HSEE
HSEE
Health, Safety, Environment and Energy Efficiency
Energy Efficiency Case Study – PETROBRAS
Claudio Rücker
Energy Efficiency Sector
Workshop US-Brazil Binational Energy Working Group (Energy Efficiency)
CEPEL – Rio de Janeiro – RJ – Brazil
10 / 08 / 2011
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Petrobras Main Figures (2009 data)
•Investments : R$ 71 billion
•Net Profit: R$ 28.98 billion
•Global Presence: 28 countries
•Reserves: 14.90 billion barrels of oil and gas equiv.
•Net Revenue: R$ 182.71 billion
•Shareholders: 463,870
•Daily Production:
• 2,526,000 barrels per day
7,197
133
78 fixed
55 floating
15
172
25,966 Km
52 owned
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Petrobras Main Figures (2009 data)
•Production Platforms: 133 (86 fixed; 47 floating)
•Vessel Fleet:172 (52 belonging to Petrobras)
•Biofuels: 5 plants
•Wind Energy: 1 pilot plant
•Fertilizers: 2 plants
•Refineries: 15
•Yield of the Refineries: 2,034,000 bdd
•Pipelines: 25,966 km
•Thermoelectric Plants: 18 plants
•Service Stations: Nearly 8,000
7,197
133
78 fixed
55 floating
15
172
25,966 Km
52 owned
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Petrobras Main Figures
Increased to 6.4 MM boe/d
in 2020, as informed in the
recent Business Plan 20112015
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Petrobras Main Figures
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Research and Development
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Energy Performance Challenges
Strategic Objectives
Maximize efficiency and minimize the intensity of GHG emissions,
reaching levels of excellence in the Oil & Gas industry, contributing
to business sustainability
Energy Efficiency
•
•
•
Corporate Quinquennial Goals
quantified
Intensity Indexes and goals
established for each B.A.
Board of Directors analyses
results quarterly
Energy Annual Report
Emissions
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Energy Efficiency and Climate Change
Source: WEO World Energy Outlook 2009 - IEA
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Energy Efficiency and Climate Change
Source: BP Energy Outlook 2030 (January/2011)
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Management Process
Corporate Policies and Guidelines
Corporate Leadership
Leaders in the Operations Units
Design Guidelines
Performance Indicators
Measurement
Goals - Benchmark
Supply Chain Management Energy
Critical Analysis
Correction of Deviations
Modeling Process
Optimization - Advanced Control - "RTO"
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Management Process
Corporate Policies and Guidelines
Corporate Leadership
Leaders in the Operations Units
Design Guidelines
PRIORITY
PDCA
Performance Indicators
Measurement
Goals - Benchmark
Supply Chain Management Energy
Critical Analysis
Correction of Deviations
Modeling Process
Optimization - Advanced Control - "RTO"
Information
Management
Systems - PRIORITY
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PETROBRAS ORGANIZATION CHART
Audit Committee
Board of Directors
Internal Audit
Ombudsman’s Office
Senior Management
CEO
Business Strategy and
Performance
Business
Committee
Management Systems Development
Legal Department
New Businesses
Human Resources
Finance
Gas and Energy
Corporate
Financial Planning
and Risk
Management
Finance
Accounting
Tax
Investor Relations
Corporate
Marketing and
Trade
Logistics and Part.
in Natural Gas
Operations and
Part. in Energy
Energy
Development
Gas Chemicals and
Liquefaction
CEO’s
Office
Petrobras
Secretary Office
Corporate Communication
Exploration and
Production
Downstream
International
Corporate
Production
Engineering
Services
Exploration
North-Northeast
South-Southwest
Pre-salt
Corporate
Logistics
Refining
Marketing and
Commercialization
Petrochemicals
Major Projects
Program
Corporate
Technical Support
to Businesses
Business
Development
South Cone LA
Americas, Africa
and Eurasia
Services
Health, Safety,
Environment and
Energy Efficiency
Materials
Research and
Development
(Cenpes)
Engineering
Information
Technology
Shared Services
Energy consumption in Petrobras totalizes 259,000 b/d and
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represents about 10% of its total production
Consumption per activity (thousands
b/d, year 2009)
Thousands b/d, year 2009
(236 boed)
Consumption
represents
~10% of
production
(363 boed)
Energy Efficiency can result in substantial outcome increases for the
Company
Source: 2009 Petrobras Consumption Report
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What´s Energy Efficiency?
