
7. Distillation
Distillation is one of the most energy intensive operations in the petroleum refinery. Distillation is used
throughout the refinery to separate process products, either from the CDU/VDU or from conversion
processes. The incoming flow is heated, after which the products are separated on the basis of boiling
points. Heat is provided by process heaters and/or by steam. Energy efficiency opportunities exist in
the heating side and by optimizi ng the distillation column.
9. Equipments
9.1 Motors
Electric motors are used throughout the refinery, and represent over 80% of all electricity use in the
refinery. The major applications are pumps (60% of all motor use), air compressors (15% of all motor
use), fans (9%), and other applications.
9.2 Pumps
In the petroleum refining industry, about 59% of all electricity use in motors is for pumps. This equals
48 % of the total electrical energy in refineries, making pumps the single largest electricity user in a
refinery. Pumps are used throughout the entire plant to generate a pressure and move liquids. Studies
have shown that over 20% of the energy consumed by these systems could be saved through
equipment or control system changes.
9.3 Compressors and Compressed Air
Compressors consume about 12% of total electricity use in refineries, or an estimated 5,800 GWh.
The major energy users are compressors for furnace combustion air and gas streams in the refinery.
Large compressors can be driven by electric motors, steam turbines, or gas turbines. A relatively
small part of energy consumption of compressors in refineries is used to generate compressed air.
Compressed air is probably the most expensive form of energy available in an industrial plant
because of its poor efficiency. Typically, efficiency from start to end-use is around 10% for
compressed air systems. In addition, the annual energy cost required to operate compressed air
systems is greater than their initial cost. Because of this inefficiency and the sizeable operating costs,
if compressed air is used, it should be of minimum quantity for the shortest possible time, constantly
monitored and reweighed against alternatives. Because of its limited use in a refinery (but still an
inefficient source of energy), the main compressed ai r measures found in other industries are
highlighted. Many opportunities to reduce energy in compressed air systems are not prohibitively
expensive.
9.4 Fans
Fans are used in boilers, furnaces, cooling towers, and many other applications. As in other motor
applications, considerable opportunities exist to upgrade the performance and improve the energy
efficiency of fan systems. Efficiencies of fan systems vary considerably across impeller types.
However, the cost-effectiveness of energy efficiency opportunities depends strongly on the
characteristics of the individual system.
9.5 Lighting
Lighting and other utilities represent less than 3% of electricity use in refineries. Still, potential energy
efficiency improvement measures exist, and may contribute to an overall energy management
strategy.
Reference:
Petrochemical Petrochemical
Refineries & Industries Refineries & Industries
Case History:
Two U.S. west coast refineries had similar expansion projects
at the same time. One plant used pure oil mist to lubricate their
motors and the other did not. During 3 1/2 years of operation, motor
bearing failure rate was about 90% lower at the plant using oil mist.
Proper Application:
Thousands of motors are currently being lubricated with pure oil mist as shown in the above illustration. Horizontal motors
with a NEMA 254 frame size (15 HP) and larger with ball bearings that have re-greaseable construction will benefit from
pure oil mist. Vertical motors with a NEMA 180 frame size (3 HP) and larger with ball bearings that have re-greaseable
construction will benefit from pure oil mist. The one location where oil mist is not applicable is for motors that must
meet the requirements of NFPA Class 1 Division 1 (Explosion Proof). Electric motors are normally used as drivers for
centrifugal pumps and when pumps are being lubricated from an oil mist system, it can be easily extended to the motors.
The same lubricant that lubricates the pumps is compatible with motors. The grease should be removed from the bearings
to facilitate flow through of the oil mist. A small amount of the oil mist will enter the interior of the motor after lubricating the
bearings; therefore a case drain must be installed in addition to the bearing bracket drains to prevent pooling of the oil.
The lubricant is not detrimental to the internal parts of the motor, however the lead wires should be sealed in the terminal
box.
The Solution:
Eliminate the manual task of lubricating motors by automating the process. New motors that are required for pure oil mist
shall be ordered “For oil mist lubrication” as supplied by the OEM. Motors that are ordered as “Provisions for oil mist
lubrication” will be shipped with the bearings packed with grease that has to be removed prior to connecting to an oil mist
system. LSC technicians can extend the existing system to serve the motor bearings or LSC can provide a stand-alone
mist system with a set of engineering instructions to allow your technicians to carry out the installation.
