MPC_Background_Slides

Report
Energy Efficiency
at Marathon Petroleum
Wayne Kinnel
Catlettsburg Energy Coordinator
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Marathon Petroleum Statistics at a Glance
 Fortune 50 company
 Established in 1887
 4th largest U.S. refiner
 Largest in Midwest
 Employees: approximately 28,000
 Headquartered in Findlay, Ohio
 Approximately 1,460 Speedway
convenience stores
 Approximately 5,000 Marathon Brand
retail outlets
 Extensive terminal and pipeline network
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Marathon Petroleum Refining System
System capacity: 1,699,000 BPCD
Garyville (LA)
522,000 BPCD
Galveston Bay TX
451,000 BPCD
Detroit (MI)
120,000 BPCD
Catlettsburg (KY)
240,000 BPCD
Texas City (TX)
80,000 BPCD
Robinson (IL)
206,000 BPCD
Canton (OH)
80,000 BPCD
BPCD = barrels per calendar day
Source: Oil & Gas Journal
As of 2/1/2013
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Catlettsburg Refining
 Complex and energy intensive processes
 Continuous operation 24/7
 Energy is second largest operating cost
 Natural gas – 75%
 Electricity – 25%
 Managing energy is imperative to remaining competitive/viable
 Resources and systems in place to monitor and improve
 Daily operational
 Medium-term activities
 Long-term strategy and projects
 Significant investments made and planned
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Catlettsburg Refining
 Expansive electrical infrastructure required
 Refinery footprint is 600+ acres
 There are 130 electric substations and approximately 2,000 electric motors
 120-130 MW of demand to operate refinery
 Largest Kentucky Power customer
 >95% of consumption is for continuously running process equipment
 Significant people resources monitor and maintain electricity infrastructure
 13 engineers
 25 electricians
 60-80 electrical contractor personnel onsite daily
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Improving Energy Efficiency
 Part of our standard work practices
 Short-term – daily operational monitoring
 Medium-term – maintenance planning activities
 Long-term – strategic projects
 Effective energy management is an “all-above” approach
6
Monitoring Daily Operations
 Significant benefits from daily attention to process operations
 Tuning process heaters
 Optimizing utilization of energy from process operations
 Monitoring sources and uses of steam
 Controlling the operation of large electrical users
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Monitoring Daily Operations
 Formal assessment program - Focus On Energy initiative – “FOE”
 To accomplish – set standards for performance
 Measure actual performance in real time
 Communicate deviations from standards
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Monitoring Daily Operations
 Supported by technical, operations, and management personnel
 Completed process unit reviews and identified 148 individual monitoring
points
 Each point assigned a dollar value, tracked and reported
 35% reduction with no investment
9
Medium-Term Activities
 Equipment maintained to perform at optimum efficiency
 Equipment upgrades and major maintenance efforts normally require a unit
shutdown
 Cycle times between shutdowns can be 5-7 years
 Data from routine equipment monitoring is used to develop shut down work
scope
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Long-Term Strategy/Projects
 On-going efforts to identify and implement energy reduction opportunities
 Energy specific projects – Insulation upgrades, steam leak repairs and
upgrades, on-line analyzers, exchanger bundle upgrades
 Energy assessment for other projects
 Crude unit project example
 Significant investment currently underway
 Process and energy efficiency improvements incorporated into scope
 Redesign of heat integration system to reduce consumption
 Improvements to fired heater for improved efficiency
 Fuel reduction of 720 MMBTU/day
 Electricity reduction of 3,000 kwh/day
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Long-Term Strategy/Projects
 All projects reviewed for energy efficiency improvement opportunities
 Standard practice to consider high efficiency motors
 Participate in industry benchmarking studies
 Identifies opportunities for improvement
 Share and implement best practices across all MPC sites
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Summary
 Efficiently using all energy sources is a business imperative
 Resources employed to manage and maintain energy infrastructure
 Programs in place to monitor and improve performance
 Efforts range from daily optimization to large multi-year, multi-million dollar
projects
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