hsee health, safety, environment and energy efficiency energy efficiency case study – petrobras...

HSEE

HSEEHealth, Safety, Environment and Energy Efficiency

Energy Efficiency Case Study – PETROBRAS

Claudio RückerEnergy Efficiency Sector

Workshop US-Brazil Binational Energy Working Group (Energy Efficiency)CEPEL – Rio de Janeiro – RJ – Brazil

10 / 08 / 2011

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1.Petrobras Main Figures

2.Petrobras 2020 Strategic Plan

3.Energy Efficiency Context in Petrobras

4.Energy Efficiency Example Cases

5.EZR Cogeneration Case

6.Challenges for Petrobras

Agenda

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133

15

17225,966 Km7,197

•Investments : R$ 71 billion

•Net Profit: R$ 28.98 billion

•Global Presence: 28 countries

•Reserves: 14.90 billion barrels of oil and gas equiv.

•Net Revenue: R$ 182.71 billion

•Shareholders: 463,870

•Daily Production:

• 2,526,000 barrels per day

52 owned

78 fixed 55 floating

Petrobras Main Figures (2009 data)

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133

15

17225,966 Km7,197

•Production Platforms: 133 (86 fixed; 47 floating)

•Vessel Fleet:172 (52 belonging to Petrobras)

•Biofuels: 5 plants

•Wind Energy: 1 pilot plant

•Fertilizers: 2 plants

•Refineries: 15

•Yield of the Refineries: 2,034,000 bdd

•Pipelines: 25,966 km

•Thermoelectric Plants: 18 plants

•Service Stations: Nearly 8,000

52 owned

78 fixed 55 floating

Petrobras Main Figures (2009 data)

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Agenda

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Petrobras Main Figures

Increased to 6.4 MM boe/d in

2020, as informed in the recent

Business Plan 2011-2015

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Petrobras Main Figures

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Research and Development

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• Corporate Quinquennial Goals quantified

• Intensity Indexes and goals established for each B.A.

• Board of Directors analyses results quarterly

Energy Efficiency Emissions

Strategic Objectives

Maximize efficiency and minimize the intensity of GHG emissions, reaching levels of excellence in the Oil & Gas industry, contributing

to business sustainability

Energy Annual Report

Energy Performance Challenges

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Agenda

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Source: WEO World Energy Outlook 2009 - IEA

Energy Efficiency and Climate Change

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Source: BP Energy Outlook 2030 (January/2011)

Energy Efficiency and Climate Change

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Corporate Policies and Guidelines

Corporate Leadership

Leaders in the Operations Units

Design Guidelines

Performance Indicators

Measurement

Goals - Benchmark

Supply Chain Management Energy

Critical Analysis

Correction of Deviations

Modeling Process

Optimization - Advanced Control - "RTO"

Management Process

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Corporate Policies and Guidelines

Corporate Leadership

Leaders in the Operations Units

Design Guidelines

Performance Indicators

Measurement

Goals - Benchmark

Supply Chain Management Energy

Critical Analysis

Correction of Deviations

Modeling Process

Optimization - Advanced Control - "RTO"

Management Process

PDCA

Information Management Systems - PRIORITY

PRIORITY

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Corporate

Financial Planning and Risk Management

Finance

Accounting

Tax

Investor Relations

Health, Safety, Environment and Energy Efficiency

Materials

Research and Development (Cenpes)

Engineering

Information Technology

Shared Services

Corporate

Marketing and Trade

Logistics and Part. in Natural Gas

Operations and Part. in Energy

Energy Development

Gas Chemicals and Liquefaction

Corporate

Technical Support to Businesses

Business Development

South Cone LA

Americas, Africa and Eurasia

Corporate

Production Engineering

Services

Exploration

North-Northeast

South-Southwest

Pre-salt

Corporate

Logistics

Refining

Marketing and Commercialization

Petrochemicals

Major Projects Program

PETROBRAS ORGANIZATION CHART

Business Strategy and Performance

New Businesses

Human Resources

Management Systems Development

Legal Department

Corporate Communication

Internal AuditOmbudsman’s Office

Petrobras Secretary Office

CEO’s Office

CEO

Senior Management

Business Committee

Board of Directors

Audit Committee

Finance ServicesGas and Energy InternationalExploration and Production Downstream

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Source: 2009 Petrobras Consumption Report

Energy Efficiency can result in substantial outcome increases for the Company

0

100

200

300

Consumo

28

74

121

23

12

259

0

1000

2000

3000

Produção

2526

Processamento

1988

Consumo

259

(363 boed)

(236 boed)

Thousands b/d, year 2009

Consumption per activity (thousands b/d, year 2009)

Energy consumption in Petrobras totalizes 259,000 b/d and represents about 10% of its total production

Consumption represents

~10% of production

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Ratio between a produced good or an accomplished service and the quantity of energy consumed for that

•In case of Petrobras:

Produce more with less energy intensity

What´s Energy Efficiency?