DRAFT
February 2000
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1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Challenges on the Horizon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Industry’s Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 Environmental Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Current Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Future Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Performance Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical and Institutional Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Research and Development Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2YHUYLHZ
Challenges on the Horizon
Petroleum is the single largest source of energy for United States. On average, every
citizen in the U.S. consumes about 20 pounds of petroleum per day. Petroleum is
critical to the U.S. economy and quality of life, providing fuels for transportation, heating
and industrial uses. Petroleum is the primary source of raw materials for the chemical
industry, which relies on petrochemicals to produce a myriad of consumer goods, from
paints to plastics. In 1996 the refining industry had over 90,000 employees, and nearly
2 million people were employed in service stations. Revenues from refining and refined
products represent a significant contribution to the U.S. gross domestic product.
In the 21st century, the petroleum industry must prepare to address many important
challenges. Major forces for change include: continuing concern for the environment;
governmental regulation and policy; higher consumer expectations for fuels and fuel
delivery systems; and global competition. In many
cases, technology research and development will be
Key Drivers Affecting the Industry
needed to meet these challenges and maintain the
{ Environmental regulations health and profitability of the industry.
{ Increasing cleanliness of fuels
{ Globalization
{ Increasing yields from crudes of decreasing The life-cycle effect of petroleum fuels on the
quality
{ environment continues to be a cause for concern. The
Uncertainty about future consumer fuels of choice
{ Pressure to reduce emissions of CO2 industry is unique in that both the processes used to
{ Attaining adequate profit margins
{ Proactively dealing with public scrutiny, refine petroleum as well as the products generated
environment, global warming and other issues (e.g., fuels) are subject to government regulation. The
combination of regulations to reformulate fuels and
reduce emissions from refinery operations make
petroleum refining one of the most heavily regulated industries in the United States. As
cash flows are diverted to ensure compliance with regulation, the direction of
technological development, as well as profitability, is often impacted.
Consumers also have a tremendous influence on markets and demand for petroleum
products. Increasingly, consumers are demanding fuels that are safe, less polluting,
inexpensive, and provide high performance. They also desire means of fuel delivery
that are quick, convenient, and environmentally sound. Advances in technology may be
needed to ensure fuels as well as fuel delivery systems meet consumer expectations.
Global competition and low profit margins have led to joint ventures, mergers, and
restructuring throughout the industry. The number of refineries has declined
dramatically since the 1980s, with those remaining operating at higher capacity and with
greater efficiency. Refineries have had to deal with the economic impacts of changing
crude prices, crude quality variability, and low marketing and transport margins, while
meeting increased demand for refined products. The industry must continue to find
Industry Response
Technology Vision 2020 describes the role of the industry in today’s economy, identifies
major goals for the future, and outlines broad technology needs. To support some of the
pre-competitive R&D needed to meet future industry goals, the vision advocates
cooperation among the petroleum industry, the U.S. Department of Energy, the national
laboratories, and academia. Government-industry collaboration and effective use of the
scientific capabilities of the national laboratory system can leverage scarce funds for
research and help to ensure that technology advances are identified and made.
The driving force behind the vision is API’s Technology Committee, which is charged
with identifying the technical areas of greatest concern to the industry and developing a
technology roadmap to address those concerns. In 1999, API took a major step to
better define research needs through a technology roadmap workshop held in Chicago,
Illinois [API 1999b]. Attendees included participants from six major oil companies, API,
and NPRA, along with representatives from the national laboratories, academia, and
consulting firms serving the industry. The dialog at this workshop provided insights on
the characteristics of the ideal refinery, attainable goals, barriers to overcome, and
priority research areas.
The results of the workshop, along with Technology Vision 2020, provide the foundation
for this technology roadmap. The goals and research priorities outlined in the roadmap
will form the basis for making new research investments by government and industry.
Hopefully it will stimulate new government-industry partnerships that will further serve to
strengthen the industry, while providing benefits to the nation in terms of energy
efficiency and environmental performance.
The technology roadmap is a dynamic working document for the API Technology
Committee. Expectations are that it will be re-evaluated periodically to ensure that
research priorities remain relevant to the needs of both the petroleum industry and its
customers.
The vision of the industry for the future is summarized as follows [API 1999a, API
1999b]:
With this vision in mind, the industry has come together to outline specific goals and the
technology research that will be needed to work toward the objectives described above.
The technology roadmap which follows is a summary of those efforts.
Energy consumption in the refinery is dominated by a few processes which are not
necessarily the most energy-intensive, but have the greatest throughput. For example,
atmospheric and vacuum distillation account for 35-40 percent of total process energy
consumed in the refinery, primarily because every barrel of crude must be subjected to
an initial separation by distillation. Another example is hydrotreating, which is used to
remove sulfur, nitrogen, and metal contaminants from feeds and products and accounts
for about 19 percent of energy consumption. Many refinery streams must be
hydrotreated prior to entering downstream refining units to reduce sulfur and catalyst
poisoning and achieve the before and after desired product quality [DOE 1998].
