Komal International is pleased to announce an extension of its portfolio of engineering services

through a strategic alliance with Kumana & Associates, a consulting firm based in Houston,
Texas, USA, which specializes in energy efficiency and water conservation. The advanced
technical knowhow agreement with K&A will supplement the oilfield equipment and
repair/maintenance services that are already available through Komal.
The new front-end engineering services being offered are follows:

Process heat recovery optimization studies, using Pinch Analysis, fouling mitigation, HX
modifications, etc.
Electrical power conservation and recovery piping and control revamps for pumps and
compressors, load management, variable speed drives
Simulation modeling/optimization of Combined Heat & Power (cogeneration) systems
Water conservation and Wastewater minimization, using Pinch Analysis
Process + Utilities Performance Indices (KPI development and on-line implementation)
Process Engineering: conceptual/planning feasibility studies, including heat & material
balances, P&IDs, equipment specs, project management, etc.
Technical Management consulting: energy strategy, technology scouting, technology
selection, technology transfer, R&D support, market studies & support, forensic audits,
owners engineer for major projects
Seminars/courses in Process Integration techniques for reducing energy consumption, and
greenhouse gas emissions

These services cover the full range of oil and gas activities:
Upstream and Midstream surface operations starting from production well to Gas-Oil-Water
separation, produced water disposal, water flooding for EOR, oil desalting, oil stabilization,
storage tank vapor recovery, oil and gas dehydration, gas sweetening, NGL recovery, gas
compression, and storage/pipeline operations.
Downstream oil refining processes including CDU/VDU, gas separation, reforming,
hydrotreating, thermal cracking, catalytic cracking, hydrocracking, coking, alkylation,
isomerization, amine treatment, sulfur recovery, hydrogen production, etc.
K&A has a team of about 10 experts on staff, as well as alliances with companies specializing in
Fired heaters, Gas turbines, Refrigeration, Data mining (statistical analysis), and implementation
of on-line CHP system optimization. The staff consultants collectively have over 300 man-years
of international work experience in N & S America, Middle-east, Europe, Asia, and Africa.

Actual progress of a comprehensive Energy Efficiency Program

Mr. Kumana holds a masters degree in chemical engineering from

the University of Cincinnati, and has more than 35 years of
experience working for manufacturing, engineering design, and
consulting firms. He has been a consultant to major corporations
world-wide including Shell, BP (Amoco), Dupont, Monsanto
(Solutia), Dow (Union Carbide), Enron, Saudi Aramco, SABIC,
Mitsubishi, Petrochina, and SASOL, as well as to US Dept. of
Energy, Natural Resources Canada, World Bank and UNIDO. He
has authored or co-authored over 75 technical papers and book
chapters, and teaches a regular 4-day public course on energy
optimization in the oil, gas and petrochemical industry (twice a
year in Houston, Tx and once a year in Europe).
Selected Publications
1. J D Kumana, Medium Scale Alcohol Technology and Economics, presented at the Annual
Technical Meeting, National Gasohol Commission, Minneapolis, Mn (July 21, 1980).
2. R Katzen, G D Moon and J D Kumana, Distillation System for Motor Fuel Grade
Anhydrous Alcohol, U.S. Patent 4,217,178 (Aug 12, 1980).
3. J D Kumana and S P Kothari, Predict Storage Tank Heat Transfer Precisely, Chemical
Engineering, Vol 89 (Mar 22, 1982), pp 127-132.
4. J D Kumana, A Review of DDGS Drying Technology, presented at the Second
Ethanol/Methanol Conference, Hamilton, Bermuda (Apr 24-26, 1983).
5. J D Kumana, A Pre-Design Strategy for Selecting Near-Optimum Cooling Water Flow
Rates, AIChE Symposium Series no. 236, Vol 80, (1984), pp 117-121.
6. J D Kumana, Ethanol from Molasses - A Technology Update, All-India Distillers
Association Conference, New Delhi, India (March 5-6, 1986).
7. J D Kumana, How to Increase Revenues from Ethanol and By-Products, presented at the
Gist-Brocades Ethanol Production Workshop, Kansas City, Mo (June 9-10, 1986).
8. D M Jenkins and J D Kumana, Pinch Technology Applications in Sugar Processing, Proc.
of SIT Annual Technical Meeting, Sydney, Australia (May 11-13, 1987).
9. J D Kumana, Control Valve Sizing Under Variable Flow Conditions Using an Electronic
Spreadsheet, Chemical Processing magazine, Vol 53, no. 8 (June 1990).
10. J D Kumana, The Impact of Excess Boiling Point Rise in Evaporators and Crystallizers,
Chem Eng Prog, Vol 86, no 5 (May 1990), p 10.
11. J D Kumana, Run Batch Distillation Process with Spreadsheet Software, Chem Eng Prog,
Vol 86, no 12 (Dec 1990), p 53.
12. R Nath, J D Kumana and J F Holliday, Optimum Dispatching of Plant Utility Systems to
Minimize Cost and Local NOx Emissions, Proc of ASME Indus Power Conf, New Orleans,
La (Mar 1992).
13. J D Kumana et al, chapters 4, 18, and 23 in Waste Minimization Through Process Design,
McGraw-Hill, New York, NY (1995).

