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ELECTRIFICATION OF INDUSTRIAL FACILITIES

April 1, 2023 | By James Turner, Ma Katrina Sanaie and Mohamad Fakhreddine,
Fluor Enterprises

Manufacturing complexes may benefit from using more electricity instead of steam
and fuel gas for their energy needs. Improved energy efficiency, lower
emissions, higher reliability and debottlenecking of utility systems may be
achieved

Electrification is a popular buzzword when energy transition is discussed. It
can have many different meanings, and depending on the subject, it can refer to
the private and business transportation fleet (cars and trucks), public
transportation (buses and trains) or manufacturing and industrial processes and
facilities.



In process facilities, replacing steam and fuel gas with electricity can provide
many benefits, from improvements in reliability to avoidance of boiler-upgrade
projects to lower overall emissions. In short, if the carbon footprint from the
electricity production is lower than the carbon footprint from producing the
energy that is replaced by electricity, then there will be a decarbonization
benefit from the electrification.

This article discusses how electrification can impact a process-focused
industrial complex, such as a chemical plant or petroleum refinery, and it
specifically focuses on applying electrification to existing industrial
facilities. For a deeper discussion of the decarbonization potential of
electrification projects, please see Part 2o f this Feature Report, Incremental
Electrification Drives Sustainability.

 


WHERE TO BEGIN

There are several questions or issues owners or managers of existing industrial
facilities may have when considering electrification of their facilities (Figure
1).



FIGURE 1. There are many questions or issues that owners or managers of existing
industrial facilities may have when considering electrification of their
facilities



Is the facility operating at its peak energy efficiency? Many operators see a
noticeable improvement in their energy intensity index (EII) from
electrification of existing steam-turbine drivers. The calculations are based on
efficient grid-electricity production, such as from renewable sources, compared
to less-efficient boiler steam production.

Improvements in energy intensity are often a part of a facility’s strategic
plans and goals, which can have a noticeable impact on its operating costs.

Are the steam-generating systems and turbines in the facility becoming obsolete,
and now require ever-growing maintenance needs? Owners may have planned
steam-boiler replacement projects or other equipment maintenance or upgrades. If
so, owners may want to consider if this investment may be better spent on
electrification. Overall equipment reliability may increase and there may be
environmental credits or rebates that can be availed with electrification
projects.

Is the facility in compliance with local regulations on pollutant emissions?
Owners may be facing looming environmental regulations that will require
significant investments, such as installation of selective catalytic reduction
(SCR) systems for steam boilers or process heaters, to avoid paying hefty fines.
An electrification project can reduce steam demand and potentially allow the
shutdown of older steam boilers, therefore reducing the cost of any required
environmental upgrades. The emissions reductions from the decrease in steam
demand resulting from electrification can also be used to offset an increase in
emissions from other process heaters with process changes that can be valuable
for other strategic goals.

Are the utility systems at capacity, or worse, out of balance? If steam, cooling
water or natural gas supply are limited in the facility, it may not be possible
to expand or carry out other projects without doing some electrification
projects. If the cost to purchase or produce electricity is lower than importing
natural gas, then electrification can reduce operating costs.

Is there a need to re-balance the steam and electricity usage, but there are
concerns about what to do with excess fuel gas? There are potential synergies in
executing an electrification project coupled with a project to increase
liquefied petroleum gas (LPG) recovery from the fuel-gas system. Burning less
fuel translates into less CO2 generation, which is a strategic driver for many
companies. By recovering more LPG and heavier material from the fuel-gas system
and replacing it with natural gas, CO2 emissions will be further reduced, even
if the fired duty does not decrease. In most markets, the revenue from the sale
of LPG products and other liquid products is more than the cost of additional
import of natural gas, so there can be financial benefits in addition to CO2
reduction.

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