Petrochemical Industry: A Study On Energy Efficiency Index in

Disseminated Document
A Study on Energy Efficiency Index in

Petrochemical Industry
LOGO
Disseminated Document
A St
Study
d on Energy
E Efficiency
Effi i Index
I d ini
Petrochemical Industry
Department of Alternative Energy Development and Efficiency (DEDE)
PREFACE

Petrochemical Industry is one of the most important primary industries to
Thailand’s economic development. It is the foundation of wide variety of industrial production
processes such as plastic and container industry, textile industry, rubber industry, agricultural
and fertilizer industry. These industries help create tremendous value added to Thailand
exporting sector. In 2006, the exporting values of upstream, intermediate and downstream
petrochemical products are 27,694, 41,729 and 15,1468 million Baht, respectively. In addition,
the country also saves millions of bath per year on importing goods. The utilization of natural
gas in the process is also a right direction on increase the value of locally available raw material
which, in turn, benefit to Thai’s economy and society as a whole. Continued expansion of this
industrial sector is foreseeable in the future.
Production process of petrochemical industry is considered one of the most energy
intensive operations. Due to increase energy consumption trend of this industry and to correctly
accommodate the future economic expansion, it is important to facilitate this industry to
efficient energy management initiatives in order to optimize the whole process while maximize
the benefit. In addition to the gain from energy conservation and higher energy efficiency, this
will enhance the capability of the industry to compete on the global scale. From these reasons,
the Department of Alternative Energy Development and Efficiency (DEDE), a responsible
governmental body who oversee the industrial energy management, considers this important
strategy and duty to promote the increase in energy efficiency of petrochemical industry. The
activities will be carried out under the Energy Conservation and Promotion Acts of 1992.
One strategy which the Department of Alternative Energy Development and Efficiency
has been executed to urge the industry about the energy efficiency is the analysis of energy
usage per production unit (Energy Index, EI). Hence it is DEDE’s initiative to develop Energy
Consumption of Petrochemical Industry in Thailand project to use the energy consumption
data of this industry as a step to develop energy benchmarking standard. Moreover, the
acquired information may be evaluated for preparation of energy efficiency index and energy
conservation of each manufacturer. Finally, the outcome of this project may lead to the right
direction on defining the appropriate future plan for energy conservation plan of petrochemical
industry.
This report is to distribute the result of this project which includes the analysis of energy
consumption index of petrochemical industry, approach on promotional plan for energy
conservation, and techniques for efficient energy usages. Authors hope that this report will
further be more or less useful to stake holders and any involved parties.
A Study on Energy Efficiency Index in Petrochemical Industry
CONTENT

PREFACE

CHAPTER 1 : OVERVIEW OF THAILAND PETROCHEMICAL INDUSTRY 1
1.1 The Petrochemical Industry Structure 1
1.2 Types of Petrochemical Industry 4
1.3 Petrochemical Feedstock 6
1.4 How Petrochemical Industry Affects Economic System 7
1.5 Energy Consumption of Petrochemical Industry in Thailand 12
CHAPTER 2 : ENERGY CLASSIFICATION OF PETROCHEMICAL INDUSTRY 14

2.1 Classification of Petrochemical Industry 14
2.2 Production Processes 15
CHAPTER 3 : ENERGY CONSUMPTION IN PETROCHEMICAL INDUSTRY 22
3.1 Energy Consumption Index 22
3.2 Specific Energy Consumption (SEC) 23
3.3 Evaluation of Energy Intensity (EI) 29
CHAPTER 4 : THE PROMOTION OF ENERGY CONSERVATION 31
4.1 Problems in Petrochemical Industry 31
4.2 SWOT Analysis 32
4.3 Promotional Plan for Energy Conservation In The Petrochemical 33
CHAPTER5 : TECHNOLOGY AND MEASURES FOR ENERGY CONSERVATION IN
36
PETROCHEMICAL INDUSTRY
5.1 Development and Improvement of Production Technology 36
5.2 Energy Efficiency Improvement for Processes and Equipments 40
SUMMARY 48
REFERENCES 50
LIST OF ABBREVIATION 52
Department of A
Alternative En
nergy Develop
pment and Effiiciency (DEDEE)
1. OVERV
VIEW OFF PETROC
CHEMICA
AL INDUSSTRY
Petroch
hemicals reefer to hydrrocarbon orgganic chemiicals producced using peetroleum
prod
ducts such ass crude oil, n
natural gas and natural gas condensates as raw m
materials.
1

1.1 The Petrrochemicaal Industryy Structurre
While th
he petrochem
mical industtry is part off the chemicaal industry, iit differs from
m the oil
refin
ning industryy in that it uses some products from
m the oil refin
nery as raw materials for specific
chem
mical produccts. Generally, companies which produce petro
ochemical products do not refine
oil themselves. Even tho
ough there are some which do so,
s they wo
ould have separate
adm
ministrations for their reffinery and th
heir petroche
emical produ
uction. In otther words, tthe main
purp
pose of thee oil indusstry businesss is to produce enerrgy, getting raw materials for
petrrochemical products
p as their by‐pro
oducts. Meaanwhile, the petrochemical industryy aims at
prod
ducing a ho
ost of chem
mical products, as sho
own in Figu uction of Thailand’s
ure 1 produ
petrrochemical in
ndustry from
m 2003 to 200
06.
18
8,000
16,372
15,660
0
16
6,000 15,034
14,239
14
4,000
12
2,000
Production (KTA)
10
0,000
8
8,000
219 6,436 6,53
36
5,707 5,935
5 5,887 6,,329 6,2 5,945
6
6,000
3,891
4
4,000 2,818
8 3,004
2,597
2
2,000
‐
2003 2004 2
2005 2006
Year
To
otal Productio
on U
Upstream Petrrochemicals
In
ntermediate Petrochemicals D
Downstream PPetrochemicalls
Source: PTIT, 2007
P

Figure 1 Production of Thailand’s petrochem
mical industryy from year 2
2003 to 2006
6.
A Study on Energy Effiiciency Index in
n Petrochemica
al Industry
In general, the petrochemical industry uses raw materials from the petroleum industry
to manufacture products such as plastic resins, synthetic fibers, synthetic rubbers, surface
coating materials and various types of adhesives. These products are considered primary raw
2 materials for human beings’ basic consumption items, occupational tools and equipment, and
various amenities for mankind. Figure 2 shows the links between the petroleum industry and
petrochemical industry; Figure 3 shows the structure of Thailand’s petrochemical industry.

Figure 2 Thailand petroleum and petrochemical network

Department of A
Alternative En
nergy Develop
3
Soource: PTIT, 20006
Figure 3 Thailand petrochhemical compplex flows
n Petrochemica
al Industry
1.2 Types of Petrochemical Industry
The petrochemical industry is classified into 3 main groups, on the basis of their
products (as shown in Figure 4).
4
Upstream Petrochemical Industry
Intermediate Petrochemical Industry
Downstream Petrochemical Industry

Value chain
component Oil & Gas
Conversion
Upstream Intermediate Downstream
Industries
Supporting: Infrastructure, Logistic, HR, Finance, Rules& Regulations

Key
activities
• E&P • Olefins • Olefins • Plastic Resins • Compounding
• Oil - Ethylene - EDC/VCM Commodity
(PE, PP, PVC, PS, EPS,
Refinery - Propylene - EO**/EG** PET)
• Gas • Aromatics - Oxo Alcohol* Engineering
(PC, POM, PBT*, Nylon
separation
- Benzene - Acrylonitrile* 6,6*, PMMA)
- Para- • Aromatics Synthetic Fibre
Xylene - Ethylbenzene** - Polyester
- Styrene - Nylon 6
- Cyclohexane** - Polypropylene
- Caprolactam - Acrylic
Syn. Rubber/
- Cumene/Phenol** Elastomers
- PTA - BR, SBR, EPDM*
Note:
- PA Syn. Coating/
Adhesives
* No local production,
- PVA*, Silicone
** Investment in progress

Figure 4 Overview of Thailand petrochemical industry

1.2.1 Upstream Petrochemical Industry
Upstream petrochemical industry is the production of petrochemical products which are
feedstock for further production of other petrochemical products (intermediate and
downstream). It consists of 7 kinds of products, or “the Seven Sisters”, which are divided into
the following 3 groups on the basis of their molecular structure:
Alkane group, which is methane‐based
Olefin group, which is ethylene‐based, propylene‐based and Mixed C4‐based
Aromatic group, which is benzene‐based, toluene‐based and xylene‐based
1.2.2 Intermediate Petrochemical Industry
Intermediate petrochemical industry uses upstream petrochemical products as feedstock
and supplies to downstream petrochemical industry. Its products are grouped on the basis of
their upstream petrochemicals, as follows:
5
Alkane Intermediates, namely, products from upstream methane, such as methanol or
methyl alcohol, formaldehyde, ammonia, phosgene, etc.
Olefin Intermediates, namely, ethylene products such as ethylene dichloride, (EDC),
vinyl chloride monomer (VCM), ethylene oxide (EO), and ethylene glycol (EG),
propylene products such as oxo alcohol and acrylonitrile
Aromatic Intermediates, namely, benzene products such as ethyl benzene (EB),
styrene monomer(SM), cyclohexane, carprolactam, and paraxylene products, etc.

