Rossiter & Associates Sample Projects

Pinch Analysis and Energy Optimization

Greenfield Site Energy Optimization Conducted pinch study for new $2 Billion Canadian Oil Sands facility. Proposed new heat integration option, which has been incorporated in the design. Also identified inherent problems in the site’s heat balance, which contributed to a fundamental change in design philosophy. This has resulted in an improved process design with savings in both capital and energy costs.
Energy Optimization of New Process Units Examined new unit design (low sulfur mogas) using pinch techniques. Identified economic opportunity to enhance feed/effluent heat recovery and reduce energy consumption by ~15%. This improvement has been incorporated in the process design.
Combined Debottlenecking and Energy Optimization Review of hydrofiner capacity revamp project identified an opportunity to re-align a single heat exchanger shell. This simultaneously saves k$500/year in energy with a one year payback and provides a low-cost option for overcoming furnace bottlenecks.
Energy Optimization of Existing Facilities Carried out site-wide pinch evaluation, utility system analysis and water minimization study. Identified numerous energy-saving opportunities totaling ~20% of site energy costs. One project, saving $1,000,000/year at zero capital cost, was implemented while the study was in progress. Several other capital projects have subsequently been implemented. These include process heat integration, boiler feed water preheat and distillation tower improvements.

Waste Minimization

Greenhouse Gas Emissions Conducted pinch study and greenhouse gas audit for $6 billion Canadian Oil Sands expansion project. Identified opportunities to reduce CO2 emissions by 235 ktonnes/yr and simultaneously reduce energy consumption by 460 MBtu/hr. These improvements were incorporated in the design.
Water Minimization Co-developed mathematical programming technique for minimizing water use and waste water generation. Applied at several locations, including refinery units, chemical plants and maintenance facility. Identified numerous practical wastewater reduction options, of which several have been implemented.
Hierarchical Design Review Extended established hierarchical design techniques to waste reduction problems. Developed hierarchical review technique and applied to refinery unit optimization and waste minimization.
Refinery Flare Gas/Hydrogen Optimization Investigated refinery fuel gas and hydrogen balances and identified options to minimize gas flaring and maximize hydrogen recovery. Options included innovative energy trading, simple re-piping, modifications to sponge tower operation, and addition of novel membrane process.