Optimized Steam and Condensate Systems in Refineries: How to Improve Operational Reliability / Safety and to Decrease Energy/Water Consumption and CO2 Emissions

An optimal management of the steam and condensate system in refineries and petrochemical plants has a direct impact not only on safety, but also on the operating costs of the plant. The production down-time due to failures of the steam system is probably the main cost-driver in this analysis. The abnormal failure of equipments and the resulting maintenance costs could also have an important financial impact. Even if the decrease of these costs is difficult to predict in advance, different case studies show the important damages and their financial impact once the failure has occurred.

The decrease of the energy and water consumptions and the related CO₂ emissions is easier to establish. Based on the auditing work done in refineries and petrochemical plants, it appears that more than 5% of the yearly steam cost and related CO₂ emissions could be saved by optimizing the efficiency of the steam and condensate system. The increase of the condensate return rate could allow saving up to 50% of the quantity of boiler feed-water used prior to the optimization. Higher rate of condensate returning to the boiler means also less water poored on the ground or in the sewer, which also has an environmental impact.

For an average-size refinery with a capacity of 150 000 barrels/day, the total saved costs represent typically several million dollars per year.