1.2.3 Downstream Petrochemical Industry
Downstream petrochemical Industry uses upstream or intermediate petrochemical
products as feedstock to manufacture downstream products or end products prior to conversion
in other industries. They are categorized by end product, as follows:
Plastic resins
Synthetic Fibers
Synthetic rubbers
Synthetic coating and Adhesive materials
ดิบสําหรับการผลิตอุตสาหกรรมปโตรเคมี

1.3 Petrochemical Feedstock
There are 2 types of feedstock for the petrochemical industry: natural gas and naphtha.
The selection of feedstock varies on the advantages and disadvantages in the access to the
6 feedstock, and therefore varies from one country to another. For instance, in countries like the
USA, Canada, and the Middle East, production of petrochemicals is from natural gas, whereas in
Japan, Korea, Singapore, and Europe, which do not have natural gas, naphtha is used instead,
since it is sold in the world market and is easy to transport. In the case of Thailand, both are
used. The type of feedstock also determines the manufacturing process used by manufacturing
plants. Figure 5 shows feedstock sources for the industry.

• Methane
Petrochemical
Gas separation Feedstock • Ethane
Wet gas • Propane‐Butane (LPG)
• NGL
Dry gas
• LPG
• Naphtha‐Gasoline
Crude oil Refinery Refined products • Gas Oil – Kerosene,
Jet, Diesel
• Fuel Oil
• Bitumen
• Etc.
• LPG
Petrochemical • Naphtha
Feedstock • Gas Oil
Condensate Petrochemical • LPG

Condensate Splitter Feedstock • Naphtha
Residue
Figure 5 Petrochemical feedstock

1.4 How Petrochemical Industry Affects Economic System

1.4.1 The Role of Petrochemical Industry in Thailand
The petrochemical industry brings in tremendous, uninterrupted revenue to the country 7
as show in Table 1. In year 2006, total revenue from petrochemical industry exceed 447.760
million Baht which is equivalent to 6‐percent of gross domestic product (GDP). Moreover, the
industry also generates important raw materials for several downstream industries such as
automachine, electrical and electronics, cosmetics, agricultural, packaging and textile industries.
The petrochemical industry has a significant effect on the development of the country
directly and indirectly. Not only does it add value to oil and natural gas, but it is also related to
numerous other industries as shown in Figure 6, for example, packaging, spare parts, electronic
parts, textile, construction, etc
Table 1 Values of Thailand’s petrochemical production
2545
2002 2546
2003 2547
2004 2548
2005 2549
2006
GDP: Current Price (MM Baht) 5,450,643 5,928,975 6,503,488 7,104,228 7,423,918
Petrochemical Status
• Total Revenue (MM Baht) 239,060 290,150 382,500 432,645 447,760
Compare to GDP 4.4% 4.9% 5.9% 6.1% 6.0%

•Net Revenue: Exclude Import 153,202 188,578 244,486 264,231 260,714
Portion (MM Baht)
Compare to GDP 2.8% 3.2% 3.8% 3.7% 3.5%
•Value Added of Petrochem. Ind.: 128,458 143,812 182,829 181,427 160,257
Exclude Import and Feedstocks
(MM Baht)
Compare to GDP 2.3% 2.4% 2.8% 2.6% 2.2%
Note: B.E.2006
2549 estimate GDP growth 4.5%, FX = 38 Bath/$

Source : PTIT Focus, 2005

.

8

Figure 6 Downstream petrochemical production values

In addition to producing ample supplies for domestic demand, in 2005 the
petrochemical industry had more than 200,000 million Baht worth of surplus output for export,
or 4.85 percent of the country’s export value.


Values Generated by Natural Gas Year 2005
Values Generated by Natural Gas – B.E. 2548
Unit: Million Baht
Gas Prod. Gas Used Direct Economic

9
835,743 790,080 Financial Multiplier
MMSCF MMSCF Benefit
Value
Valuelost
183,676
• Industry Value lost
ifif import
import fuels
fuels
– Electricity 79.6% 194,899 9 (194,899 - 183,676 = 11,223
(194,899 - -imported
electricity 183,676f uel = value
= 11,223
added)
– E&P 100.0% 230,749 9
electricity - imported fuel = value added)
414,82 8
– Petrochemical 11.3% - 100,576 9
(NG) 158,277 Incremental
Incremental
- 57,701 values
valuesforgone
forgone
(Condensate) * 9 ififindigenous
indigenous
–LPG gas
gasnotnotused,
used,
9.1% 25,802
(excl. LPG for feedstock) and import
and import
66,400
fuel
fuelinstead
instead
• Government Take
– Income Tax - E&P 36,957
– Royalty - E&P 29,443


Figure 7 values generated by natural gas year 2005
Figure 7 shows that the petrochemical industry, which uses only 11.3 percent of natural
gas, generates as much revenue as 158,277 million Baht., whereas electricity industry, which
uses 79.6 percent of natural gas, generates 197,899 million Baht. In other words, revenue from
petrochemical industry is approximately 80 percent that of electricity generation, but
petrochemical industry uses only 14 percent of the volume of natural gas used in generating
electricity. This is the reason why Thailand must conduct a serious study and continue to
develop petrochemical products.

1.4.2 Petrochemical Production
1) Production
• Production Capacity
10
In 2006 production capacity of Thailand’s petrochemical industry was
19,000,000 tons, comprising 6.5 million tons upstream products, 4.5 million tons of intermediate
products, and 8.0 million tons of downstream products, as shown in Figure 8. It can be seen that
the industry has continuously expanded from year 2002 onward, with a total of 4.0 million tons
growth between years 2002 and 2006.
2002
2545 2546
2003 2004
2547 2005
2548 2006
2549
B.E.2549 is estimation data
Figure 8 Thailand petrochemical production capacity

• Production and Production Rate
Thailand produced nearly 16,000,000 tons of petrochemical products in 2005
and was then expecting more than 16,000,000 tons for 2006 (Figure 9). In downstream
industries, the production increased highest from years 2005 due to the new downstream plants
have been started to produce in various petrochemical substance for example cyclohexane and
PTA. The Intermediate products also illustrated an increase, while upstream products decreased
due to halt in operation for the purpose of maintenance and repair.

KTA Thailand Petrochem ical Production
18,000
16,000
14,000
12,000
10,000 11
8,000
6,000
4,000
2,000
0
2545
2002 2546
2003 2547
2004 2548
2005 2549
2006
Upstream Intermediate Downstream

N.B. Years 2006 approximated values.

Figure 9 Production volume of petrochemical products from years 2002 to 2006 (PTIT)

Table 2 Average operation capacity of Thailand‘s petrochemical industry from years 2003‐2006
Petrochemical Capacity Average (%)
Industry 2002 2003 2004 2005 2006
Upstream 89 99 98 94 90
Intermediate 85 98 100 90 81
Downstream 86 87 88 86 85
Source: PTIT, 2006
Upstream and intermediate petrochemical production had an average of 90‐95 percent,
while downstream production had 85 percent of production capacity. In 2006 downstream
production slightly decrease as newly set‐up facilities were not operating in full yet.
Analyses of recent periods have found that production and marketing have been
growing satisfactorily, and will continue to rise. The liberalization of petrochemical trade during
the past decade plus the country’s managing to sail through the 1997 economic crisis have
helped strengthened the Thai entrepreneurs, who saw the need to unite to increase their
business potential. Markets have expanded noticeably, both domestically and abroad.

1.5 Energy Consumption of Petrochemical Industry in Thailand
The petrochemical industry relies heavily on energy. With its present growth rate, and
as companies are also constantly trying to expand their production, consumption of electricity,
12 gas and fuels will increase unavoidably, no matter how much emphasis is given to energy
conservation.
1.5.1 Energy consumption
From the data compiled from 30 plants producing upstream, intermediate and
downstream petrochemicals, the study has found that consumption of energy is highest in the
upstream industry, (data from all the plants in Thailand) as shown in Table 3
Table 3 Energy consumption in Thailand’s petrochemical industry
Petrochemical Audited Energy Use (Ktoe)

Industry Plants (%) Year 2005 (%) Year 2006 (%)
Upstream 100 2,172 68.91 2,186 64.48
Intermediate 43 213 6.76 475 14.01
Downstream 32 768 24.33 729 21.50
Total 3,152 100.00 3,390 100.00
However, energy consumption of the country’s entire industrial sector, including food,
drinks, textiles, wood, chemicals, paper, ceramic, cement and metal (referred from energy
consumption data from DEDE’s energy consumption annual report), was selected to compare
the energy used in the petrochemical industry. It was found that the petrochemical sector
consumes 15 to 17 percent of the total industrial sector’s consumption.

