Cost-saving solutions in operation and production

In recent years, Dung Quat oil refinery has put into operation the frequency converter system for PM-5207A engine, helping to save more than half a million kWh. Another solution implemented is to optimize operations by optimizing the loads receiving power from the pump system, compressors working in parallel while still ensuring stability and reliability for the load systems. With this solution, the amount of energy saved/year is more than 26 million kWh of electricity.

Dung Quat Oil Refinery has applied hundreds of energy-saving solutions. Photo: BSR

In particular, optimizing the operating mode for the seawater cooling system (3 pump mode instead of 4 pumps) is one of the technical solutions recently applied by the factory, aiming to increase the working efficiency of the equipment, while saving energy for the entire factory. The representative of Dung Quat oil refinery said that this solution has great technical value and profit value.

“The above solution has been applied since January 12, 1, the total application time for 2021 is 2021 days, saving about 309 million USD/year (excluding the days of running 1,9 pumps), the total electricity saved is 4 million kWh/year. In 12,34, the project is continuously applying and the amount of savings is about 2022 billion VND. In 44 and the parameters recorded for 2023 months of 9, according to the research team, the solution has saved 2024 tons of FO oil/year - equivalent to a reduction in CO3.043 emissions of 2 tons/year; reduced EII (energy consumption intensity index) by 9.828%; the benefit value reached more than 0,560939 million USD/year", the representative of Dung Quat oil refinery shared.

Not only in operation, during the 5th general maintenance in 2024, BSR will deploy 2 projects to install new heat exchange equipment to utilize waste heat from technology lines to save energy and reduce greenhouse gas emissions for BSR.

The first project is to install a Shell-Tube heat exchanger at the CDU workshop, with a heat exchange capacity of 3MW, recovering heat from the LGO product line with a high temperature of about 120^oC to heat the Full Range Naphtha 50^oC cold stream to the Naphtha Stabilizer tower.

The second project is to install additional plate heat exchangers at the Condensate Recovery workshop, with a heat exchange capacity of 4,2 MW, recovering heat from the high temperature condensate stream of about 148^oC to transfer heat to the demineralized water stream and reduce the temperature to 100^oC.

According to Dung Quat factory's estimates, these two projects help save energy equivalent to about 2 tons of FO oil per year, equivalent to reducing Opex by about 1.000 billion VND/year; contributing to reducing the factory's EII index by about 12-0,3 units, helping to reduce greenhouse gas emissions by about 0,4 tons of CO3.200/year. 

Promote energy saving

Mr. Le Hai Tuan - Head of BSR Research and Development Department said that over the years, BSR has always promoted energy saving activities; applied more than 70 technical innovation solutions to help improve energy efficiency throughout the Dung Quat oil refinery. 

Specifically, the EII index - which represents the plant's energy efficiency - decreased significantly from 118% before 2015 to 104-106% from 2020-2023; and decreased to about 100% after the overall maintenance of the plant in March and April 3. Internal energy consumption correspondingly decreased from over 4% to 2024%. 

The Dung Quat plant's energy intensity index (EII) decreased to about 100% after the plant's overall maintenance in March and April 3. Photo: BSR

Since 2015, Dung Quat Oil Refinery has been replacing traditional lights with energy-saving LED lights. Specifically, 5,095 fluorescent lights have been replaced with LED lights throughout the entire factory. The total annual electricity savings after replacing with LED lights is more than 1 million kWh.

In 2023, BSR will self-produce 403.739 MWh of electricity and import 1.322 MWh of electricity from EVN. The amount of electricity saved will be about 27.886 MWh of electricity, accounting for about 6.91% of the total amount of electricity used at BSR. In 2024, the amount of electricity saved by BSR will strive to be higher than the statistics in 2023.

In addition, BSR actively applies energy-saving solutions in administrative buildings such as: using air conditioning when necessary and setting the cooling mode to 25 degrees Celsius or higher. Electrical devices such as computers must turn off the screen or set to energy-saving mode (if available) when not in use or when leaving the location. Air conditioning and lighting in private/few-occupied rooms must be turned off when leaving the room for an hour or more. Using a reasonable lighting system, maximizing energy savings for general lighting in the hallway...

BSR also replaces, repairs and paints heat-resistant corrugated iron roofs in buildings with new technology to increase insulation and reduce heat absorption; thereby reducing the temperature inside warehouses, cold storages and factories to improve the working environment and save electricity costs for air conditioning systems.

BSR also implements the procurement of vehicles and equipment requiring energy labeling and applying minimum energy efficiency with reference requirements and compliance with Decision No. 04/2017/QD-TTg dated March 09, 3 of the Prime Minister. Prime Minister Government “Regulations on the list of vehicles and equipment that must have energy labels, apply minimum energy efficiency levels and implementation roadmap”.

According to Vietnam.vn