Engineering costs in the Implementation of clean technologies in refineries

Introduction

Engineering costs in the petroleum refining industry are at a crossroads. The pressure to adopt greener practices in refineries is increasing, and with it, the need to implement green technologies. While these technologies offer a competitive advantage by enabling better analysis of environmental costs and strengthening corporate image, their implementation brings with it significant economic challenges.

Investing in clean technologies is a fundamental step towards a more sustainable future, but what are the real costs associated with this transformation? In this article, we will delve into the complex world of engineering costs involved in implementing these technologies in refineries; initiated by an efficient research and development process and managed under strategic project planning. We will provide an accurate overview that allows our readers to better understand the challenges and opportunities presented by this transition.

What are clean technologies in refineries?

Also known as green technologies, these are innovations designed to minimize environmental impact. In the context of refineries, these technologies include refinery processes and equipment that reduce greenhouse gas emissions, improve energy efficiency and minimize waste. Examples include:

• Hydrogenation processes: reduce sulfur and nitrogen content in fuels.
• Carbon capture and storage: Sequester CO₂ emissions to prevent their release into the atmosphere.
• Biofuels: Use of renewable raw materials to produce fuels.
• Energy efficiency: Optimization of processes to reduce energy consumption.

What is the need for clean technologies in refineries?

Environmental pollution is one of the biggest problems that has affected mankind for many centuries, and this situation began to worsen from the First Industrial Revolution until today, being caused by companies such as refineries and people.

From the 1970s onwards, consumers began to express their concern about the depredation of the ecosystem, seeking to purchase environmentally friendly products and demanding that companies rethink their production strategies and techniques. Among the improvements in production techniques, the implementation of clean technologies is considered as a viable solution for refineries to control the pollution they generate from the beginning of their production cycle.

Several factors drive this process. The following are the most relevant ones related to the subject of the article:

• Environmental regulations: Increasingly restrictive standards on pollutant emissions.
• Demand for clean energy: Consumers and governments are looking for more sustainable energy sources.
• Climate change: The need to reduce greenhouse gas emissions.
• Competitiveness: Companies that adopt clean technologies can gain competitive advantages.

Engineering costs components of clean technology projects

Implementing clean technology in refineries involves significant investment in several engineering areas. However, these costs are offset by long-term benefits, including emissions reductions, regulatory compliance, and operational efficiency improvements. To maximize the return on investment, detailed planning and adoption of strategies that optimize each of these costs is crucial.

The costs involved in implementing EST’s in refineries are varied and can be grouped into different categories. The main costs involved in this process are detailed below:

Research and development (R&D)

This involves the design, experimentation, and optimization of new clean technologies prior to their implementation in a refinery. The Cost Components are:

• Salaries of engineers and specialists.
• Test equipment and materials.
• Advanced research and development (R&D) software.
• Other costs of pilot tests and feasibility studies.

Design and strategic planning

The design of systems and processes adapted to the technologies and engineering planning for their integration into the existing infrastructure requires cost components, such as:

• Consulting and engineering services.
• Development of plans and 3D models.
• Environmental impact assessments and technical feasibility studies.

Procurement of refinery equipment and materials

Cost components:

• Specialized refinery equipment costs (e.g., carbon capture units, cogeneration systems).
  Construction materials and installation components.
  Import costs and tariffs (if applicable).
• Installation and construction
• Installation process of refinery equipment and construction of infrastructure required for new technologies.

Labor for installation and construction.

• Rental of specialized machinery and tools.
• Rental of machinery and specialized tools.
• Construction costs of new facilities or adaptation of existing ones.

Personnel training and development

Training of personnel to operate and maintain the new technologies.

• Training programs and workshops.
• Educational manuals and resources.
• Costs of external consultants and trainers.

Machinery and tools rentalIntegration and start-up

Process of integration of new technologies into the existing system and commissioning.

• Integration and calibration tests.
• Troubleshooting and technical adjustments.
• Commissioning supervision and certification.

Regulatory compliance and certifications

Ensuring that technologies comply with all regulations and obtain the necessary certifications.

• Certification fees and audits.
• Legal and compliance consulting services.
• Documentation and administrative paperwork.

Long-term maintenance and operation

Ongoing maintenance and operation of refining operations:

• Preventive, predictive and corrective maintenance programs.
• Daily operating costs (energy, consumables, labor).
• Continuous technological upgrades and improvements.
• Advanced strategic planning software.

Waste and emissions management

Additional processes and technologies to manage waste and emissions generated by new technologies.

• Waste treatment systems.
• Emissions monitoring equipment.
• Waste disposal costs.

Factors influencing costs

The most relevant factors involved in this process are:

• Complexity of the technology: More innovative or more integrated technologies tend to be more expensive.
• Project scale: Larger projects imply higher costs.
• Supplier availability: A limited supply of suppliers can increase costs.
• Regulatory requirements: Stricter regulations can increase design and construction costs.

Economic impact of clean technologies in refineries

The implementation of these technologies in refineries can generate long-term economic benefits, despite the initial investments:

• Reduced operating costs: lower energy and feedstock consumption.
• Generation of new revenues: Sale of carbon credits or production of biofuels.
• Improved corporate image: Increased attractiveness to investors and customers.

The future of clean technologies

The future is promising. The trend towards the adoption of more sustainable solutions is expected to continue, driven by:

• Technological advances: The development of new technologies, such as artificial intelligence, refinery equipment made of composite materials and machine learning, will further optimize refining processes.
• Operating strategies: Refineries are beginning to employ solar and wind energy sources, not only to reduce their carbon footprint, but also to reduce their dependence on fossil fuels.
• Government policies: Governments will continue to implement stricter regulations to reduce emissions and promote clean energy.
• Consumer pressure: Consumers are increasingly demanding more sustainable products, which will force companies to adapt.

Conclusions

The implementation of clean technologies in refineries represents a significant challenge for the industry, but also an opportunity to achieve a more sustainable future. Engineering costs are an important factor to consider, but can be effectively managed through careful strategic planning, investment in research and development (R&D) and collaboration with suppliers and technology partners.

As technology advances and regulations become more stringent, refiners that take a proactive approach to implementing clean technologies will be better positioned for the future.

“Embrace clean technologies and lead the change toward a sustainable future in refining.”

References

Own source