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Energy Efficiency at Marathon Petroleum. Wayne Kinnel Catlettsburg Energy Coordinator. Marathon Petroleum Statistics at a Glance. Fortune 50 company Established in 1887 4th largest U.S. refiner Largest in Midwest Employees: approximately 28,000 Headquartered in Findlay, Ohio

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energy efficiency at marathon petroleum

Energy Efficiencyat Marathon Petroleum

Wayne Kinnel

Catlettsburg Energy Coordinator

marathon petroleum statistics at a glance
Marathon Petroleum Statistics at a Glance
  • Fortune 50 company
  • Established in 1887
  • 4th largest U.S. refiner
    • Largest in Midwest
  • Employees: approximately 28,000
  • Headquartered in Findlay, Ohio
  • Approximately 1,460 Speedway convenience stores
  • Approximately 5,000 Marathon Brand retail outlets
  • Extensive terminal and pipeline network
marathon petroleum refining system
Marathon Petroleum Refining System

System capacity: 1,699,000 BPCD

Garyville (LA)522,000 BPCD

Catlettsburg (KY)240,000 BPCD

Robinson (IL)

206,000 BPCD

Galveston Bay TX 451,000 BPCD

Detroit (MI)120,000 BPCD

Texas City (TX)80,000 BPCD

Canton (OH)80,000 BPCD

BPCD = barrels per calendar day

Source: Oil & Gas Journal

As of 2/1/2013

catlettsburg refining
Catlettsburg Refining
  • Complex and energy intensive processes
    • Continuous operation 24/7
  • Energy is second largest operating cost
    • Natural gas – 75%
    • Electricity – 25%
  • Managing energy is imperative to remaining competitive/viable
  • Resources and systems in place to monitor and improve
    • Daily operational
    • Medium-term activities
    • Long-term strategy and projects
  • Significant investments made and planned
catlettsburg refining1
Catlettsburg Refining
  • Expansive electrical infrastructure required
  • Refinery footprint is 600+ acres
  • There are 130 electric substations and approximately 2,000 electric motors
    • 120-130 MW of demand to operate refinery
    • Largest Kentucky Power customer
    • >95% of consumption is for continuously running process equipment
  • Significant people resources monitor and maintain electricity infrastructure
    • 13 engineers
    • 25 electricians
    • 60-80 electrical contractor personnel onsite daily
improving energy efficiency
Improving Energy Efficiency

Part of our standard work practices

Short-term – daily operational monitoring

Medium-term – maintenance planning activities

Long-term – strategic projects

Effective energy management is an “all-above” approach

monitoring daily operations
Monitoring Daily Operations

Significant benefits from daily attention to process operations

Tuning process heaters

Optimizing utilization of energy from process operations

Monitoring sources and uses of steam

Controlling the operation of large electrical users

monitoring daily operations1
Monitoring Daily Operations

Formal assessment program - Focus On Energy initiative – “FOE”

To accomplish – set standards for performance

Measure actual performance in real time

Communicate deviations from standards

monitoring daily operations2
Monitoring Daily Operations

Supported by technical, operations, and management personnel

Completed process unit reviews and identified 148 individual monitoring points

Each point assigned a dollar value, tracked and reported

35% reduction with no investment

medium term activities
Medium-Term Activities

Equipment maintained to perform at optimum efficiency

Equipment upgrades and major maintenance efforts normally require a unit shutdown

Cycle times between shutdowns can be 5-7 years

Data from routine equipment monitoring is used to develop shut down work scope

long term strategy projects
Long-Term Strategy/Projects
  • On-going efforts to identify and implement energy reduction opportunities
  • Energy specific projects – Insulation upgrades, steam leak repairs and upgrades, on-line analyzers, exchanger bundle upgrades
  • Energy assessment for other projects
  • Crude unit project example
    • Significant investment currently underway
    • Process and energy efficiency improvements incorporated into scope
    • Redesign of heat integration system to reduce consumption
    • Improvements to fired heater for improved efficiency
    • Fuel reduction of 720 MMBTU/day
    • Electricity reduction of 3,000 kwh/day
long term strategy projects1
Long-Term Strategy/Projects
  • All projects reviewed for energy efficiency improvement opportunities
    • Standard practice to consider high efficiency motors
  • Participate in industry benchmarking studies
    • Identifies opportunities for improvement
  • Share and implement best practices across all MPC sites

Efficiently using all energy sources is a business imperative

Resources employed to manage and maintain energy infrastructure

Programs in place to monitor and improve performance

Efforts range from daily optimization to large multi-year, multi-million dollar projects