14. R J Doherty and J D Kumana, A Step-by-Step Approach to Energy Conservation,

Chemical Processing (Jan 1996), p 90.
15. B Linnhoff, R A Tainsh and J D Kumana, Intelligent Networking of Process Wastewater
Streams in the Chemical Industry, GVC conference Verfahrenstechnik der Abwasser und
Schlammbehand-lung, Wurzburg, Germany (Oct 1996).
16. J D Kumana, Integrated Water Management - A Systematic Approach, presented at
AIChEs CWRT workshop, St Louis, Mo (Nov 10, 1999).
17. J D Kumana, Use Spreadsheet-based CHP Models to Identify and Evaluate Energy Cost
Reduction Opportunities in Industrial Plants, Proc of 23rd Industrial Energy Technology
Conference, Houston, Texas (May 2001).
18. J D Kumana, A Stochastic Approach to Calculating Return on Investment, Proc of First
International Symposium on Exergy, Energy and Environment, Izmir, Turkey (July 13-17,
2003).
19. J D Kumana, Pinch Analysis: A Practical Tool for Effective Water Management, Proc of
Petrotech 2003 Conference, Bahrain (Sep 29 Oct 1, 2003).
20. J D Kumana and Ahmed S Aseeri, Electrical Power Savings In Pump And Compressor
Networks Via Load Management, Proc of 27th Industrial Energy Technology Conference,
New Orleans, La (May 2005).
21. J D Kumana , Success Factors for a Corporate Energy Program, presentation at 29th
Industrial Energy Technology Conference, New Orleans, La (May 9-10, 2007).

22. J D Kumana, Meaningful Energy Efficiency Performance Metrics for the Process
Industries, Proc of 31st Industrial Energy Technology Conference, New Orleans, La (May
12-15, 2009).
23. J D Kumana, Using Corporate Standards and Procedures to Promote a Sustainable Energy
Program, presented at the Texas Chemical Council Annual EHS Conference, Galveston,
Texas (June 10, 2010)
24. J D Kumana, Corporate Energy Management Programs: A Case Study, Chemical News
(India), (Nov 2010).
25. J D Kumana, Analysis Tools for Integrated Process Optimization: Energy, Emissions, and
Throughput, presented at AEEs 33rd World Energy Engineering Congress, Washington,
DC (Dec 8-10, 2010).
26. J D Kumana, Effective Fouling Control Methods for Improving CDU Performance and
Economics, International Petroleum Refining (Jan 2012) pp 21-31

Highlights of Project Experience Oil, Gas & Petrochemicals

Client

Plant Description

Scope of Work

American Cyanamid
(Cytec), Milton, Fl
Apache Corp
Monument, NM, USA
Arco Chemical (now BP),
Channelview, Tx
Commercial Alcohols, Ltd
Varennes, Quebec
Conoco/Pennzoil JV
Westake, La, USA
ConocoPhillips Maljamar,
NM, USA
Devon Energy
Oklahoma City, Ok, USA
DCP Midstream (Duke
ConocoPhillips), Linam
Ranch, NM, USA
DuPont, Wilmington, De
Essar Oil Ltd,
Vadinar, Gujarat, India
Lubrizol Corp
Deer Park, Tx
Monsanto (Solutia),
Decatur, Al
Monsanto (Solutia),
Sauget, Il
Monsanto (Solutia),
Chocolate Bayou, Tx
Monsanto (Solutia),
7 N American sites
Mitsubishi Heavy Indus,
Tokyo, Japan
Navajo Refining Co (Holly
corp), USA
Occidental Petroleum
Los Angeles, Ca, USA
Olin Chemicals,
Lake Charles, La
PetroChina, Karamayi,
XinJiang, China
Petrowax,
Smethport, Pa, USA
Quaker Chemical Co,
Belle Glade, Fl
Refineria Isla (PdVSA),
Curacao
SABIC,
Jubail, Saudi Arabia