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– Reduce 10% and 5% the energy intensity, between 2009 and 2015, in its Downstream and Thermal Plants, respectively

– Reduce 65% the natural gas flaring, between 2009 and 2015, in its Upstream operations

– Considering R&D and projects of energy efficiency, Petrobras will invest US$ 1.2 billion until 2015

Petrobras Energy Efficiency Goals

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– Downstream: Motorization of large condensate turbines, energy integration, process units optimization, modernization of thermoelectric systems

– Thermal Plants: Convertion symple cycle in combined cycle thermal plants

– Upstream: natural gas compression and logistics investments

Main Projects

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Agenda

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Example of Advanced Control in a Gas Process Unit

• Investiment: US$ 270,000

• Results:– Earnings:

US$ 14 million(in energy efficiency and production)

– Extra production:16,410,000 m³ LGN/year(increase of 9%)

– Energy economy: 2 to 10%

Example of energy efficiency projects

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Furnaces and Boilers Soot Blowing Modernization

Projects

• Refinery Case Example:– Investment: US$ 1.74 million– Energy economy: 305 b/d– Carbon emission avoided:

38,000 tons CO2/year


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Condensate and Steam Modernization Projects

• Fertilizer Plant Example Case :– Investiment: US$ 1.5 million– Condensate recuperated: 20 t/h– Natural gas economy: 4,920 m3/day– Carbon emissions avoided: 3,700 ton

CO2/year


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Fluid Catalytic Cracking (FCC) Turboexpanders

• Recovery energy by substituting pressure reducing valves by a turbine coupled to an electric generator

• 5 refineries• 98 MW of total installed capacity


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Variable Speed Driver Projects

• Refinery Example Case (6 pumps)

– Investiment: US$ 1.7 million– Energy Economy: 800 MWh/year– Carbon emissions avoided: 83 ton

CO2/year

Fonte: WEG


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Dessalinization Units Projects

Offshore Platforms Dessalinization Example Case :

• 3 production units

• Reducing of potable water transportation by ships

• Dessalinization water capacity: 255 m³/day

• Investment: US$ 1.7 million

• Energy economy: 5.2 b/d

• Carbon emissions avoided: 829 ton CO2/year


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Heat Recovery Projects

Process Unit Example Case :• Reduce 70% of furnace thermal

demand

• Investments: US$ 15 million

• Energy economy: 55,000 m³/day of natural gas

• Carbon emissions avoided: 40,000 tCO2/year


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Thermal Solar Energy Projects

Onshore Oil Well Case Example:• To take the paraffin off from the well column• Energy economy: 0.35 b/d

• Carbon emissions avoided: 35 ton CO2/year


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Agenda

HSEE EZR Cogeneration Plant

• This project consists of an integration of two different Business Areas of Petrobras (Downstream and Gas & Energy):

– The RPBC Refinery old boilers were with low energy efficiency

– The Gas & Energy was looking for new thermal plants business opportunties

HSEE EZR Cogeneration Plant – Main Equipments

• 1 Gas Turbine: 171.7 MW (ISO)

• 1 HRSG (120 bar; 42 bar; 12 bar)

• 1 Condensate Steam Turbine: 55 MW

• 2 Auxiliary Boilers

• Startup in 2010

• 2011 in pre-operation

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Combined Cycle Thermal Plant

SteamElectricity

Steam

415 t/h

415 t/h

196 MW

Fuel

Efficiency = 82%

Efficiency = 77,5%

Fuel

19,541 TJ/year

12,953 TJ/year

Without integrationFuel = 23,360 TJ/a

With integration - cogenFuel = 19,541 TJ/year

Energy Economy3,819 TJ/year1,771 b/d

Electricity196 MW

Fuel

Efficiency = 60%10,407 TJ/year

RPBC Boilers EZR Cogeneration Plant

Global Efficiency = 69% Global Efficiency = 82%

EZR Cogeneration Plant – Energy Economy

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Combined Cycle Thermal Plant

SteamElectricity

Steam

415 t/h

415 t/h

196 MW

Fuel

Efficiency = 82%

Efficiency = 77,5%

Fuel

Without integration With integration - cogenCO2 Avoided

Electricity196 MW

Fuel

Efficiency = 60%

RPBC Boilers EZR Cogeneration Plant

EZR Cogeneration Plant – Carbon Emissions

1,532,500 tCO2/year 1,136,500 tCO2/year396,000 tCO2/year

85% FO15% NG

951,500 tCO2/year

100% NG581,000tCO2/year

78% NG22% RG

1,136,500 tCO2/year

CO2 Index = 0,34 tCO2/MWh CO2 Index = 0,26 tCO2/MWh

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• Results:– Energy economy: 1,771 b/d

– Carbon emisisons avoided: 396,000 ton CO2/year

– Lower carbon intensity in Petrobras energy profile– Lower NOx emissions

EZR Cogeneration Plant – Conclusion

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Agenda

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• Implement a new management model for Energy Efficiency

- Future vision - KPIs and goals- New corporative standards

• Insertion of Energy Efficiency requirements in Petrobras new design models

- More efficient designs- Consider the carbon emission

• Projects of energy efficiency in the actual plants- Priorize energy efficiency projects in the Company portfolio

2

3

Operational Efficiency Increases

Profitability Increases

Company Image

Prepare to Future Scenarios

1

Energy Efficiency Challenges in Petrobras

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Thanks!

Claudio RückerEnergy Efficiency Sector

[email protected]

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