Over the last twenty years the industry has reduced its energy consumption (Btu/barrel
of crude) by nearly 30 percent. This has been accomplished through conservation
measures, consolidation of capacity, shut downs of older, smaller, inefficient facilities,
and continued improvements in technology. Substantial technological progress has
been made, for example, in development of catalysts (e.g., multi-functional catalytic
cracking catalysts) which have greater intrinsic activity, higher yields, and more
tolerance to poisoning – all of which impact the energy required for processing.
Refineries have also made increasing use of practices that improve overall energy
efficiency, such as plant heat integration, recovery of waste heat, and implementation of
improved housekeeping and maintenance programs. These activities continue to result
in incremental improvements in energy efficiency throughout the U.S. refinery system.
In recent years, energy intensity has
remained relatively constant.
However, the cost of energy for
Figure 2. Relative Energy Use of heat and power still accounts for as
Major Refinery Processes much as 40 percent of operating
costs in the refinery. When faced
with high environmental costs and
Coking
low margins, refiners will
Catalytic
Hydrotreating increasingly look to improvements
in energy efficiency to lower costs
Alkylation
and increase profitability. Advances
Catalytic Reforming in technology will remain a viable
option for improving the way energy
Fluid Catalytic Cracking
is used, particularly for very energy-
Vacuum Distillation intensive processes.
Atmospheric
In the distribution, delivery and
Distillation
retail end of the industry, energy
0 200 400 600 800 is consumed in the form of fuels
~Annual Energy Use (Trillion Btu) for transportation of refined products
and in power used for heating and
lighting facilities. Improvements to this consumption can potentially come from engines
and vehicles with better mile/gallon performance; and improvements in retail station
construction, sizing, supply logistics, and lighting.
To strive for the ideal refinery in 2020, the industry has identified broad performance
targets for energy efficiency and process improvement. There are two central themes
underlying these goals: (1) to identify, develop and implement entirely new technology
and practices to replace currently used inefficient, energy-intensive technology, and (2)
to improve the energy efficiency of existing technology and practices, where possible.
Energy benefits can also be achieved by improving process yields (the percent of
product obtained from the feedstock). The objective is to obtain more product and less
byproduct or waste than is currently obtained, using the same or less process energy.
Potential routes for improving yields are new, more selective catalysts, better chemical
pathways for conversion of hydrocarbons, and the use of bioprocessing.
Technical Barriers
In refineries, an imposing barrier to improving energy efficiency is the intrinsic
inefficiency of refining processes. For example, during the refining of crude fractions,
hydrogen is repeatedly added and removed. Cracking and coking processes, which
break large, heavy hydrocarbons into smaller molecules, require the input of hydrogen.
Other processes, such as catalytic reforming, produce hydrogen along with aromatic
hydrocarbons. If hydrogen is not generated in sufficient quantity as a byproduct of
processing, then it must be produced independently, at a high energy cost.
Technical barriers that limit process improvement fall into several key categories –
process engineering, sensing and measurement, and process modeling. An imposing
barrier to implementing better processes is that there are simply not enough alternatives
to the conventional way of refining crude. Alternatives are needed, for example, to
replace processes requiring severe operating conditions (e.g., very high temperatures
and pressures, cryogenics, acid catalysts). Processes operating at ambient conditions,
such as bioprocesses, could be candidates but are currently not well-developed.
Increase fuel
conversion efficiency
through research on at
least 2 alternative
technologies that utilize
waste streams.
Table 1. High Priority R&D Topics for Energy Efficiency and Process Improvement
Likelihood of
Importance to Energy Savings Short Term Potential
Topic Industry Potential Success Competitive Issue
Apply data to
modeling techniques Develop capability
Develop measurement for computational
technology to obtain to allow prediction of
yield, composition, catalyst design.
process data to support
new models. and property data,
and tie results into
process control and Develop >5 new
Increase knowledge of monitoring. chemical catalysts for
fundamental relationships low-temperature
between structure and environments.
properties, particularly in
mixtures. Develop improved
catalysts for deep Increase catalyst life
diesel desulfurization. by 2-fold through new
sulfur and nitrogen-
tolerant catalysts.
Other priority research areas that impact energy use include the need to improve fuel
conversion efficiency, and development of more effective, alternative separation
processes to distillation. Fuel conversion efficiency could be improved through the
development of technologies that use waste streams as fuel, such as fuel cells that use
propane or fuel gas, or new concepts such as pulse combustion fuel cells. Membranes
that are capable of efficiently separating hydrocarbons are needed, as well as entirely
new, low-energy alternatives to distillation that go beyond membranes.
