An Olefin Unit's Energy Audit and Implementation

Abstract

This paper will discuss an Energy Audit conducted in 1976 on Union Carbide's Texas City No. 3 Olefins Ethylene Unit. Staffing, planning, and conduct of an Audit are reviewed. Project endorsement by the multifunctional Energy Audit Team is used to prioritize capital programs. The paper will describe several projects having possible application in other Olefin plants. Preparation and use of an Energy Curve reviewed. An Energy Index graph projects improvements to be achieved by implementation of a four-year $44 million capital program which resulted from the Audit. Reorganization of the Olefin unit technical staff to complete the energy conservation program is covered. Several techniques being used to insure operator and maintenance commitment to energy conservation are reviewed.

The Texas City No. 3 Olefins Unit is an LPG based ethylene plant rated in excess of one billion pounds per year. Since start-up in 1968, energy costs have escalated by a factor of ten. The unit's current energy bill exceeds $45 million per year. Between 1972 and 1977 the Olefin plant conversion energy index increased by 40%. Concerned with rising fuel price and decreasing energy efficiency, management decided to conduct an Energy Audit on the Olefins Unit. This paper discusses the audit and implementation of the resulting conservation program. The paper is divided into four sections:

I. The Energy Audit II. Energy Curve III. Energy Index and Energy Projects IV. Operating Department Organization