Acrylic polymer and fibers

plant
170-well 2500 bpd oil-field
production lease
Beta phenyl ethanol plant

Optimum HEN retrofit for energy savings,

using pinch analysis
Identify cost-effective electric power savings
potential (24%)
Detailed process engineering, based on
licensed Sumitomo process
Reactor debottlenecking and design of
ether/aldehyde distillation system.
Optimization of 32 MBD Hydrocracking and
20 MBD Catalytic dewaxing units
Identify cost-effective electric power savings
potential (23%)
Identify cost-effective electric power savings
potential (20%)
Identify cost-effective elec power savings
potential (13%); more with cogeneration

60,000 gpd synthetic ethanol

plant
New lube oil plant at 240 MBD
refinery
300-well 1600 bpd oil-field
production lease
150-well oil-field lease in
southeastern New Mexico
170 MMscfd midstream gas
processing plant
Kevlar process
300 MBD oil refinery
Polyisobutylene plants (2)
Acrylic fibers and nylon
intermediates
12-unit complex producing
chlorinated C6H6 compds
Acrylonitrile plant
Misc specialty chemicals mfr,
batch and continuous
Styrene monomer synthesis &
refining
100 MBD refinery in New
Mexico
80-well 1200 bpd oil-field
lease in New Mexico
TDA/TDI complex, incl
phosgene & HyCO
200 MBD lube oil refinery
revamp + expansion
Petroleum wax extraction and
refining plant
Tetra-hydrofuran from furfural
200 MBD oil refinery
2 MeOH plants + 1 MTBE
plant (Ibn Sina + Ibn Zahr)

Pinch analysis of refrigeration system

Analysis of crude oil fouling in the CDU
preheat train
Electric power minimization for refrigreration
and cooling water systems
Water conservation to debottleneck WWT
capacity, using pinch analysis
(a) Total site energy pinch study
(b) Total site water pinch study
Refrig system and cooling tower
debottlenecking study (pinch analysis)
Opportunity Assessment studies to identify
scope for cost reduction
Optimization of new HEN and distillation
sequence, using pinch analysis
Preliminary assessment of energy saving
potential via CHP optimization
Identify cost-effective electric power savings
potential (25%)
Optimum HEN retrofit for energy savings,
using pinch analysis
Optimum HEN retrofit for 6 units + 5 new
units + Site Utilities (energy+water)
Optimum HEN retrofit for energy savings and
NOx emissions reduction
Techno-economic feasibility study
5-day training course in process integration
using pinch analysis
Energy audit and optimization of heat recovery
and CHP systems

Sasol Chemical Industries,

Sasolburg, South Africa

Coal gasification and

chemicals complex

Sasol Chemical Industries,

Secunda, South Africa
Saudi Aramco, corp engg,
Dhahran, Saudi Arabia
Saudi Aramco, Shedgum
Gas Plant, Saudi Arabia
Saudi Aramco, Juaymah
Gas Plant, Saudi Arabia
Saudi Aramco, Yanbu
Refinery, Saudi Arabia
Saudi Aramco, Hawiyah,
Saudi Arabia
Saudi Aramco, Safaniya,
Saudi Arabia
Saudi Aramco, Jeddah,
Saudi Arabia
Saudi Aramco, Rabigh,
Saudi Arabia
Saudi Aramco, Ras Tanura,
Saudi Arabia
Saudi Aramco, Riyadh,
Saudi Arabia
Saudi Aramco, Manifa CPF,
Saudi Arabia
Saudi Aramco, corporate
engineering, Dhahran, Saudi
Arabia

Coal gasification and

chemicals complex
Oil stabilization, oil refining,
and gas processing plants
2200 MMscfd gas processing
plant, incl NGL rec
NGL condensate fractionation

Southern Union Gas, Jal,

NM, USA
Tesoro, Los Angeles,
California, USA
Tex-Penn Inc,
Houston, Tx, USA
Tosco (now Tesoro),
Avon/Martinez, Ca, USA
XTO Energy
Eunice, NM, USA

