Refineries - Steam Turbines

Below you will find the calculations on how we formulated the figure of equivalent cars globally.

Refineries - Steam Turbines: Calculation

Calculate Pump Time
2000 Total Number of Rotating Equipment Per Site
5% Proportion of Turbines
100 Total number of Turbines Per Site
90% Utilisation
7884 Utilisation Hours Per Year Per Turbine
788,400 Total Turbine Utilisation Hours Per Year Per Site
Calculate Pump Seal Energy Saving Usage #1
100% %Turbines
100 Turbines per Site
90 kg/hr LP steam loss per turbine
709,560 kg/year per turbine
0.18 kg CO2 eq per kWh steam
129,140 kg/year CO2 eq per turbine
28 cars/year per turbine
12,913,992 kg CO2 eq per site
2,807 cars per site
Scale up For Global Usage
715 Global Number of Refineries
9,233,504,280 kg CO2 eq
2,007,284 total number of equivalent cars globally 

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The following assumptions have been made....
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Steam loss is a major problem in Refineries

A leading refinery in the UK was having trouble with seal leakage from existing carbon box technology on their 150#, 600# steam turbines. Based on prior experience the refinery approached AESSEAL® for an alternative solution.

Improving Reliability, Increasing Efficiency

Without Steam Turbine Seal

With Steam Turbine Seal

Example Return On Investment

Steam Turbine Upgrade Example LBS/HR
TONS/HR
Retrofitting steam turbines with dry gas seals/labtecta
200 $0.12
Potential Savings per turbine per Annum Costs
Steam Loss per year per ton per machine
$28.35
Cost of 150# steam - ton per year per machine
$1,051.20
Cost of Steam loss per Turbine
$29,801.52
Manual drain off of lube oil per year per machine
$4,200.00
Total Savings per turbine / 100 turbines
Savings per year per machine
$34,001.52
100 machines
$3,400,152.00
Reliability conversion per turbine
2 STS Dry Gas Seals
$13,000.00
3 LabTecta ST Bearing Isolator Seals
$2,000.00

$15,000.00
Return On Investment 
Return on Investment per machine upgrade
 5.28 months
4 Year Reliability Initiative (25 turbines per year)
Target 25 steam turbine upgrades per year
$375,000.00
Four year refinery upgrade cost
$1,500,000.00
Total four year cummulative cost saving
$4,000,300.00

Steam Turbine Case Study Download

  • Reference: CH01446
  • Savings: £2,250,000 per annum
  • ROI: 5.28 months

Explore

If enough businesses act, together we can slow down or help to prevent Global Warming.

Why we are Taking Action

The purpose of this communication is to encourage the Boards of companies worldwide to create a simple to understand policy.

Real World Examples

Just a few examples where we have the know-how to do things differently and help both the environment and the bottom line.

A Summary of Evidence

We estimate that widespread adoption of more climate-friendly policies in industry globally, could have the equivalent impact of taking 422.5 million cars off the roads.