1.5.2 Proportion of Energy Consumption in Petrochemical Industry
Consumption data compiled from selected manufacturing plants in 2006 shows the main
energies used in the manufacturing process of products consists of electricity, steam, natural gas
(NG), liquid petroleum gas (LPG), diesel oil, fuel oil, and others (process off‐gas, fuel gas, etc.) as
13
shown in Table 4 and illustrated in Figure 10
Table 4 Proportion of Energy Consumption (%)
Energy Type Ratio (%)**
Natural Gas 42.0
Steam 38.0
Electricity 6.0
Fuel oil 1.7
Diesel oil 0.6
LPG 0.6
Others (Process off‐gas, Fuel gas, etc.) 11.1
Total 100
**estimation value from participating petrochemical plant

Electricity
Fuel Oil
6%
Diesel
1.7% Others
0.6%
11.1%
LPG 0.6%

Steam
38%

Natural Gas
42%

Figure 10 Proportion of energy consumption in years 2006

As shown above, natural gas is the topmost energy being used in petrochemical
production (mostly as direct fuel for the oven, or direct heat), while stream is second in quantity.
Other types of energy, also estimated from consumption in the production process, are used at
smaller quantities.
2.CLASSIFICATION OF PETROCHEMICAL INDUSTRY

2.1 Classification of Petrochemical Industry
14
The petrochemical industry covers a vast array of products, and the manufacturing
processes vary from one product to another. Sometimes the same products use different in raw
materials, technological processes, and even different equipment. For this reason, energy is
used in varying amounts.
However, from this study, in which consumption of energy is compared using
international basis, the industry is classified on the basis of production process, with the aim to
present an analysis of indices of energy consumption which are correct, suitable and beneficial
but without harming the existing plants from where data were given. The study result will reveal
overall facts and figures of each group as a whole, and not of individual products. This is
because there are not too many petrochemical plants in Thailand, and presenting too detailed
data may be revealing confidential information of the businesses.

Therefore, petrochemical industry were divided into 3 groups as follows:
Upstream Petrochemical Industry)
- Olefins Group
- Aromatics Group
Intermediate Petrochemical Industry
Downstream Petrochemical Industry
- HDPE
- PS, PP, EPS
- Emulsion PVC, ABS, SAN, PC

2.2 Production Processes

2.2.1 Upstream Petrochemical Production
Upstream petrochemical industrial process aims at producing primary feedstock for the
next group of products. Its production process is shown in Figure 11‐13 (source: PTIT 2006), with 15
7 major products, namely, methane, ethylene, propylene, Mix C4 benzene, toluene and xylene as
the basic chemicals for further petrochemical development. There are 2 major processes, as
follows:
1) Cracking Process
Cracking is a process in which molecules of raw material are dissociated into smaller
ones. There are two types of cracking process, thermal steam cracking and catalytic cracking.
Thermal Steam Cracking Catalytic Cracking
Steam cracking is the dissociation of raw Dissociation of larger, stable molecules
material such as ethane and propane requires catalysis. Refinery products such
yielding important petrochemical products, as gasoil and fuel oil may be passed
through catalytic cracker to obtain gasoline
ethylene and propylene, mixed C4, pyrolysis
and diesel as major products and by‐
gasoline. Methane and hydrogen are also product, propylene, which is primary
some of major by‐products. petrochemical product.
2) Reforming Process
Reforming of hydrocarbon structure may be accomplished by the use of heat,
pressure and/or catalyst in order to obtain desired products. This process converts heavy
naphtha to aromatics such as benzene, toluene and xylene as well as hydrogen as by‐product.
Reforming may be carried out by several following methods.
Dehydrogenation is a process in which hydrogen atoms are being taken away from
saturated hydrocarbons structure leaving product of unsaturated hydrocarbons such as
the dehydrogenation of cyclohexane to aromatics.
Dehydrocyclization is a process in which hydrogen atoms are being taken away from
aliphatic hydrocarbons yielding aromatics such as dehydrocyclization of paraffin.
Dealkylation is the extraction of alkyl group from toluene and xylene yielding benzene.
Transalkylation or Disproportionation is the combination process of two molecules
resulting in two new molecules which are bigger and smaller than precursor ones i.e.,
catalytic transalkylation of toluene to benzene and xylene.
Isomerization involves the molecular restructuring of material while retaining the same
number of atoms i.e., isomerization of o‐xylene and m‐xylene to p‐xylene.
16
Figure 11 Production processes of methane, ethylene, propylene and mixed‐C4 from NG or
propane
Figure 12 Production processes of methane, ethylene propylene and mixed‐C4 from naphtha or
gas oil
Figure 13 Production processes of benzene, toluene and xylene
2.2.2 Intermediate petrochemical Process
Intermediate petrochemical industrial process uses upstream products as feedstock for
downstream production industry. Intermediate products can be divided into the following
classes:
17
Olefin Intermediates
Aromatic Intermediates
Alkane Intermediates
The production process of Intermediate petrochemical is complex and differs from one
product to another. It is also related directly to downstream process. See Figure 14‐16

Figure 14 Production process of Vinyl Chloride Monomer (VCM)

Figure 15 Production process of Styrene Monomer (SM)

18
Figure 16 Production process of Pure Terephthalic Acid (PTA)

2.2.3 Downstream Production
Downstream petrochemical industrial process relies on upstream and intermediate
production process in producing what is to be converted to final products. Downstream
products can be grouped as follows:
Plastic Resins, compose of
• Commodity Plastics
• Engineering Plastics
• High Performance Plastics
Synthetic Fibers
Synthetic Rubbers, Elastomers
Synthetic Coating and Adhesive Materials
Polymerization is a major process for production of downstream petrochemicals. This
process involves the combination of monomers into long chain polymer. Typically,
polymerization process requires the use of catalysts, heat and pressure in order to achieve
complete reactions. Polymerization may be performed by several methods such as:
Gas phase polymerization under high pressure and temperature
Solution phase polymerization under high pressure and temperature
Bulk or batch polymerization under moderate pressure and temperature
Suspension polymerization under moderate pressure and temperature
Emulsion polymerization under moderate pressure and temperature
19
Figure 17 Production process of LDPE

Figure 18 Production process of LLDPE by solution phase polymerization

Figure 19 Production process of LLDPE by solution phase polymerization
20
Figure 20 Production process of PVC by suspension polymerization

VCM
Recovery
Latex
VCM Slurry
Polymerization Reactor Storage and Dryer Grinding Classifier
Stripper
Seiving
Storage
Raw Material Raw Material
Storage and
Preparation
Packing
PVC Resin
Figure 21 Production process of PVC by emulsion polymerization

Figure 22 Production process of PP
21
Figure 23 Production process of PVC Resin
Figure 24 Production process of PP by gas phase polymerization

Figure 25 Production process of ABS

3. ENERGY CONSUMPTION IN PETROCHEMICAL INDUSTRY

3.1 Energy Consumption Index
22
Appropriate calculation of indices of energy consumption in the petrochemical industry
used in Thailand and worldwide are: Specific Energy Consumption (SEC) and Energy Intensity
(EI). Assessment is necessary in order to lead to development of plant efficiency. SEC is
calculated from the energy that a plant consumes during a cycle of operation, for example, one‐
month, per product of that same period. EI is defined as the proportion between the energy
consumed in the production process the country’s gross domestic product (GDP) or other unit
such as ton of product, production value, transport value, etc. The energy consumed being
analyzed differently depending on its source, for example, heat, electricity energy, or total
energy. The calculation method is as follows:

Energy Consumption (MJ)
Specific Energy Consumption (SEC ) =
Primary Products (Ton)
Energy Consumption = Purchased Fuel + Plant Fuel – Export Utilities
Primary Products = Main Product (Ton)

EnergyConsumption ⎛ TOE ⎞
Energy Intensity(EI) = ⎜ ⎟
Valueof PrimaryProducts ⎝ MMBaht⎠
Energy Consumption = in unit ton of oil equivalent (TOE)
Value of primary product = value of primary products in million baht per ton

The indices will be tremendously helpful in monitoring and controlling energy
consumption. Therefore, plants should monitor them recorded monthly. The collecting data
can reflex whether consumption is increasing or decreasing, and be used for energy
benchmarking as a useful tool for evaluating the efficiency of the plant.

The scope of this study focuses only petrochemical plants; it does not include gas
separation plants and oil refineries. It assesses plants according to their products, from
upstream products ‐‐ olefins plants and aromatic plants ‐‐ to downstream, stopping at plastic
resin plants, and excluding plastic compounding and other industries.
23
The energy consumption figures used are drawn from the main production process; it
does not cover utilities, transportation, and offices units. The analysis takes into account all
factors that affect operation efficiency. For example, in the case of olefins plants, where other
products are manufactured in addition to the main products, only the olefins being ethylene and
propylene will be considered, not mixed C4 or other olefins, which are in much smaller
quantities, of unstable prices, and not the main target products of the plants.

3.2 Specific Energy Consumption (SEC)
Analysis results of the assessment of the 30 plants joining the study project are
presented in term of overall average, maximum and minimum values of the years 2003‐2006, as
shown in Table 5 and in sections 3.2.1 to 3.2.3.