90 MM scfd gas processing

plant
360 MBD fuels refinery

230 MBD fuels refinery

1600 MMscfd gas plant, incl
NGL recovery
2400 MBD crude oil GOSP +
desalting + dehydration facility
85 MBD fuels refinery
400 MBD fuels refinery
300 + 225 MBD fuels
refineries
120 MBD fuels refinery
900 MBD crude oil GOSP +
desalt + dehydration facility
Oil & gas production, oil
refining and gas processing

Waste lube oil reclamation

plant
156 MBD oil refinery
170-well 2500 bpd oil-field
production lease

(a) Water conservation and wastewater

minimization study, (b) Energy optimization
study; using pinch analysis
Water conservation and wastewater
minimization study; using pinch analysis
Quick Energy audits (6 major sites), including
gas processing and oil refning
Detailed energy optimization study total site,
incl CHP model
Optimum HEN retrofit design, ASDs, Energy
Performance Indices
Detailed energy optimization study total site,
incl CHP model
Conceptual energy optimization study total
site, incl CHP model
Detailed energy optimization study total site,
incl utilities (cogen)
Mgmt of detailed energy optimization study
outsourced to EPC contractor
Development+application of optimum load
mgmt strategies for pump networks
Mgmt of detailed energy optimization study
outsourced to EPC contractor
Detailed energy optimization study of H2 prod
+ HCU + CHP model + cogen strategy
Energy-optimized design of new plant,
including utilities (cogen)
Developed + taught multiple energy
optimization courses (>100 students)
Developed and deployed Energy
Performance Indices
Prepared five Best Practice manuals related
to energy efficiency
Revised corporate standards and procedures
to include energy efficiency
Identified cost-effective elec savings potential
(10%) + cogeneration (65%)
Capacity debottlenecking of Delayed Coking
Unit via HEN retrofit (20%)
Process development, detailed process design
Total site energy study using pinch analysis
Identify cost-effective electric power savings
potential (15%)

Highlights of Project Experience Water Conservation & WW Minimization

Client
Amoco, Yorktown, Va
Monsanto (Solutia),
Decatur, Alabama
Monsanto (Solutia),
Sauget, Illinois
Monsanto (Solutia),
Chocolate Bayou, Tx
Sasol Chemical
Industries, Sasolburg,
South Africa
Sasol Chemical
Industries, Secunda,
South Africa
Jefferson Smurfit,
Monroe, Michigan
Mead Westvaco Corp,
Escanaba, Michigan
Mead Westvaco Corp,
Chillicothe, Ohio
Rayonier Inc,
Jesup, Georgia
Tyson Foods,
Cumming, Georgia

Plant Description
Oil refinery
Acrylic fibers and nylon
intermediates
12-unit complex
producing chlorinated
C6H6 compds
Acrylonitrile plant
Coal gasification and
chemicals complex
Coal gasification and
chemicals complex
110 TPD linerboard mill

Scope of Work
Water conservation stsudy
Water conservation to debottleneck
WWT capacity, using pinch analysis
(c) Total site energy pinch study
(d) Total site water pinch study
Refrig system and cooling tower
debottlenecking study (pinch analysis)
(a) Water conservation and wastewater
minimization study, and (b) Total site
energy optimization study; using pinch
analysis
Water conservation and wastewater
minimization study; using pinch analysis

Energy savings, water conservation and

wastewater minimization
1650 TPD bleached Kraft Combined thermal and water
pulp/paper mill
conservation retrofit study, using Pinch
Analysis
950 TPD bleached Kraft Combined thermal and water
pulp/paper mill
conservation retrofit study, using Pinch
Analysis
1700 TPD bleached Kraft Combined thermal and water
pulp/paper mill (3 lines)
conservation retrofit design, using Pinch
Analysis
20,000 birds/h poultry
Simulation model, retrofit for WWT
processing facility
capacity debottlenecking via water
conservation

Fired heater (L) with Air-preheater (R) at an oil refinery

Amine absorber/stripper unit for gas sweetening at a midstream gas plant

Heat Exhanger preheat train at an oil refinery

Molecular sieve beds for gas dehydration at a midstream gas plant

Tank Battery at an Upstream oil field, including gas-oil separator, heater treater (not visible) and oil/water storage.

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