In process improvement, the most important research area is developing the capability
for real-time process measurements. A primary objective is the capability to rapidly,
precisely, and accurately obtain information on the composition of feeds and products,
and be able to interpret this information for use in process optimization. This will require
the development of on-line, real-time chemical composition analyzers that can performin
refinery operating environments. To support this capability, research is needed to
devise measurement
technologies that will obtain
Generate
the data needed for
Real-Time Process
Measurements Data for computational methods for
Models
process design as well as
control. Data obtained
Structure-Property through real-time measure-
Modeling Tools
Relationships ments can be used to develop
on-line intelligent processing
Supported Ideal Refinery systems, which have been
Characteristics: identified as a high priority.
• Fully Automated Data will also support the
• Intelligent Controls INTELLIGENT REAL-
• Well-Understood Processes TIME PROCESSING
development of automated
• Increased Safety & Reliability modeling mechanisms and
• Maximized Use of Energy
predictive modeling
techniques, which can provide
Figure 5. R&D Links for Intelligent Real-Time Processing a means to capture knowledge
gained from operating
experience and apply it to process optimization, design and control. Research to better
understand the fundamental relationships between structure and properties, particularly
in mixtures, will be needed to support both model design and interpretation. Figure 5
illustrates the critical links between R&D in these areas.
Robust biocatalysts that can operate in severe refining environments are a high priority.
Research is needed to overcome the sensitivities inherent in the current generation of
biocatalysts, and to increase the reaction rates and selectivity of biocatalysts. Particular
areas of interest include the conversion and upgrading of hydrocarbon streams, and
removal of heteroatoms (e.g., nitrogen, sulfur). Research is needed to study the
biological mechanisms of these catalysts with regard to selectivity and activity for
specific reactions. Methods for controlling the activity and selectivity of biocatalysts are
also needed (e.g., directed evolution, bioenergetics).
Leap-frog technology is
Supported Ideal Refinery
Characteristics:
needed to reduce the large
MILD
PROCESSING
CONDITIONS
• Maximized Use of Energy amount of energy used in
• Zero Emissions
• Increased Safety and Reliabilty distillation throughout the
refinery complex. Alternative
Catalysts for Low
Real-Tim e
Better Sulfur separation technologies may
Measurm ents of Alternative Robust Temperature
Temperature Reduction
Separations Biocatalysts Controls
Environm ents Com position and
Temperature
Technology be one answer (e.g.,
membranes, reactive
New Materials New Separations
Robust Biocatalysts
New Catalysts
Better Selectivity
Low Emissions
distillation). Another route is
Process Models Diverse Feedstocks
Com putational Chemistry bypassing the initial distillation
of crude altogether through
Figure 6. R&D Leading to Mild Processing Conditions revolutionary new pathways,
such as thermal cracking.
Other possibilities include processes that convert gases directly to liquid fuels, or that
clean and upgrade the crude in the field, before it enters the refinery.
Many of the technologies and research areas discussed above will support processing
of hydrocarbons under milder conditions (temperatures, pressures, less corrosive) than
is currently possible. Operation at less severe conditions will lead to lower energy
consumption, reduced emissions, and improved safety and reliability (see Figure 6).
Both hazardous and non-hazardous wastes and other residuals are produced, recycled,
treated, and disposed of during refinery operations. The method of disposal of these
residuals depends upon the nature of the residual and applicable regulations. Residuals
are generated from many refining processes,
from the handling of the petroleum products
Volatile Organic through wastewater treatment. Overall,
Particulates
Compounds refineries recycle about 54 percent of the
557 MMlbs
(VOCs) 18 MMlbs
residuals produced, according to 1995 data.
Carbon
Further, the trend towards increased recycling
Monoxide (CO)
313 MMlbs Sulfur continued in 1996, with about 60 percent
Oxides recycling of residuals [API 1997c].
(SOx) 2001
Nitrogen
MMlbs
Oxides Petroleum refining and the use of refined
(NOx) 1063 products are impacted by a number of
MMlbs
environmental laws and regulations. Some of
the most significant statutes are those that focus
Figure 5. Estimated Air Emissions from on altering the formulation of products (mostly
Combustion of Fuels in Refineries, 1996 fuels) to reduce air emissions generated by their
use. These often require substantial changes in
The cost of controlling emissions to air, land and water is high. Petroleum refiners spent
about $5.5 billion in 1995 on environmental compliance [API 1997b]. About 40 percent
of this was for capital expenditures; the remainder was for
operation and maintenance of equipment for environmental
Residuals from Refineries (1995) control and abatement.