Table 5 Range of specific energy consumption (SEC) in MJ/Ton of upstream intermediate and
downstream petrochemical industry in year 2004‐2006
SEC
Petrochemicals Products (MJ/Ton)
– Olefins Olefins (Ethylene, Propylene) 16,900 ‐ 24,900

Upstream
– Aromatics Aromatics (B, T, X) 3,200 ‐ 17,100
Intermediate PTA, EB, SM, PA, EG, Polyol 1,900 ‐ 27,000
HDPE 2,700 – 3,600
Downstream PS, PP, EPS 1,000 – 2,000
Emulsion PVC, ABS, SAN, PC 2,700 – 12,500

The SEC value from the 30 participating plants reveals a rather wide range which can be
explained by the limited number of the plants existing in the country. The plants produce
different products, and even similar products are manufactured with different technologies and
processes. Nevertheless, compared to the USA (see Table 10), SEC value of petrochemical
industries in Thailand fall in almost the same bracket.
Deepartment of Alternative En
nergy Develop
pment and Effficiency (DEDEE)
Also, consum
mption of en
nergy for diffferent prod
ducts vary in quantity, depending on
n the
kind of p
product, thee raw materiaal used, tech
hnology, production proccess, size of the plant an
nd its
production capacity,, etc.

24 3.2.1 Energy Consumptiion in Upsstream Ind
dustry
Oleefins Aromatic Production A

Aromatic Production Olefin
25
5,000 900,000
771,888 839,46
66
800,000
Specific Energy Consumption (MJ/Ton)
721,300 727,164
4
20
0,000 700,000
600,000
Productivity (Ton)
510,502 505,354
4
15
5,000
500,000
400,000
10
0,000
280,045 2
294,979
300,000
5
5,000 200,000
100,000
0 0
2003 2004 20
005 2006
Year

F
Figure 26 Sp
pecific energgy consumpttion (SEC) of upstream peetrochemical industry

Olefins
Table 6 Specific energy consump
ption (SEC) o
of upstream p
petrochemiccal industry ––olefins in ye
ear
2003 – 20066
Upstream Pe
U etrochemicaal‐Olefins
SEC (MJ/Ton)
2
2003 2004 2005 2006
6 Average
16,000‐24,500 17,000‐24,800 17,0
000‐25,100 16,500‐24
4,900
average averagee aaverage averagge 21,227
199,892 20,419 21,092 21,168

Tablle 6 shows tthat SEC of o
olefin group of productss is higher th
han the otheer groups. Th
his is
becausee olefins prod
duction requ
uires a more complicated
d process, mo
ostly thermaal cracking, w
which
A Study o
on Energy Efficciency Index in Petrochemica
al Industry
consumes a lot more energy than intermediate and upstream industries. However, most of
these olefins producing plants use steam produced during the production process itself. They
even have surplus steam to sell to nearby plants. But in the data cited here, the sold amount is
excluded, and only energy consumed in the manufacturing of the products is taken into account.
25
This study finds that the SEC value from all olefins plants in Thailand does not differ
much from that of the same industry in other countries (as shown in Table 10). But the wide can
be explained by the fact that there are only 4 olefins plants in all of Thailand, each with a
markedly different production technology. In addition, only 2 main types of feedstock are used,
that is, ethane and naphtha. In producing olefins (ethylene and propylene) alone, the plants
using ethane as feedstock naturally consume less energy than those using naphtha, because
ethane is of smaller molecules, which can be cracked easily. But this does not mean that plants
using naphtha are of a disadvantage. In fact they do have valuable by‐products which they can
sell to compensate for the cost of energy.

Aromatics

Table 7 Specific energy consumption (SEC) of upstream petrochemical‐aromatics in year 2003‐
2006
Upstream Petrochemical ‐ Aromatics
SEC (MJ/Ton)
2003 2004 2005 2006 Average
3,000 ‐ 8,700 2,800 ‐ 8,500 3,300 ‐ 17,000 3,100 ‐ 17,000
average average average average 6,987
5,708 5,425 8,146 7,960
Remarks: The values of SEC in 2003 and 2004 are lower than those of 2005 and 2006 because some of the
participated plants did not collected data during those years. Thus SEC values for 2005 and
2006 are more realistic..

The upstream, aromatic production industry in Thailand consists of 4 plants, almost all of
which give importance to manufacturing 3 high value products – benzene, toluene and xylenes.
From studying the SEC value of this group of products, it is found that energy consumption also
has a wide range, again because aromatic plants in this country use different raw materials,
technologies and processes. In plants which use condensates as raw materials, the production
nergy Develop
process is more com
mplicated than the oness that use byy‐products su
uch as raffin
nates and mixed‐
xylene, aand thereforre consume m
much more eenergy. How
wever, they can produce more varieties of
products and at largger amounts.

26

3.2.2 Energyy Consump
ption in In
ntermediaate industtry

Intermediate Productiion
25
5,000 250,000
20
0,000 200,000
174,277
Productivity (Ton)
146,287
15
5,000 135,454
1 139,,368 150,000
10
0,000 100,000
5
5,000 50,000
0 -
ป 2546
2003 ป 2547 20
2004 ป 25548 ป 2549
005 2006

Figgure 27 Speecific energy consumption (SEC) of inttermediate p
petrochemiccal industry

Table 8 Specific energy consump
ption (SEC) o
of intermediaate petrochemical industtry in year 20
003‐
2006
Inttermediate P
Petrochemiccal Industry
SECavverage (MJ/Ton
n)
2
2003 2004 2005 2006* Average
2,100 ‐ 10,300 1,900 ‐ 10,5
500 1,900
0 ‐ 10,500 1,900 ‐ 28,,000
aveerage average avverage averagee 4,685**
4,,533 4,659 4
4,659 4,841
Remarks *SEC for 20
006 is higher than those of
o other yearss because onee participated
d plant which high
energy consumption was starting up p that year.
**Calculated from all SEC vvalues from 2003‐2006 except one particcipated plant which high en
nergy
consumpttion that start operating in 2006

A Study o
al Industry
Department of A
Alternative En
nergy Develop
The SEC
C value of plants produccing intermediate petrocchemical pro
oducts (PTA, EB, SM,
PA, EG and Polyyol) has a ratther high (Taable 8) especially in 2006 when plan
nts were in ttheir first
stagge of operaation and their
t energyy conservation measurres and/or production process
adju
ustments were not yet in unt of energgy quite high. In addition
n place, makiing the amou n to that,
the products aree numerous (PTA, EB, SM
M, PA, EG and Polyol), aand productiion technolo
ogies and 27
raw materials markedly
m vaaried. How
wever, to prroduce high value petrochemical products,
p
mally more eenergy is neeeded, and the by‐productts are usuallyy high in valu
norm ue as well.
3.2.3 Eneergy Consu
umption in
n Downstream Petrochemicaal
SEC Downstreeam Downstream Production
25,000 250,000
20,000 200,000
Productivity (Ton)
147,069
9
15,000 139,739 150,000
121,623 124,,225
10,000 100,000
5,000 50,000
0 -
2003
ป 2546 2004
ป 254547 2005
ป 2548 ป2006
2549
Figure 28 Specific eneergy consum
mption (SEC) o
of downstreaam petrocheemical industtry

Tablle 9 Specificc energy conssumption (SEEC) for Down
nstream Petrrochemical yyear 2003‐20
006
Downstreaam Petroche
emical Indusstry
SEC (MJ/Ton)
2003 20
006 2005 2
2006 Averagge
9
900‐12,000 900‐1
11,900 900‐15,000 1,800
0‐11,000
3,712
2
average averrage average avverage
3,993 3,6
652 3,610 3
3,601
n Petrochemica
al Industry
The SEC value of plants producing downstream products (HDPF, PS, PP, EPS, PVC, ABS, SAN and
PC) averaged out during 2003 and 2006 also has a rather high discrepancy (Table 9). This is
because most of the industry (the participating plants in this study project) produces mainly
plastic resins ‐‐commodity plastics and specialty plastics. Usually specialty plastics such as
28 thermosetting plastics consume more energy, because the process is more complicated. Even
among commodity plastic production plants, the amount of energy consumed varies. Special
grade plastics such as the medical‐grade consume higher energy than lower‐grade plastics.

