Energy Experts worked extensively with industry to develop a range of Best Management Practices (BMPs) covering key unit operations in the upstream oil and gas industry. Through this knowledge, Energy Experts is continuing to develop a range of equipment/process-specific energy management programs to assist the industry in implementing cost-effective energy conservation programs. These programs build on our strengths and address some of the largest and most common energy reduction opportunities identified to date. Current programs include:

• Amine Plant Optimization    
• Sulphur Plant Optimization     
• Tail Gas Incinerator Optimization    
• Desiccant Dehydration Optimization; and    
• Fired Heater Management Program.    

Amine and Sulphur Plant Optimization

Amine plant and sulphur plant energy optimization programs are a direct result of our 30+ years of experience in testing and optimizing these processes. Amine plants are one of the largest energy consumers in the gas processing industry. Sulphur plants, on the other hand, are a significant source of energy and should be optimized and integrated into a facility’s total energy balance. Significant opportunities exist to improve the process, increase sulphur recovery, optimize energy use and reduce overall facility emissions through a combined optimization program. Energy Experts uses the in-plant testing capability, engineering expertise and process simulation tools available in both Amine Experts and Sulphur Experts to facilitate energy optimization.

Tail Gas Incinerator Optimization

This program includes a number of components including:

• Sulphur Plant simulation and optimization using Sulsim®    
• Incinerator combustion simulation using a proprietary empirical model (INCWRD)     
• Developing stack-top temperature and tiered Approval recommendations to maximize energy efficiency    
• Coordination of assessment (dispersion modelling) and demonstration (stack testing) programs to support regulatory applications; and    
• Regulatory and public consultation support.    

Energy Experts also provides the engineering support and services necessary to implement new technology which can significantly improve energy conservation and GHG reductions possible from tail gas incineration systems.

Desiccant Dehydration Optimization

Desiccant dehydration is a very energy intensive process but is required when very low dew point control is needed or when selective removal of water is required in the presence of hydrocarbon liquids. The energy requirements for desiccant dehydration are directly related to:

• Water content of raw gas    
• Dried gas specification     
• Type of desiccant    
• Equipment configuration; and    
• Regeneration cycle    

Energy Experts can undertake a full system evaluation to identify energy saving opportunities and establish control parameters to ensure consistently good operation.

Fired Heater Management Program

Energy Experts has developed a Fired Heater Management Program to assist clients in optimizing fuel use in fired heaters. Energy Experts works with companies to compile a comprehensive inventory of equipment, screen units, prioritize opportunities and train staff to implement the program. Energy Experts has developed some critical tools to facilitate program implementation. They include:

• Fired Heater Database: A database template, using Microsoft Access, has been developed to facilitate preparation of a comprehensive inventory. The program is based on the recommendations of the Fired Heater BMP and provides a user-friendly interface to input all required information. Data can be input manually using drop-down menus, or existing electronic information can be imported directly into the database.


• Screening Tool: A screening tool has been incorporated into the database to identify priority candidates for optimization based on available design and operations information. Screening parameters are customizable (e.g. design heat flux, duty cycle) and can be modified to meet specific needs.nbsp;    


• Optimization Tool: This tool uses design and operating information, as well as the results of field investigations, (e.g. combustion analysis), to identify key optimization opportunities. The analysis presents options to improve overall efficiency of individual heaters and calculates the potential fuel gas volume, cost and GHG emission savings arising from the recommended optimization activities. The tool also allows evaluation of user-defined modifications, such as burner change-out, and provides the economic basis to support these capital projects.    

A key feature of the Program is “Capacity Building”. We will train existing operations staff through a combination of workshop-style sessions and hands-on training to build the skill necessary within organizations to implement the Program. Our staff will design a pilot program, train Field Staff and work with them to complete the following tasks:

• Balance field heat requirements and identify opportunities to eliminate heaters or take advantage of an alternative heat sources    
• Conduct combustion efficiency measurements and adjust burners     
• Right-size, replace and set up new burners    
• Review design-basis for new heaters; and    
• Set up an appropriate monitoring and maintenance program    

Once completed, the program is evaluated and modified as necessary for full company-wide implementation.