The industry has identified a number of broad targets for environmental performance
that are in line with the industry’s vision for 2020. Specific targets focus on reducing
emissions to air, land and water; using risk-based standards; and establishing a sound,
flexible approach for improving environmental performance.
By the end of the year 2000, the industry hopes to effectively establish quantitative
targets for reductions in emissions, wastes and wasterwaters, using a risk-based
approach. As risk-based quantitative targets are established, the industry can work
more definitively toward meeting specific goals. The goal is to establish a mutally
cooperative process to reduce emissions, rather than being driven by regulation. An
important part of this effort over the next decade will be continually improving the tools
by which risk-based evaluation is done. To evaluate progress, industry proposes to
publish a report in 2000 on environmental performance, and to report every 5 years
thereafter, including incremental improvements.
Technical Barriers
Technical as well as institutional barriers impact how the petroleum industry addresses
environmental concerns. While some of these cannot be addressed by research,
technological advances may have a significant influence on whether they remain
barriers over the next two decades.
Current sensing capabilities place some limits on the ability to control and reduce air
emissions. Cost-effective reliable means for detecting leaks in pipes, valves, and
equipment in the refinery (e.g., those that give rise to fugitive emissions) are currently
not available. Effective sensing systems for such leaks could enable control and/or
elimination of many sources of fugitive emissions altogether.
Key challenges for control and reduction of wastewater are the costs involved in water
recycle, as well as dealing with the corrosion problems (e.g., salts) that may arise from
water reuse. Some wastewater streams represent very dilute solutions, which make it
very difficult and costly to separate undesirable constituents. Understanding of the
wastewater constituents in general, and their specific impacts on aquatic life, is limited.
As more is understood about the actual effects of wastewater constituents on
ecosystems, processes can be designed to cost-effectively reduce those impacts.
Institutional Barriers
The data, models, and processes currently supporting the development of regulations
inhibits the industry from taking a more effective approach to improvements in
environmental performance. A key barrier is that the models currently in use to
determine impacts and facilitate the regulatory process are inadequate and out-dated.
The result is models that produce results that exaggerate the impact of refineries.
Research and development can help overcome some of the most critical barriers to
achieving continuous improvements in environmental performance (see Figure 6).
Develop an agreed-upon method for risk assessment, emphasizing 3 key areas: 1) toxicity and
TOP exposure to humans, 2) uncertainties in extrapolation of data from animals to humans, and 3) new
approaches for current assessment tools with conservative assumptions.
Improve capability for remote sensing, with respect to at least 2 important environmental
performance areas: 1) fugitive emissions, and 2) site contamination/remediation.
Energy Likelihood of
Importance to Savings Short Term Potential
Topic Industry Potential Success Competitive Issue
Improved System for Leak Detection and Repair High Medium High Low
Improved systems for leak detection and repair are a critical area of research,
particularly to achieve goals for mitigation and control of volatile hydrocarbons and air
toxics. Remote sensing technology that is portable and cost-effective is most desirable.
Research should be conducted in concert with instrument vendors, universities and
government laboratories (NASA, DOE labs). One possible future technology is the use
of Vatellite techniques for detecting hydrocarbon releases remotely from space. An
increasing number of satellite systems, having the capability to obtain high resolution
spectral data over a wide range of wavelengths (“hyperspectral remote sensing”), are
expected to be launched into orbit in the near future. Recent airborne studies sponsored
by the Geosat Committee Inc., a consortium of petroleum companies and others who
use remote sensing, have demonstrated that these techniques can facilitate
environmental assessments of sites with hydrocarbon contamination. As these systems
become more widespread, information on hydrocarbon emissions from processing and
Many of the currently available inspection technologies are intrusive or destructive, and
must be used when equipment is in ‘shut-down’ mode, rather than providing on-line
information about equipment integrity. For example, traditional strength testing of
metals is destructive, and involves taking a sample and testing it to its point of failure.
To prevent catastrophic failures, inspection of equipment operating in high temperature
or corrosive environments (heat exchangers, storage tanks, reactor vessels) typically
requires shut down of the process on a regular basis. Abnormal operating conditions
such as equipment start-up and shut-down also tends to increase vulnerability. In the
absence of global inspection technologies, material evaluation often occurs locally. It is
therefore necessary for the operator to use good engineering judgement to identify the
most likely locations for material degradation. Failures also occur in places where
inspection is difficult to conduct (pipe supports, gaskets, under insulation).