Ratio between a produced good or an accomplished service
and the quantity of energy consumed for that
•In case of Petrobras:
Produce more with less energy intensity
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Petrobras Energy Efficiency Goals
– Reduce 10% and 5% the energy intensity,
between 2009 and 2015, in its Downstream
and Thermal Plants, respectively
– Reduce 65% the natural gas flaring,
between 2009 and 2015, in its Upstream
operations
– Considering R&D and projects of energy
efficiency, Petrobras will invest US$ 1.2
billion until 2015
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Main Projects
– Downstream: Motorization of large
condensate turbines, energy integration,
process units optimization, modernization of
thermoelectric systems
– Thermal Plants: Convertion symple cycle in
combined cycle thermal plants
– Upstream: natural gas compression and
logistics investments
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Example of energy efficiency projects
Example of Advanced Control
in a Gas Process Unit
•
Investiment: US$ 270,000
•
Results:
– Earnings:
US$ 14 million
(in energy efficiency and
production)
– Extra production:
16,410,000 m³ LGN/year
(increase of 9%)
– Energy economy: 2 to 10%
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Example of energy efficiency projects
Furnaces and Boilers Soot
Blowing Modernization
Projects
• Refinery Case Example:
– Investment: US$ 1.74 million
– Energy economy: 305 b/d
– Carbon emission avoided:
38,000 tons CO2/year
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Example of energy efficiency projects
Condensate and Steam
Modernization Projects
•
Fertilizer Plant Example Case :
–
–
–
–
Investiment: US$ 1.5 million
Condensate recuperated: 20 t/h
Natural gas economy: 4,920 m3/day
Carbon emissions avoided: 3,700 ton
CO2/year
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Example of energy efficiency projects
Fluid Catalytic Cracking
(FCC) Turboexpanders
•
•
•
Recovery energy by substituting
pressure reducing valves by a
turbine coupled to an electric
generator
5 refineries
98 MW of total installed capacity
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Example of energy efficiency projects
Variable Speed
Driver Projects
• Refinery Example Case
(6 pumps)
– Investiment: US$ 1.7 million
– Energy Economy: 800 MWh/year
– Carbon emissions avoided: 83 ton
CO2/year
Fonte: WEG
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Example of energy efficiency projects
Dessalinization Units
Projects
Offshore Platforms Dessalinization Example Case :
•
3 production units
•
Reducing of potable water transportation by ships
•
Dessalinization water capacity: 255 m³/day
•
Investment: US$ 1.7 million
•
Energy economy: 5.2 b/d
•
Carbon emissions avoided: 829 ton CO2/year
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Example of energy efficiency projects
Heat Recovery
Projects
Process Unit Example Case :
•
•
•
•
Reduce 70% of furnace thermal
demand
Investments: US$ 15 million
Energy economy: 55,000 m³/day of
natural gas
Carbon emissions avoided: 40,000
tCO2/year
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Example of energy efficiency projects
Thermal Solar
Energy Projects
Onshore Oil Well Case Example:
• To take the paraffin off from the well
column
• Energy economy: 0.35 b/d
• Carbon emissions avoided: 35 ton
CO2/year
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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EZR Cogeneration Plant
• This project consists of an integration of
two different Business Areas of Petrobras
(Downstream and Gas & Energy):
– The RPBC Refinery old boilers were with low
energy efficiency
– The Gas & Energy was looking for new
thermal plants business opportunties
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•
•
•
•
EZR Cogeneration Plant – Main Equipments
1 Gas Turbine: 171.7 MW (ISO)
1 HRSG (120 bar; 42 bar; 12 bar)
1 Condensate Steam Turbine: 55 MW
2 Auxiliary Boilers
• Startup in 2010
• 2011 in pre-operation
EZR Cogeneration Plant – Energy Economy
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RPBC Boilers
Fuel
EZR Cogeneration Plant
Steam
12,953 TJ/year
Efficiency = 77,5%
196 MW
415 t/h
Electricity
Fuel
Combined Cycle Thermal Plant
19,541 TJ/year
196 MW
Electricity
Efficiency = 82%
Steam
415 t/h
Fuel
10,407 TJ/year
Efficiency = 60%
Without integration
Fuel = 23,360 TJ/a
Global Efficiency = 69%
Energy Economy
3,819 TJ/year
1,771 b/d
With integration - cogen
Fuel = 19,541 TJ/year
Global Efficiency = 82%
EZR Cogeneration Plant – Carbon Emissions
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RPBC Boilers
Fuel
EZR Cogeneration Plant
Steam
85% FO
15% NG
951,500 tCO2/year
Efficiency = 77,5%
196 MW
415 t/h
Electricity
Fuel
Combined Cycle Thermal Plant
196 MW
Electricity
78% NG
22% RG
1,136,500 tCO2/year
Efficiency = 82%
Steam
415 t/h
Fuel
100% NG
Efficiency = 60%
581,000tCO2/year
Without integration
1,532,500 tCO2/year
CO2 Index = 0,34 tCO2/MWh
CO2 Avoided
396,000 tCO2/year
With integration - cogen
1,136,500 tCO2/year
CO2 Index = 0,26 tCO2/MWh
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EZR Cogeneration Plant – Conclusion
• Results:
– Energy economy: 1,771 b/d
– Carbon emisisons avoided: 396,000 ton CO2/year
– Lower carbon intensity in Petrobras energy profile
– Lower NOx emissions
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Agenda
1. Petrobras Main Figures
2. Petrobras 2020 Strategic Plan
3. Energy Efficiency Context in Petrobras
4. Energy Efficiency Example Cases
5. EZR Cogeneration Case
6. Challenges for Petrobras
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Energy Efficiency Challenges in Petrobras
•1 Implement a new management model for Energy
Efficiency
- Future vision
- KPIs and goals
- New corporative standards
•
2
Insertion of Energy Efficiency requirements in Petrobras
new design models
- More efficient designs
- Consider the carbon emission
•
3
Projects of energy efficiency in the actual plants
- Priorize energy efficiency projects in the Company portfolio
Profitability
Increases
Operational
Efficiency Increases
Company Image
Prepare to Future
Scenarios
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Thanks!
Claudio Rücker
Energy Efficiency Sector
rucker@petrobras.com.br