3.2.4 Energy Consumption in Other Countries
Table 10 summarizes the energy consumption of petrochemical products in other
countries. The data shows the difference in SEC from product to product. The energy
consumption depends mainly on products. The difference in technologies, processes, and raw
materials contribute to the difference in SEC.
Table 10 Specific energy consumption (SEC) of petrochemical products in other countries
Product SEC SEC average

(MJ/Ton) (MJ/Ton)
Olefins 12,561 ‐ 25,120 18,841
Aromatics (BTX) 2,310 ‐ 3,521 2,917
Ethylene Glycol (EG) 3,488 ‐ 6,017 4,753
Ethylbenzene 3,028 ‐ 3,498 3,263
Styrene monomer (SM) 33,396 ‐ 45,113 39,255
Terephthalic acid (PTA) 3,121 ‐ 5,145 4,134
Polyethylene (PE) 1,483 ‐ 3,993 2,738
Polypropylene (PP) 1,129 ‐ 1,260 1,195
Polyvinyl chloride(PVC) ‐ 2,896
Source: Energetics Incorporated, 2000

Table 11 Specific energy consumption (SEC) of petrochemical products in Thailand and other
countries
USA Thailand
Products
SEC (MJ/Ton) SEC (MJ/Ton)
29
Olefins 12,561 ‐ 25,120 16,900 – 24,900
Aromatics (BTX) 2,310 ‐ 3,521 3,200 – 17,000
Ethylene Glycol (EG) 3,488 ‐ 6,017
Ethylbenzene 3,028 ‐ 3,498
1,900 – 10,500
Styrene monomer (SM) 33,396 ‐ 45,113
Terephthalic acid (PTA) 3,121 ‐ 5,145
Polyethylene (PE) 1,483 ‐ 3,993 2,700 – 3,600
Polypropylene (PP) 1,129 ‐ 1,260 1,000 – 2,000
Polyvinyl chloride(PVC) ‐

3.3 Evaluation of Energy Intensity (EI)
Energy Intensity (EI) was evaluated as energy in term of Ton of Oil Equivalent (TOE) per
value of one ton of product (million baht). The data from energy auditing of participated plants
and the value of petrochemical products in 2006 from Petroleum Institute of Thailand was used
in the calculation.

Table 8 Energy Intensity, EI (TOE/million baht) for petrochemical industry between 2003‐2006
EI EI
Petrochemicals Products
(TOE/mil Baht) (MJ/1,000 Baht)
Olefins (Ethylene,
Olefins Propylene) 0.98 ‐ 1.5 410 – 630
Upstream
Aromatics Aromatics (B, T, X) 20.4 ‐ 10.5 100 – 440
PTA, EB, SM, PA, 0.79 – 5.0

Intermediate EG, Polyol 30 – 210
HDPE, PS, PP, EPS, 0.26 – 3.3

Downstream PVC, ABS, SAN, PC 10 ‐ 140
nergy Develop

15.00
1
Specific Energy Consumption (TOE/Mil Baht) 12.44 12.49
11.73 12.04
30
10.00
1
4.96 5.01
5.00 3.51 3.30
2.57 2.5
56 2.57 2.55
1.35 1.22 1.18 23
1.2
0.00
2003 2004 20005 2006
Upstream: Olefins 11.73 12.04 122.44 12.49
Upstream: Arromatic 3.51 3.30 4.96 5.01
Intermediate 2.57 2.56 2.57 2.55
Downstream 1.35 1.22 1.18 1.23

Figurre 29 Energyy Intensity, EI (TOE/millio
on baht) for P
Petrochemical Industry b
between years
2
2003‐2006

Energy inten decreases in order from olefin upstre

nsity, in the petrochemiccal industry d eam,
aromatic upstream,, intermediaate and dow
wnstream products. As indicated eearlier, upstrream
petrocheemical is co
omplicated and
a consumed more en
nergy than other
o processes. Upstrream
product is normally cheaper than
t products from otther categories. Comp
paring upstrream
products with down
nstream prod
duct s which
h consume le
ess energy aand sell at high price, en
nergy
intensityy (EI) of petrochemical products tend
d to decrease
e from upstrream producct to downstrream
product as indicated
d in Figure29
nly a small reduction of energy conssumption, fo
However, on or example, 2
2‐5 percent o
of all
the enerrgy consumeed, does lessen the total energy consumption in tthe industriaal sector.

A Study o
al Industry
4. THE PROMOTION OF ENERGY CONSERVATION
The petrochemical industry requires high energy consumption. Therefore energy is a
vital factor in the business competition, because it has a direct effect on the production cost.
And for this reason, the state sector and the private businesses involved are turning their 31
attention to the conservation of energy, from organizing activities in the organization,
advertising and promoting awareness, to setting measures to conserve energy in both the
production sector and the service sector. But since the petrochemical industry depends greatly
on technology and highly specific expertise, very much unlike most other industries, it is
therefore capital intensive. This study project which compiles all related information, facts and
figures, analyzes the strength, weaknesses, opportunities and threats (SWOT), assesses and
recommends directions for the promotion of energy conservation, which can lead to adoption of
plans for effective conservation of energy.

4.1 Problems in Petrochemical Industry
Problems in the conservation of energy in the petrochemical industry can be divided into
the following 4 respects:
1) Energy management
Lack of a unified source of information on the industry, either on the production
process or energy use
Lack of central coordination, information compilation, advice and counseling
needed for good management and efficiency
Lack of support in research and education to develop production technology
and manage the industry in a complete cycle
2) Technology
Dependence on machinery and advanced technology from abroad
3) Economy
High cost of machines and technology as well as maintenance, as a capital
intensive industry
Expensive raw materials such as natural gas, crude oil, and machinery parts
imported from abroad
4) Human Resource
Need for advice and technology transfer from foreign experts
Lack of local expertise
nergy Develop

4.2 SW
WOT Analysis

ngths
Stren Weakknesses
32 Natural resources can be ffound withinn Lo
ogistic managgement is noot efficient
th
he country en
nough
Most of the p
M lants are located in a Te
echnological developmen nt still relies on
cluster foreign counteerparts
Th
he plants andd machineryy are up‐to‐date Pe
ersonnel in th
he field are n
not enough
an
nd in new coondition
Th
he local market is considerably large
ortunities
Oppo Threaats
Th
he domestic market is exxpandable Co
ompetitors are of an advaantage
Th
here is roomm for market growth Th
here is oversu
upply at pressent
ovverseas Trade barrier m
measures aree enforced
Beenefits from carbon emisssion tradingg
(C
CMD)
En
nergy price iss high

R
Recommend
dations Forr Energy Con
nservation Planning
Theree should be a petrochem mical managgement plan which integgrates the diifferent aspe

ects
of the industry, aaiming at susstainable conservation o
of energy
Entrepreneu urs should shhare utilities, so that ene n be minimizzed, energy use
ergy loss can
policies can be centralizeed, and demand‐supply rrisks can be minimized as well.
d be mapped
Plans should d out to add vvalue to by‐p
products in aa complete ccycle, or even
n to
produce furtther energy ffrom by‐prodducts.

Short-TTerm Plan • 0-3 yeears
1) Energyy 2))

Managemeent Technoology
Medium
m-Term Plan • 3-5 yeears
3) 4) Human
H
Long-TTerm Plan • Up to 5 yeears Economiccs Ressource
F
Figure 30 Ennergy manageement plan in petrochemicaal industry
A Study o
al Industry
4.3 Promotional Plan For Energy Conservation In The Petrochemical
From the study of problems found in the petrochemical industry, the SWOT analysis, and
the above recommendations by project advisors, the following plan is roughly drafted for the
different aspects and in different stages: 33
Energy conservation plan
Short‐term (0‐3 yrs) Mid‐term (3‐5 yrs) Long‐term (up to 5 yrs) Targets
1. Energy Management
1. Create awareness 1. Create creativity in 1. Create an energy 4 Energy saving culture
in energy energy saving culture. is created
conservation. conservation. 4 Energy consumption
is reduced in the long
run.
2. Encourage large‐ 2. Encourage small‐ 2. Encourage all 4 Energy is used
scale scale petrochemical efficiently
entrepreneurs to entrepreneurs in entrepreneurs to 4 Production
develop their own the converter continually efficiency is
energy industry to use manage energy accelerated and
management to energy efficiently. wisely below‐standard
increase energy products are
use efficiency. weeded out.
4 Energy cost is
reduced
3. Plan for a central 3. Manage central 3.Promote the system 4 Energy loss is
utility system to utility systems for of integrated minimized, or
be shared in the ample sharing, e.g. complex energy is
industrial sector. wastewater management of recovered
treatment, shared utilities such 4 Production in
different types of as energy recover, the industry is a
electricity plants and management complete cycle
for use in the of by‐products. and of highest
industry efficiency
4. Set up a central 4.The central body 4. The central body 4 There is a good
body to compile must have good must be able to use system of
databases for the knowledge information and knowledge
industry. management, be knowledge in management,
able to disseminate benchmarking, and with the use of
databases which
up‐to‐date assist are constantly
information and entrepreneurs. updated
give advice and 4 Knowledge is
suggestions to shared on a
entrepreneurs constant basis.
4 The whole
industry is
developed in the
same direction