Ideally, by 2020, refineries would be significantly safer, more energy efficient and more
reliable. Refineries would be highly instrumented to ensure structural integrity of
equipment, and would be monitored
using global, on-line non-invasive
Future Characteristics inspection techniques. These
{ Refineries are highly instrumented and controlled techniques would allow for
{ Global, on-line, non-invasive inspection is routine immediate detection of loss of
{ Immediate detection of loss of containment is
containment, and provide early
possible
{ Fouling of heat exchangers is essentially eliminated warnings for corrosion and potential
{ Inspection does not require people, and provides flaws in structural integrity.
complete knowledge of equipment condition
{ Downtime is minimized
Inspection would be conducted
{ Refineries approach incidents related to loss of automatically, without people, and
containment would provide complete knowledge
of equipment conditions at all times.
Performance Targets
The petroleum industry has identified a number of performance targets for inspection
and containment boundary integrity. An overall goal is to be recognized as one of the
top U.S. industries in the areas of safety and reliability, based on the Solomon Index. To
support this goal the industry will strive to achieve no significant containment boundary
releases and eliminate unplanned downtime and slow downs. While safety and energy
efficiency are the primary issues, the high cost of incidents as well as equipment
maintenance are also major factors. To address the issue of cost, the industry has
identified specific targets for reducing capital and operational losses as well as the costs
associated with inspection.
Technical Barriers
The inspection techniques that do exist are often destructive or intrusive, and
inadequate for on-line non-destructive evaluation of equipment integrity. Of particular
importance is the lack of self-sensing methods to monitor for corrosion and residual
stress. Sensing methods for inspection of metals at high temperatures and pressures
are also limited.
Research Needs
Research and development needed to overcome the major barriers to the development
and use of better inspection methods is shown in Figure 8. The highest priority research
need is the development of global, on-line inspection technology (see Table 3). Global
inspection technology offers a step-out opportunity from current methodologies for
assessing equipment integrity. Global implies that the inspection occurs at locations
remote from the probes. In contrast, conventional inspection methods limit their
examinations to the immediate vicinity of the probe. For example, with radiographic (RT)
methods, the inspection only occurs at the position of the film. With conventional
contact ultrasonics testing (UT), the inspection occurs under the probe or immediately
adjacent to it. When using penetrant testing (PT), the inspection only occurs where the
dye materials and developer have been applied.
Five critical research areas include ultrasonics for pressure vessels, corrosion under
insulation inspection, buried piping inspection, equipment fouling detection, and models
for placement of improved corrosion probes. Work is already on-going on some
advanced global piping inspection technologies, including long range guided wave
ultrasonics and electrical pulsing. Although test results show potential promise for these
technologies, additional development is still required for advancement to commercial
viability. Originally developed for piping inspection, it appears that these technologies
would be applicable for vessel inspection.
Global inspection methods for vessels are equally enticing as piping inspection
technologies. A global vessel inspection methodology would provide increased
confidence regarding the detection of localized corrosion. With this improved confidence
in the inspection, run lengths between maintenance turnarounds and manned vessel
entries can be increased. Maintenance turnarounds are usually scheduled in order to
make equipment available for inspection. Increased operating run lengths improves
energy efficiency by increasing utilization of employed capital equipment. The goal of
research in this area would be to deliver a prototype hardware/software system suitable
Reduce corrosion
Reliably quantify problems by
corrosion rates and developing a cheap,
materials deterioration easy method for
rates using limited data testing crude
sets. corrosivity.
Improve maintenance
HIGH procedures and failure
Develop smart
systems for
analysis for high
analysis of equip-
temperature equipment
ment inspection
through techniques for on-
data.
stream refractory
inspection.
Design non-contact
sensors and measurement
technologies for on-stream
inspection of welds.
Table 3. High Priority R&D Topics for Inspection and Containment Boundary Integrity
Production and use of transportation fuels have long been associated with concerns
about emissions and energy conservation. Historically, these concerns have been
addressed independently, rather than as part of an integrated system. For example,
emissions concerns have driven the establishment of tailpipe standards for heavy-duty
engines and light-duty motor vehicles. Energy concerns have been addressed by
government-mandated fuel economy standards for light-duty vehicles, and by consumer
demands for lower operating costs for heavy-duty vehicles.
In some cases, steps taken to address emissions concerns can exacerbate energy
concerns, and vice versa. For instance, the use of reformulated gasoline (RFG) to
reduce vehicle emissions can be detrimental to energy conservation due to increased
energy expended in producing and transporting the fuel, and reduced fuel economy that
results from its use. Similarly, lowering sulfur levels in gasoline and diesel fuel may
reduce tailpipe emissions, but at a cost of increased energy usage in producing these
fuels. Optimized strategies for dealing with emissions and energy concerns require
integrated approaches that consider complete life-cycle impacts of various fuel, engine,
and after-treatment systems.
