P.1 

OAR Box 1784 

Prepped by Ollie Stewart 

Document Number: 

81)11-1-^2^ 

Docket Number: 

A-84-44 

Printed 10/31/2008 8:05:41 AM Sheet 81 of 143 
P.2 

ENERGY 

REQUIREMENTS 

FOR THE HPI 

The energy consumed by the HPI is a small fraction 

of the total energy value of its finished products. But 

since hydrocarbons (crude oil, natural gas and coal) 

furnish more than 90% of the world's total energy 

needs, that fraction represents a huge amount of energy—an estimated 5.0 Quads in the U.S. alone in 

1985. 

An integrated refinery uses energy equivalent to 

about 10% of the total energy content in the crude oil 

it processes. All of the refinery's needs could be derived from its own crude oil feed, but many installations are designed to use available supplemental fuels. Table 1 shows the types and quantities of fnelsused by U.S. refineries in 1982, the last year for which 

data are available. 

The fuel requirements of any one refinery depend 

on the nature of the feed, the final product yield and 

the level of individual product quality. By their nature, some products such as lube oils and petrochemicals require a disproportionately greater quantity of 

processing energy per unit of product output. 

The petrochemical and natural gas processing sectors represent extremes in HPI energy consumption. 

Petrochemicals, for example, can use one-third or 

one-half of its feed's energy content just to supply the 

energy of conversion. On the other hand, natural gas 

processing requires very little, by comparison. The 

distribution of energy sources for refining, petrochemicals and gas processing in 1985 is estimated as 

shown in Table 2. 

In either a crude oil refinery or a natural gas processing plant, much of the energy consumption is for 

liquid-vapor phase changes. Some of the more successful energy conservation measures so far have 

come from taking the heat from a vapor liquefaction 

step and adding it to some liquid vaporization step. 

Thus, heat once discarded as waste during a cooling 

step is now recycled to the system. 

The HPI is expected to continue its drive to reduce 

energy requirements per unit of thruput. The reduction is accomplished by installing more efficient furnaces for better fuel use, installing more heat exchangers to use product heat as feed preheat, 

installing pumps and compressors for a net gain from 

low level heat sources and adding instruments to 

keep closer control on process conditions. Cogeneration is another technology that promises to lower HPI 

energy requirements. More information on HPI cogeneration is given on the next page. 

Ongoing projects of energy conservation get impetus from high energy prices and stringent environmental requirements. Conservation projects offer 

mixed blessings. When other industries install energy-saving equipment, they decrease the demand 

for the HPI's products—fuels. Nevertheless, conservation measures help the HPI operate more efficiently 

and, hence, more profitably. 

Sharing energy needs among units introduces another situation. Each unit becomes more dependent 

on the operation of some other unit. The combinations can get very complex. Then it is worthwhile to 

add computer-based power advisory and control systems. The computer uses consistent energy terms to 

relate changes among many units. Such controls 

avoid those situations where a net energy loss could 

result from an energy savings in one unit that imposes a greater energy usage by another. 

The growing awareness of energy requirements has 

given new insight into the varied value of heat input. 

It is no longer adequate to simply specify BTU requirements. It is now important to identify the source 

of those BTUs. Some may come from waste heat having low or negative value. Others may come from the 

purchase of very valuable outside fuels. This trade off 

appears repeatedly to influence the selling price of 

commercial fuels. 

TABLE 1 

FUELS CONSUMED BY U.S. REFINERIES 

IN 1982 

Heat 

Quantity Content 

Source Consumed Quads* 

Purchased Electricity 

Natural Gas 

Other Purchased 

Fuels 

Internal Products as 

Fuel 

Total 

Crude Run to Stills 

0.08x1012kWh 

0.56x1012Scf 

(coal and steam) 

0.28x109bbl 

4.31x109bbl 

0.28 

0.58 

0.04 

1.67 

2.57 

25.0 

•Quads - 1x1015BTU 

Source: U.S. Dept. of Energy, "Petroleum Supply Monthly" DOE EIA4109 (82 

03) through (S3 02). Sum of Table 19 by months. 

Note: Purchased electricity is greater than normal because of a 10-fold increase 

in January, 1982. Thereafter, purchases returned to normal. 

TABLE 2 

ESTIMATED 1985 ENERGY 

REQUIREMENTS FOR U.S. 

REFINING 

Purchased Electricity 

Purchased Fuel 

Internal Fuels 

Total 

PETROCHEMICALS 

Purchased Electricity 

Purchased Fuel 

Total 

GAS PROCESSING 

Purchased Electricity 

Purchased Fuel 

Internal Fuels 

Total 

U.S. HPI Total 

HPI 

Quads* 

0.2 

0.5 

1.7 

2.4 

0.2 

1.6 

1.8 

Negligible 

0.1 

0.7 

0.8 

5.0 

• Quads - 1 x 10'5 BTU 

Source: Independent Petroleum Association, Supply and Demand 

Committee, reported at meeting in Reno, Nevada, May 5-7, 1982. 

Adjusted to account lor estimated 1985 product demand and later 

purchase patterns. 

26 ENERGY REQUIREMENTS Market Data 1985—Prepared by Hydrocarbon Processing