Maximizing Energy Efficiency in Petroleum Refining: Case Study—Delayed Coker Unit in an Egyptian Refinery

Delayed coker units are energy intensive processes in refining industries to convert the bottom of the barrel to valuable light hydrocarbons and coke. Energy efficiency of such units has become a target to minimize emissions of carbon dioxide and thus reduce global warming concern. Process integration is a key tool for better energy recovery. A revamping method is proposed to modify an existing network of a delayed coker of an Egyptian refinery to increase energy efficiency, improve profit and cut greenhouse gas emissions. The method is based on graphical techniques and employing Pinch Analysis principles embedded in commercial simulators. The case study considered consists of 29 exchanger units and 36 process streams. The DCU produces LPG with flow of 6.6 t/h, Naphtha with 12.1 t/h, LGO with 35.6 t/h, HGO with 48.9 t/h and coke with flow of 44.1 t/h. The case study resulted in savings of 4.8 MW of hot utility, savings of energy costs of 3,128,854 $ per annum, and equivalent amount of CO2 of 13,426 t/year is reduced annually, contributing to less impact of global warming and climate change. Cutting consumption of energy sources and reducing the CO2 flows to the atmosphere achieve both the SDGs #12 (Responsible Consumption and Production) and #13 (Climate Action).