Short‐term (0‐3 yrs) Mid‐term (3‐5 yrs) Long‐term (upto 5 yrs) Targets
2. Technology Management
34 4 Knowledge and
1. Encourage learning 1. Promote research 1. Carry out research
of know‐how from and development in and development on Best Practice of
abroad and production a regular basis the industry are
research in technology and the used as guidelines
Disseminate the
production application of 4 The whole system
know‐how of Best
technologies that research by of petrochemical
Practice production is
improve efficient entrepreneurs who
use of energy. have potential Encourage improved,
entrepreneurs to including emission
Furnace upgrade reduction, energy
apply research
/replacement efficiency, and
results in value adding.
Repair Leaks and improvement of
Improve energy use in their
fractionation industry
efficiency
Develop catalysts
Reactor design/
Improve
fractionators
efficiencies
Recover heat from
flue gas and recover
steam from blow‐
down
Develop energy
management
software
2. Deliver research
study to pilot
entrepreneurs
subject
Deliver research
study to amendment
production process
of pilot factory in
order to select best
practice factory of
Petrochemical
Industry
Short‐term (0‐3 yrs) Mid‐term (3‐5 yrs) Long‐term (upto 5 yrs) Targets
3. Economics Dimension
1. Use economic and 1. Use economic and 1. Use economic and 4 The industry

financial tools as financial tools to financial tools to develops 35
incentives for help entrepreneurs encourage efficiency in
entrepreneurs to to develop entrepreneurs to energy use in the
save energy production increase sustainable long run
technology that help energy efficiency
Reduce tax on 4 Entrepreneurs are
increase energy
import of machines Give special interested in
efficiency
and equipment preferences/ waive participating in
that help increase Give special taxes for the project
energy efficiency. preferences to entrepreneurs who
entrepreneurs who have joined in
are able to save sustainably reducing
energy. energy
consumption
4. Human Resource Development Dimension
1. Develop human 1. Develop human 1. Develop human 4 The number of

resource in the resource in the resource at all levels petrochemical
petrochemical petrochemical of education in the experts is
industry. industry petrochemical increased
industry
Conduct training Send personnel (in 4 Dependence on
programs to create the state and private Offer programs in foreign experts is
understanding and sectors) to take energy, such as reduced
increase efficiency courses/study trips energy
in energy in petrochemical conservation,
conservation, such production abroad, energy
as seminars to so that they will management, etc.
exchange views on come back to train
Best Practice others in turn
Conduct short
training courses for

upstream,
intermediate and
downstream
industry
entrepreneurs as
well as converter
industry
entrepreneurs
5. TECHNOLOGIES AND MEASURES FOR ENERGY CONSERVATION
IN THE PETROCHEMICAL INDUSTRY

Energy conservation measures in the petrochemical industry can be divided into two levels:
36 1) Development and improvement of production technology
2) Energy efficiency improvement for processes and equipments

5.1 Development and Improvement of Production Technology
There are 2 major types of energy that have been used in the production processes of
petrochemical industries; thermal and mechanical energies. Mechanical energy is used to
control the working conditions of the equipments, i.e. control the system pressure, mixing the
chemicals. Mechanical energy mostly generated from electrical energy. Thermal energy is used
in many activities, such as preheat raw materials before entering reactors, heat for chemical
reactions, and energy for chemicals separation.
Energy conservation is achieved by changing and improving production process
technologies to facilitate less energy consumption, i.e. reduce the production temperature
and/or reduce the production pressure. The following section provides few developed
technologies that have been applied to petrochemical industries.
Some Technologies Developed for the Petroleum and Petrochemical Industry
Technology Sample
1) Process Control Natural networks, Knowledge based system
Analytical tools, Site integration,
2) Process Optimization and Integration
Advance process control
Catalysts with Higher selectivity, Increase life
3) Catalytic (Catalyst and Reactor)
time
4) Reactor Design, Advance distillation Process intensification, Reactive distillation,
column Dividing‐wall column
5) Bio‐technology for treatment facilities Bio‐feedstock, Bio‐Treatment
6) Combustion technology Low NOx burner, High efficientcy burner
Reverse osmosis (RO), Low maintenance
7) Utilities
pump
8) Power Generation Co‐generation, Gasification, Power recovery
Dehydrogenation, Hydro‐pyrolysis (non‐
9) Others catalytic), Byproduct upgrading technologies,
Using heavy feedstock

5.1.1 Catalysts
For all petrochemical production processes, catalysts are vital basis for chemical reaction
and process efficiency in the refinery. Catalysts are used in the main refining processes such as
37
hydroheating, reforming, hydrocracking, alkylation, and isomerization. Catalysts can improve
the production efficiency and reduce the energy consumption by increasing the conversion rate
of chemical reactions, increasing the selectivity of chemical reactions, reducing the rate of side‐
reactions, and/or improving the reaction condition by reducing the process pressure and/or
temperature.
The main directions for research and development of catalyst is on improving the
production process efficiency by higher activity, longer life, lower cost catalysts that can
optimized process conditions. In general, each catalyst is specific to each production process,
i.e. it cannot be applied to all production plants with similar products but different production
processes. The selection of appropriate catalyst for each specific process requires proper study
and research.
Benefits of catalyst to energy saving
First, catalysts reduce the activation energy

of chemical reactions and allow the reaction
to be carried out at lower temperature and
pressure. For example, catalyst reduces the
activation energy for C‐C bonds rupture and
cracking can be done at moderate
temperature and pressure in comparison to
steam cracking.
Second, catalysts increase the selectivity of Source http://hisina.en.alibaba.com
chemical reactions; reduce the rate of side

reactions
Third, catalysts remove coke which is formed
during the cracking process. Coke, de‐coked
during catalyst regeneration, reduced energy
efficiency of the process by hindering heat
transfer is constantly removed by catalyst
that are in turn‐decoke through catalyst‐
regeneration (or catalyst‐decoking)
Source: http://amtintl.com/reactorinternals.htm
Catalyst
5.1.2 Distillation and Separation
The example of technologies for separation processes improvement are Vacuum Swing
Adsorption Process (VSA), Mechanical Vapor Recompression (MVR), advanced distillation
columns, membrane and combined refrigeration systems. In VSA process, solid sorbents with
38
high selectivity for light olefin, such as ethylene and propylene, over paraffin (such as ethane and
propane) is used to improve energy efficiency. MVR can be used in conventional
propane/propylene splitter. These techniques can reduce energy consumption by 5 percent in
comparison to steam cracking.
Advanced Distillation Column

Advanced distillation column technology has been developed since 1930s. One type
of such column is divided‐wall distillation. Divided‐wall column integrates two conventional
distillation columns into one column in order to increase heat transfer efficiency. Divided‐
wall columns for butadiene extraction can save 15 percent of specific energy consumption in
comparison to conventional butadiene distillation. Other advanced distillation column
technologies are Extractive distillation, Reactive distillation, and Azeotropic distillation.

5.1.3 Membrane Technology
Membrane is one of the well established technologies for many production processes.
However, its application in steam cracking is quite limited. Membranes are usually made from
polymer such as polypropylene or inorganic materials. Membrane technologies can be applied
in the separation processes of olefin and paraffin, gasses in hydrogen recovery unit, and coke
and water in water purification process. In general, the application of membrane technologies
in petrochemical industries is still in the developing stage. The major drawbacks of the
technology are the inability of membrane to withstand severe operating conditions. It also
requires regular replacement and maintenance.
39

source U.S. Department Of Energy, 2002

Figure31 Current and proposed hybrid technology for the separation of isoprene from a
C5 mixture

5.1.4 Power Generation
Petrochemical industries, especially the upstream plants, consume a lot of energy.
Many of these plants have their own electrical and energy production units. These units are vital
for plants energy saving. The industry is identified as one of the industries with highest potential
for application of co‐generation or Combined Heat and Power production. Petrochemical
processes use energy in the form of heat, steam, cooling, and electricity extensively. Co‐
generation power plants utilize waste heat, which considered loses in standard plants. In
addition, transportation losses are minimized when power generation units are located in the
plant vicinities.
In applying the energy conservation technologies to the petrochemical industries,
studies on the advantages and disadvantages, and their effects are necessary. Most of the
petrochemical process technologies are imported and process modification requires
permission from the producer, or licensor. Although adaptation of the technology for a
specific process may reduce energy consumption, the technology cost may exceed that of the
reduced amount of energy. So it may not be wise to do so. A case in point is the substitute of
a new catalyst which can work at lower temperatures. The licensor has to give permission to
make sure that it will work, since the change could affect other equipment previously
designed for a certain catalyst. Also, the new catalyst used usually costs more. Hence
cost/benefit assessment should always be carried out before any modification.

5.2 Energy Efficiency Improvement for Processes and Equipments
และปรับปรุงที่ใชในกระบวนการผลิต

5.2.1 Energy Management
40 A systematical management is another important approach for efficient use of energy.
An organization‐wide energy management program creates a foundation and provides guidance
for energy management throughout the organization. Most petrochemical plants have a
responsible unit for energy management. Smaller plants may not have this designated unit and
opportunities for improvement may not be promoted due to some limitations such as the lack of
coordination between internal units, misunderstood support given to efficient energy use
projects, financial limitations, or lack of good financial management, etc.
.