There are also environmental concerns surrounding fuel delivery systems at the retail
level (i.e., at the gas pump), as well as potential environmental and safety impacts
during transportation of fuels from the refinery to the customer. To date these concerns
have been addressed through incremental improvements, such as better valves, or
pump handles that reduce or prevent releases of volatile hydrocarbons.
Petroleum products are expected to be a predominant fuel of choice for consumers well
into the next century. Their makeup is continually changing, however, to meet new
regulatory demands. Other factors influencing fuels include the decreasing quality of
available crude feedstocks, and the development of alternative non-petroleum
transportation fuels (electricity, biomass).
Future Characteristics
In the future, fuel delivery systems would be safer and easier to use. Retail fuel delivery
systems for gasoline and other transportation fuels would be entirely sealed, and totally
automated, requiring no human touch for delivery. Distribution systems would support a
broad variety of products as well as entirely new fuels.
Performance Targets
The industry has identified a number of performance targets to improve fuel delivery
systems and create the high performance, safe fuels desired by consumers. The
industry will strive to effectively balance
the need for cleaner products with
Performance Targets for Fuels & Fuel Delivery customer demands for high
{ Reduce emissions from mobile sources performance. An important component
{ Create products that are cleaner, satisfy customer will be taking steps to prevent the
needs, and meet performance requirements impacts to human health and the
{ Maintain product quality all the way to the customer
{ Reduce expenditures for product quality testing by 75% environment from fuel exposures and
combustion of fuels in vehicles.
Technical Barriers
There are a number of barriers to better fuel delivery and reduced vehicle emissions. In
general, there is no integrated, systems approach being taken to develop engine
technology with lower mobile source emissions. Further, the industry has little
knowledge in advance on how new or reformulated fuels are going to actually perform in
advanced technology vehicles (prototypes are not available for testing).
Sulfur tolerant catalysts or other sulfur-tolerant control technologies, which could reduce
emissions in vehicle exhaust/tailpipes, have not been successfully developed. Current
technology for control of nitrogen oxides and particulates from diesel-fueled vehicles is
also inadequate. Finally, emission controls now in place on vehicles have a tendency to
deteriorate.
Fuel delivery systems at service stations are not leak-proof, and contribute to emissions
of volatiles. The open systems currently in place are sometimes inadequate, and release
emissions during refueling of storage tanks.
Research and development needed to improve fuel delivery systems and reduce vehicle
emissions are shown in Figure 9. R&D is categorized as top and high priority, and
aligned by time frame for expected results. Arrows describe the main relationships
between research.
Figure 9. Research and Development Needs for Fuels and Fuel Delivery
Develop sulfur-tolerant
Develop a systems
TOP emission control systems
approach to
in diesel engines.
fuel/technology
interaction.
Test new versions of
reformulated fuels, very
low sulfur fuels to Develop >3 sulfur-
quantify emissions. tolerant catalysts.
Severe sulfur reduction from both gasoline and diesel fuel is generally regarded as
producing large emissions benefits -- but at a cost in terms of dollars and energy usage.
There is the potential to derive similar emissions benefits from fuels with higher sulfur
levels by:
Severe reduction of NOx emissions under lean conditions remains a major challenge.
Some promising technologies involve periodic or continuous injection of a chemical
reductant to transform NOx to N2. Often, this reductant is the hydrocarbon fuel itself,
thereby resulting in an obvious fuel economy penalty. Development of improved
reductants, or other NOx-control technologies, could lead to energy savings.
For improved fuel delivery systems, the ultimate objective is better systems that
minimize or eliminate leaks from the storage and delivery of fuels. The current delivery
process, from refinery to customer, should be evaluated to identify sources of emissions.
New equipment is needed that is leak-proof and easy to install, so that current systems
can be retrofitted.
Table 4. High Priority R&D Topics for Fuels and Fuel Delivery
Cooperative advantages
700
500
Trillion Btu annually
300
100
0
Coking Catalytic Alkylation Catalytic Fluid Catalytic Vacuum Atmospheric
Hydrotreating Reforming Cracking Distillation Distillation
2 Source: Energy and Environmental Profile of the U.S. Petroleum Industry, U.S. DOE, OIT Dec. 1998.
p Petroleum industry steers the way
In February 2000, petroleum industry leaders signed a
compact with the U.S. Department of Energy’s Office of
Industrial Technologies (OIT) to work together through
the Industries of the Future initiative. This initiative is
now paving the way for strategic joint development of
technologies by government, national laboratories, and Refiners Associations, has identified the technical areas
academia, and industry in alignment with the industry- of greatest concern to the industry and developed a technol-
defined vision, Technology Vision 2020. ogy roadmap to address them. The roadmapping process is
encouraging new government-industry partnerships that will
A key driving force behind the Petroleum Industry of the further strengthen the industry, while providing benefits to
Future is the American Petroleum Institute’s Technology the nation in terms of energy efficiency and environmental
Committee, which, along with the National Petrochemical performance.
