Optimal Energy Strategy for a Complex Brownfield Ethane Recovery Maximization Project
Authors: AlGhailani Mi , Sajjad Saqib 
Published: October 2023

In the world of industrial development, the pursuit of energy optimization takes center stage, driven by the urgent need for sustainable solutions and the fight against climate change. Within this context, brownfield projects, with their intricate complexities, stand as crucial battlegrounds. These projects face the challenges posed by existing infrastructure, diverse process units, and stringent environmental regulations. However, within these challenges lie opportunities to reduce costs, minimize emissions, and improve overall project economics.

Recognizing the significance of energy optimization in the face of climate change, ADNOC embarked on a mission to achieve sustainable development in every aspect especially in project management. This paper provides a comprehensive account of the optimal energy strategy implemented for a complex brownfield project, with the aim of maximizing ethane recovery from various ADNOC Gas Plants. Brownfield projects imposes both challenges and opportunities due to the complex nature of such projects.

To tackle these challenges head-on, ADNOC implemented an integrated energy strategy, carefully analyzing and optimizing energy aspects throughout the project's lifecycle. Following the Project Energy Optimization (PEO) Framework, this strategy provided a structured process for assessing and optimizing energy aspects, ensuring that energy planning and reporting were upheld throughout the project.

Building upon this knowledge, Energy Management team undertook meticulous methods and procedures to develop an optimized energy strategy for the ethane recovery project. Energy workshops were conducted, and Energy Reports were prepared to evaluate different power supply options, steam generation techniques, and waste heat recovery configurations at each stage of the project. Performance indicators such as emissions, and economic viability were utilized to assess the effectiveness of each supply option scenario.

The optimization process highlighted various challenges and limitations, including operational constraints, technical feasibility, and potential conflicts between energy efficiency and other project objectives. To tackle these hurdles effectively, a comprehensive understanding of project requirements, collaborative efforts among stakeholders, and continuous monitoring and optimization throughout the project's lifecycle are essential. Overcoming these challenges can significantly enhance the effectiveness of energy optimization in complex brownfield projects.

The comparative analysis of power and steam supply options revealed the benefits and limitations of each alternative. While importing power from the grid proved to be the optimal solution due to its low carbon intensity, limitations on maximum grid power supply necessitated the evaluation of different supply combinations. The optimized scheme maximized the utilization of available waste heat and minimized the dumping of spare LP steam in condensers, thereby enhancing energy efficiency and reducing operational costs.

In summary, the implementation of the optimal energy strategy in the complex brownfield ethane recovery project at ADNOC Gas Plants exemplifies the potential benefits of energy optimization. The study's findings offer valuable insights for future brownfield projects, underscoring the significance of energy strategy optimizations in maximizing efficiency, reducing emissions, and ensuring long-term project success.