Project Background
Against the backdrop of the "Dual Carbon" goals, the petroleum refining and chemical industry—a sector characterized by high energy consumption and high emissions—faces severe pressure to conserve energy and reduce emissions. As a key regional player in the refining and chemical sector, Shandong Taihao Petrochemical Co., Ltd. operates traditional refining units that have been in service for many years; consequently, their energy consumption metrics exceed the industry average. This not only inflates the company"s production costs but also runs counter to the national philosophy of green development. To achieve sustainable development and enhance its core competitiveness, Taihao Petrochemical has decided to launch a retrofit project aimed at improving energy efficiency and reducing carbon emissions within its refining units.
Retrofit Measures
Upgrade of Waste Heat Recovery Systems: Taihao Petrochemical conducted a comprehensive assessment of the waste heat resources available within its facilities and installed high-efficiency waste heat recovery devices on key equipment, such as heating furnaces and fractionation towers. For instance, an air preheater was added to the flue gas outlet of the heating furnace to utilize the residual heat from the flue gas to preheat the combustion air, thereby boosting the furnace"s thermal efficiency from the original 88% to 9...by over 2%, resulting in annual savings of approximately 25,000 tons of standard coal. Concurrently, the overhead condensing system of the fractionation column was retrofitted to incorporate new, high-efficiency heat exchangers; this modification enables the recovery of condensation heat from overhead oil and gas streams to preheat the feedstock oil, thereby further reducing the facility"s overall energy consumption.
Energy-Saving Retrofit of Motor Systems: The company replaced all high-energy-consuming asynchronous motors within the facility with high-efficiency permanent magnet synchronous motors, complemented by the installation of variable frequency drive (VFD) systems. By precisely controlling motor speeds and adjusting power output in real-time according to production loads, the system effectively eliminates reactive power losses that typically occur when motors operate under low-load conditions. Statistics indicate that following this motor system retrofit, the overall electricity savings rate reached 15%–20%, resulting in an annual reduction in electricity consumption of approximately 12 million kilowatt-hours.
Process Optimization and Intelligent Control: Leveraging advanced process simulation software, Taihao Petrochemical undertook a comprehensive optimization of its refining processes. By fine-tuning process parameters—such as reaction temperatures, pressures, and material ratios—the company successfully enhanced feedstock conversion rates and product yields, while simultaneously reducing energy [consumption] during the production process......consumption. Concurrently, an intelligent production monitoring and control platform was established, enabling real-time monitoring of plant operational status and data analysis. Based on production data, the platform automatically adjusts process parameters and optimizes production workflows, ensuring the facility consistently operates at peak efficiency.
Project Outcomes
Following more than a year of retrofitting and operation, the comprehensive energy consumption of Taihao Petrochemical’s refining facility has been drastically reduced. Energy consumption per unit of product has dropped by 18% compared to pre-retrofit levels, resulting in an annual reduction of approximately 68,000 tons in carbon dioxide emissions. Simultaneously, product quality has seen significant improvement; the yield of high-value-added products has increased by 5 percentage points, generating over 80 million RMB in additional annual economic benefits for the enterprise. This project has not only facilitated Taihao Petrochemical’s green transition but also provided valuable reference experience for energy-saving and carbon-reduction retrofits at similar refining and chemical enterprises across the country.