A waste-heat ammonia absorption refrigeration unit refrigeration, invented in 1850, has been largely replaced
provides a Rocky Mountain refiner with a reduction in by compression refrigeration, a simpler system which is
regulated emissions, additional LPG and gasoline recovery, less capital-intensive and easier to operate. However, the
and a less than two-year payback. This advanced design ability to utilize free waste-heat allows absorption refrigera-
unit was integrated into an existing operation. It uses tion to gain the economic advantage over compression.
highly compact heat and mass transfer equipment along
with state-of-the-art materials. Waste-heat from the OIT partnered with national laboratories and private indus-
reformer is used to power the unit, which recovers try to demonstrate that ammonia absorption refrigeration
valuable products from the refinery waste fuel header. can effectively utilize refinery waste-heat to recover valu-
able resources. The technical and economic results of this
Ammonia absorption refrigeration is very useful for
project show that government-industry partnerships do
production of chilled fluids from waste-heat energy
provide valuable benefits to the industry and the nation.
and operates well at 250°F (121°C ) or lower. Absorption
3
High-priority research needs results
b
Based on industry-defined priorities and recommendations, OIT awards cost-
shared support to projects that will improve the industry’s energy efficiency
and global competitiveness. All awards are made on a 50 percent cost-shared
basis through a competitive solicitation process. Solicitations are open to col-
laborative teams with members from industry, academia, national laboratories,
and other sectors that have a stake in the future of the petroleum industry.
The petroleum industry has identified research priorities in the following areas:
Environmental performance
The impact of petroleum operations and products on the environment is a
major area of emphasis. Key research topics aimed at continuous improvement
in environmental performance include a method for risk analysis/assessment
and an improved system for leak detection and repair.
4
New separation technology for refining
Demonstrated success
OIT has worked with the petroleum industry in many capacities to develop, demonstrate, and deploy
energy-efficient and environmentally improved technologies. Selected emerging or commercially available
technologies applicable to the petroleum industry include:
• Waste Heat Process Chiller • Low-Profile Fluid Catalytic Converter (FCC)
• Force Internal Recirculation (FIR) Burner • Advanced Process Analysis for Refining
Micro Gas Chromatograph Controller PSA Product Recovery from Residuals Advanced Materials for Reducing Energy
Gasoline BioDesulfurization Process Refinery Process Heater System Laser Sensor for Refinery Operations
Enzyme Selectivity for Desulfurization Flame Image Analysis and Control Laser Ultrasonic Tube Coke Monitor
Catalytic Hydrogenation Retrofit Reactor Thermal Image Control for Combustion Mechanical Integrity Global Inspection
New Nanoscale Catalysts Based Carbides Rotary Burner Demonstration Gas Imaging for Leak Detection
Selective Catalytic Oxidative Dehydrogenation Low-NOx — Low-Swirl Burner Corrosion Monitoring System
Oxidative Cracking of Hydrocarbons to Ethylene Internal Recirculation Burner Metal Dusting Phenomena
Alkane Functionalization Catalysts Novel Low-NOx Burners Intermetallic Alloy for Ethylene Reactors
Low-Profile Catalytic Cracking Alloy Selection for High Temperatures
Selective Surface Flow Membrane
Catalytic Hydrogen Selective Membrane
Advanced Process Analysis for Refining
Multi-phase Computational Fluid Dynamics
Gas-Phase Thermodynamics Modeling
Membrane Reactor for Olefins
Membrane to Recover Olefins from Gaseous Streams
Energy-Saving Separations Technologies
BestPractices
Annual electricity savings of more than 12 million kWh and over $700,000
were achieved by a large West Coast refiner using OIT’s Motor Challenge.
This industry-government partnership assists the refining industry by identi-
fying near-term gains in energy efficiency that can be achieved by adopting
existing technologies. This program uses a “systems approach” to motors,
drives, and motor-driven equipment that results in reduced energy consump-
tion. The West Coast refiner used this program to identify and justify
upgrades on motors, motor drives, and power recovery turbines.
6
How to get involved