Energy Management System
[Energy Management System, EMS]
An EMS should start with a
commitment within the organization to
seriously develop and improve energy
usage on a continual basis. Top
administrators of the plant must be
sincerely willing to engage in it. A policy
must be established for the use and
conservation of energy, and a team set up
to oversee the policy implemented. An
action plan must be mapped out in stages,
with regular assessment of the
performance, using figures collected at
intervals, technical assessment and
benchmarking. By doing so, administration
can improve the baseline and set goals for
future developments..
5.2.2 Steam generation
Steam generation is an important unit in the refinery (Figure 32). Steam is used
throughout the petrochemical production process. In the U.S.A, it is estimated that 30 percent
of energy used in the refinery is in the form of steam. Steam can be generated by process waste
41
heat recovery, cogeneration and boilers. Steam is expensive to produce and supply and is non‐
storable. Therefore, the used of steam should be carefully considered and assessed since the
efficiency improvement in steam generation and distribution are possible.

Source: Worrell and Galitsky, 2005

Figure 32 Steam generation process

Steam is used in many of the petrochemical production processes, i.e. process heating,
drying or concentrating, steam cracking, and distillation. Figure 33 shows how steam is loss from
the system during the production processes (U.S.Department of Energy, 2005).

Guide to saving energy for steam generation system
• Boiler Feed Water Preparation
• Improved Process Control
• Reduce Flue Gas Quantities
• Reduce Excess Air
• Improve Insulation
• Maintenance
• Recover Heat from Flue Gas
• Recover Steam from Blow down
• Reduce Standby Loss
5.2.3 Steam Distribution System
Velocity and pressure drop are the key parameters in the designing of steam distribution
system. The cost and energy loss are higher for oversize steam pipe while a too small pipe may
lead to erosion and higher pressure drop. Steam demands can change over time, and
42
occasionally steam may be underutilized. It may be too costly to adjust the system for changed
steam demand. However, checking and shutting off the excess distribution lines can effectively
reduce steam losses. Other energy saving measures in the steam distribution system is
summarized as follow:

Figure 33 Steam losses in steam distribution system

Guide to saving energy in the steam distribution system
• Improve Insulation
• Maintain Insulation
• Improve Steam Trap
• Maintenance Steam Trap
• Automatically monitoring of steam trap
• Repair Leaks
• Recover Flash Steam
• Return Condensate

5.2.4 Heat exchangers
Heat exchangers are common operations in refinery process. Steam is heated and
cooled many times during the process. The optimum design and control of the equipment can
significantly affect energy consumption efficiency.
43
Most processes in a complex refinery occur under high temperature and pressure,
therefore managing and optimizing heat transfer among processes is very important to energy
saving. A deposit in heat exchanger units and piping, fouling, hinders heat transfer and increases
energy consumption
Fouling in Heat exchangers
Operation and design can be the causes of fouling. There are several methods that
attempt to reduce fouling including using sensors for early warning, physical and chemical
methods to create high temperature coatings, using ultrasound, as well as improving the
design and operation of facilities. Current researches are focusing on principle of fouling and
redesign of heat exchangers and reactors. Methods for fouling reduction are focusing on
process and temperature control, regular maintenance and cleaning of heat exchanger and,
retrofit of reactor tubes
5.2.5 Process heater
The furnaces and boilers in a petrochemical plant consume over 60 percent of the total
fuel. The efficiency of heater can be improved by improving heat transfer characteristics and
flame luminosity, installing of recuperators or air‐preheaters, and improving the control system.
New burners have been designed to improve air and fuel mixing and to be more efficient heat
transfer. Other burners such as lean‐premix burners, swirl burners, pulsating burners and rotary
burners are also improved. Safety and environmental issues, such as reduction of NOx, has to be
addressed in selecting these new burners.
Guide to energy saving in heat transfer system
• Maintenance : Regular maintenance of burners, draft control and heat
exchangers is essential to maintain safe and energy efficient operation of a
process heater
• Air‐preheating:
• New Burner: New burner technology reduces cost for operation and emissions
treatment
5.2.6 Distillation
Distillation is a process which uses energy to separate products on the basis of boiling
points. Heat comes from process heaters and/or steam. Energy saving in this process can be
achieved by optimizing distillation column.
44

Energy saving opportunity in distillation column
• Operation Procedure: The optimization of the reflux ratio of the distillation
column can make significant energy savings.
• Check Product Purity: The reflux rate should be decreased in small increments
until the desired purity is obtained.
• Reducing Re‐boiler Duty
• Upgrade Column Internals: New tray designs can result in enhanced separation
efficiency and decrease pressure drop
• Stripper Optimization: Optimization of these parameters can reduce energy use
considerably

5.2.7 Motors
Petrochemical facilities use electric motors in many stages of production, consuming
over 80percent of total electricity. Equipments with electric motors include pumps (60% of all
motor use), compressors (15%), fans (9%), and other equipments (16%). Systematic approach
for optimizing the demand and supply of motor system instead of focusing on individual
components often provides the most energy savings.

Guide to energy saving in motor system (Motor optimization)
• Sizing of Motors: Motors and pumps that are sized inappropriately result in
unnecessary energy losses
• High Efficiency Motors: High efficiency motors reduce energy losses through
improved design, better materials, tighter tolerances, and improved
manufacturing techniques
• Power Factor: The power factor can be corrected by minimizing idling of electric
motors
• Voltage Unbalance
• Adjustable Speed Drive (ASDs) Variable Speed Drives (VSDs) : ASDs better match
speed to load requirements for motor operations

5.2.8 Pumps
Pumps use 60 percent of electricity use for motors which is approximately 50 percent of
the total electrical energy in refineries. It is estimated that over 20 percent of energy use for
pumps can be saved by optimizing equipment and/or control system. In fact, priority should be 45
given to cost in this investment, since the lifetime of pumps can be up to 20 years.
Pumping systems include a pump, a driver, pipe, control systems such as adjustable
speed drives, and a part of the overall motor system. Systematic approach for optimizing the
motor system also includes pumping system. The main approaches for optimizing the pumps
operation are reducing friction, or adjusting the system to the best efficiency point (BEP)
indicated in the pump curve. Friction can be reduced by correcting the pipe size, using surface
coating and polishing, and adjusting the pump speed drives.
Guide to energy saving in pumping system (Pumps)
1) Operation and Maintenance: Better maintenance will reduce these problems and
save energy
• Replacement of worn impellers, especially in caustic or semi‐solid applications.
• Bearing inspection and repair.
• Bearing lubrication replacement, once annually or semiannually.
• Inspection and replacement of packing seals. Allowable leakage from packing seals is
usually between two and sixty drops per minute.
• Inspection and replacement of mechanical seals. Allowable leakage is typically one to four
drops per minute.
• Wear ring and impeller replacement. Pump efficiency degrades from 1 to 6 points for
impellers less than the maximum diameter and with increased wear ring clearances
• Pump/motor alignment check.
2) Monitoring
• Wear monitoring
• Vibration analyses
• Pressure and flow monitoring
• Current or power monitoring
• Differential head and temperature rise across the pump (also known as thermodynamic
monitoring)
• Distribution system inspection for scaling or contaminant build‐up
3) Reduce need
4) More Efficient Pumps
5) Correct Sizing of Pump and Matching Pump to Intended Duty
6) Use Multiple Pump: using multiple pumps is the most cost‐effective and most energy
efficient solution for varying loads
Guide to energy saving in pumping system (Pumps) cont’d
7) Trimming Impeller or Shaving Shaves
8) Controls: shut off unneeded pumps or reduce the load of individual pumps until
needed.
46
9) Adjustable Speed Drive (ASDs) or Variable Speed Drives (VSDs)
10) Avoid Throttling Valve : Extensive use of throttling valves or bypass loops may be an
indication of an oversized pump
11) Correct Size of Pipes : Correct sizing of pipes should be done at the design or system
retrofit stages where costs may not be restrictive
12) Replace Belt Drives
13) Precision Castings, Surface Coatings and Polishing: The use of castings, coatings, or

polishing reduces surface roughness that in turn, increases energy efficiency.
14) Sealing

5.2.9 Air Compressors
Air compressor is equipment that consumes a lot of energy in the burner. Large‐sized air
compressors may use electric motors, steam turbines or gas turbines
Guide to energy saving in compressor
1) Compress air maintenance
• Blocked pipeline filters increase pressure drop. Keep the compressor and
intercooling surfaces clean and foul‐free by inspecting and periodically cleaning
filters. Keep motors and compressors properly lubricated and cleaned.
• Inspect fans and water pumps for peak performance.
• Inspect drain traps periodically to ensure they are not stuck in either the open or
• closed position and are clean
2) Proper monitoring and maintenance
3) Reduce leaks in pipes and equipment
4) Reducing the Inlet Air Temperature.
5) Maximize Allowable Pressure Dew Point at Air Intake.
6) Properly Sized Regulators.
7) Sizing Pipe Diameter Correctly.
8) Adjustable Speed Drives (ASDs).
9) High Efficient Motors
5.2.10 Fans
In the petrochemical facilities, fans are used at boilers, burners and cooling towers. Their
efficiency varies according to the fan types (Figure 34).
47
Energy saving opportunity in fans
• Fan oversizing: However, it may often be more cost‐effective to control the speed
than to replace the fan system.
• Adjustable Speed Drives, ASDs: Significant energy savings can be achieved by
installing adjustable speed drives on fans
• High efficiency belts (Cog Belts).

