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YOKOGAWA

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Yokogawa Electric Corporation

CO2 emissions reduction solutions and potential benefits

Energy Efficiency

Since the 1970s oil crisis, the refining industry in Japan has dealt with rising energy prices and strict regulations by reducing energy consumption and cutting CO2 emissions. Refinery operators have accomplished this by introducing some of the world’s most advanced technologies, and have been supported in this by Yokogawa's systems, solutions, and engineering capabilities. Yokogawa has been involved in more than 900 refinery projects and has established strong credibility in this industry. The company provides solutions that achieve energy savings through increased efficiency.
Example of potential benefits (approximate annual returns for a 100 kbd refinery)
Heavy fuel oil reduction : up to 50,000 FOE-kL CO2 emissions reduction : up to 150 ktons CO2 reduction rate : up to 12 %
*The values vary depending on the progress of the activities of customers.

Refining flow diagram

Energy KPI managment
Energy consumption visualization and key performance indicator (KPI) management

To achieve energy savings and reduce CO2 emissions at refineries, the status of emissions and energy consumption must be clearly visualized. Yokogawa provides a comprehensive range of solutions such as field sensors and production management systems that rely on the latest technologies to monitor and manage energy related parameters.
  • Visualization through operation management
  • Visualization through production management
  • Visualization of field data
Reducing excess O2 % in furnace/boiler flue gas
Reducing excess O2 % in furnace/boiler flue gas
When excess oxygen (O2) is present in flue gas, incomplete combustion is the result. Usually, O2 is kept within 1.5 - 2% of the optimum level; however, it has been shown that laser sensing technology can improve the speed and reliability of CO/O2/CO2 measurement and lead to even further reductions in excess O2, resulting in additional energy savings.

Advanced control for atmospheric distillation
The fractionator in an atmospheric distillation unit is highly complex and difficult to operate. Yokogawa has an advanced control solution for fractionators that relies on multivariable model predictive control and quality estimation technologies.

Advanced control for other types of distillation columns
For other types of distillation columns such as stabilizers, splitters, de-ethanizers, de-propanizers, and aromatic (BTX) fractionation units, Yokogawa has a number of advanced solutions for quality estimation control, multivariable model predictive control, and low-pressure control that can improve yield and reduce energy consumption.
  • Stabilizer
  • Splitter
  • De-ethanizer
  • De-propanizer
  • Aromatics (BTX) unit, etc
Optimum operation in desulfurization process
There are several hydrodesulfurization processes for removing sulfur from naphtha, kerosene, light gas oil, heavy gas oil, heavy oil, and other fuels. By controlling the upper limit of the standard sulfur value to reduce a reactor’s weight average temperature (WAT), energy savings can be obtained.

Optimum operation in catalytic reforming process
Catalytic reforming in a reactor unit relies on research octane number (RON) control and maximum charge control as well as WAT control, which is based on the temperature profile of the reactor. This improves yield and saves energy

Optimum operation in fluid catalytic cracking (FCC) process
Fluid catalytic cracking (FCC) units play an essential role in the production of value-added products. The use of multivariable model predictive control to enhance the operation of the FCC increases the yield of value-added products and realizes energy savings.

Operation assistance system for process automation
An operation assistance system ensures consistent product quality and reduces operator workload by providing standardized operational procedures based on the expertise of a refinery’s most experienced operators.
Reductions in tank yard / shipping facility
Reductions in tank yard / shipping facility
Oil movement automation systems (OMS) improve the efficiency of refinery tank yard and shipping facility operations.
  • Optimized management of product shipping schedule
  • Blend property control (BPC)
  • Prevention of contamination and reduction of slop oil by automatic path selection
  • Optimum combination of pumps
Optimizing common header balance
Reductions in tank yard / shipping facility
Optimizing common header balance
By optimizing the balance of gas, hydrogen, and steam supply and demand at a refinery's common headers, energy loss can be minimized.
  • Hydrogen gas header optimum control system
  • Fuel gas header optimum control system
Optimization of boiler, turbine, and generator (BTG) plant
The optimization of operation and control at a BTG plant consisting of multiple boilers, turbines, and electric power generators helps save energy.

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