Figure 34 Typical belts use in motor system

SUMMARY

This study classify the petrochemical industries and assesses the energy consumption
48 index of each group, for the purpose of assessing the potential and basedline of energy
conservation and giving recommendations for systematical and efficient energy conservation in
upstream, intermediate and downstream industries. Data concerning the technologies and
energy conservation measures used by plants are compiled and evaluated for the benefit of the
overall industry.
Petrochemical plants are grouped on the basis of the product, into upstream,
intermediate and downstream plants, and information is collected of the years 2003‐2006, from
30 sample plants participating in the project. The indices used for the study are Specific Energy
Consumption (SEC) and Energy Intensity (EI). It is found that in general the plants have good
monitoring of their production, with the exception of some producing under capacity or
temporary shutdown for repair. Comparison of energy use at the plants finds that energy
consumption indices have a wide range, even between plants producing the same products. This
can be explained by the use of different raw materials and/or production technologies, as well as
the small number of entrepreneurs there are. However, analysis results reveal data not much
different from other countries, and that Thailand’s petrochemical industry is consuming less
energy.
There are 2 levels of energy conservation: in the development and improvement of the
production technology, and in management and improvement of the efficiency of equipment in
energy consumption. Catalyst technology has a very significant role in the manufacturing of
products due to reduce operating condition i.e., pressure and temperature, particularly catalysts
in the reforming, hydrocracking, alkylation and isomorization processes. Also effective in the
production system are reactor design and advanced distillation and separation process. For
example, membrane technology can increase equipment efficiency markedly. So does
improvement of power generation by combine heat and steam or co‐generation. Development
of the system must go hand in hand with management and improvement for efficient use of
existing equipment. In addition to this, there should be a monitoring and quality control system
in place.
Unlike other industries, the petrochemical industry requires advanced and specific
technology and expertise. This study finds that the main problems and obstacles in energy
conservation lie in the lack of a centralized/coordinated database needed for good and efficient
management, support of research and development in the production technologies, complete
cycle of management of the industry, as well as expert consultants. Added to this, this is an
industry which relies heavily on advanced technological machinery entirely from abroad, making
the cost very high and dependent on the global market and the fluctuation of the Baht currency.
Therefore, in promoting energy conservation, the problems should be solved in short, medium 49
and long terms, respectively, using a concrete success energy index.
In addition to recommendations given here, training programs are designed to support
further conservation of energy by giving basic knowledge concerning conservation of energy and
acceleration in efficiency of its use, enhancing the potential of participants as experts in the
field, particularly in petrochemical management standards, testing and analysis of energy
consumption, and energy saving projects. A website is also designed, with the purpose of being a
channel for coordination and follow‐up of trainees and organizations concerned. Also being
developed are database software for the recording and processing of related data such as
energy consumption data, production data, energy use indices, technologies/standards of
energy saving, etc. which can link up with the Department of Alternative Energy Development
and Efficiency.
Fruitfully, this study project is carried out with the objective of presenting feasible ways
to promote efficient energy conservation, in both production technology and energy
management. It includes in‐depth measures for efficient energy conservation and sustainable
human resource development. The ultimate goal is for the petrochemical industry to make the
most of the energy used, thus increasing Thailand’s competitive edge and its ability to tackle the
present and future global energy crisis.

****************************

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50
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REFERENCES (CONT’D)

20. โครงการฐานขอมูลดานการผลิต และการซื้อขายผลิตภัณฑปโตรเคมี. เอกสารการวิจัย วิทยาลัยปโตรเลียมและปโตรเคมี.
จุฬาลงกรณมหาวิทยาลัย. 2531.
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http://www.oie.go.th/industrystatus2_th.asp. ตุลาคม 2549.
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บริษัท เดียรบุค จํากัด: กรุงเทพ ฯ. 2535.
23. วีรพล จีรประดิษฐกุล. สถานการณและนโยบายพลังงานไทย. เอกสารสรุปผลการประชุมกลุมยอยทางวิชาการครั้งที่ 2.
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อุตสาหกรรม มหาวิทยาลัยศิลปากร. 2533.

LIST OF ABBREVIATION
Acrylonitrile Butadiene
ABS MUSD Million United State Dollar
Styrene
52 ACN Acrylonitrile MX Mixed Xylene
BMA Butyl methacrylate NG Natural Gas
BR Butadiene Rubber NGV Natural Gas for Vehicles
OX or O‐
CFR Cost and Freight Ortho‐Xylene
Xylene
DDI Domestic Direct Investment PA Phthalic Anhydride
E&P Exploration and Production PBT Polybutyl Terapthalate
EDC Ethylene Dichloride PDH Propane Dehydrogenation
EG Ethylene Glycol PE Polyethylene
EO Ethylene Oxide PET Polyethylene Terephthalate
Ethylene Propylene (Diene)
EPDM PMMA Polymethyl Methacrylate
Monomer
EPS Expandable Polystyrene POM Polyoxymethylene
EVA Ethylene Vinyl Acetate PP Polypropylene
FDI Foreign Direct Investment PS Polystyrene
GDP Gross Domestic Product PTA Pure Terephthalic Acid
HDPE High Density Polyethylene PVA Polyvinyl alcohol
HR Human Resource PVC Polyvinyl Chloride
PX or P‐
IMP.R/M Imported Raw Material Para‐Xylene
Xylene
KTA Kilo Ton Per Annual SAN Styrene Acrylonitrile
LDPE Low Density Polyethylene SBL Styrene Butadiene Latex
Linear Low Density
LLDPE SBR Styrene Butadiene Rubber
Polyethylene
LPG Liquefied Natural Gas SEA South East Asia
MEG Monoethylene Glycol SM Styrene Monomer
MMA Methyl Metacrylate UPR Unsaturated Polyester Resin
MMSCF Million Standard Cubic Feet VCM Vinyl Chloride Monomer
MTBE Methyl Tertiary‐Butyl Ether
The Department of Alternative Energy Development and Efficiency (DEDE)
Ministry of Energy
17 Rama I rd.
Pathumwan BKK. 10330
Tel 0-2223-2311 LOGO
www.themegallery.com
Fax 0-2226-3943

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A Study on Energy Efficiency Index in

CHAPTER 2 : ENERGY CLASSIFICATION OF PETROCHEMICAL INDUSTRY 14

Soource: PTIT, 20006

Figure 3 Thailand petrochhemical compplex flows

Supporting: Infrastructure, Logistic, HR, Finance, Rules& Regulations

Condensate Petrochemical • LPG

• Total Revenue (MM Baht) 239,060 290,150 382,500 432,645 447,760

Compare to GDP 4.4% 4.9% 5.9% 6.1% 6.0%

Gas Prod. Gas Used Direct Economic

B.E.2549 is estimation data

KTA Thailand Petrochem ical Production

Upstream Intermediate Downstream

Petrochemical Audited Energy Use (Ktoe)

Figure 16 Production process of Pure Terephthalic Acid (PTA)

Figure 17 Production process of LDPE

Figure 18 Production process of LLDPE by solution phase polymerization

Figure 20 Production process of PVC by suspension polymerization

Figure 21 Production process of PVC by emulsion polymerization

Figure 22 Production process of PP

Figure 23 Production process of PVC Resin

Figure 24 Production process of PP by gas phase polymerization

Figure 25 Production process of ABS

– Olefins Olefins (Ethylene, Propylene) 16,900 ‐ 24,900

Intermediate PTA, EB, SM, PA, EG, Polyol 1,900 ‐ 27,000

Oleefins Aromatic Production A

Product SEC SEC average

Olefins 12,561 ‐ 25,120 18,841

Aromatics (BTX) 2,310 ‐ 3,521 2,917

Ethylene Glycol (EG) 3,488 ‐ 6,017 4,753

Ethylbenzene 3,028 ‐ 3,498 3,263

Styrene monomer (SM) 33,396 ‐ 45,113 39,255

Terephthalic acid (PTA) 3,121 ‐ 5,145 4,134

Polyethylene (PE) 1,483 ‐ 3,993 2,738

Polypropylene (PP) 1,129 ‐ 1,260 1,195

Aromatics (BTX) 2,310 ‐ 3,521 3,200 – 17,000

Polyethylene (PE) 1,483 ‐ 3,993 2,700 – 3,600

Polypropylene (PP) 1,129 ‐ 1,260 1,000 – 2,000

PTA, EB, SM, PA, 0.79 – 5.0

HDPE, PS, PP, EPS, 0.26 – 3.3

Energy inten decreases in order from olefin upstre

Theree should be a petrochem mical managgement plan which integgrates the diifferent aspe

1. Use economic and 1. Use economic and 1. Use economic and 4 The industry

1. Develop human 1. Develop human 1. Develop human 4 The number of

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chemical reactions; reduce the rate of side

Advanced Distillation Column

13) Precision Castings, Surface Coatings and Polishing: The use of castings, coatings, or

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