Case Study
Refineries
Challenge
A 15 MMTPA refinery was underperforming in margin generation due to suboptimal crude selection, high energy use, shutdowns, and operational inefficiencies.
Solution
Ingenero conducted a pacesetter audit, analyzing power consumption, fuel losses, shutdown data, and operational philosophy. A margin improvement model was developed for strategic decision-making.
Outcome
- $2.3/bbl potential uplift in Gross Refinery Margin
- Optimized crude basket and energy consumption
ImpactX
Heat Integration Unlocks $700K in Refinery Savings
Challenge
A Mumbai refinery needed to maximize crude preheat without new equipment.
Solution
Using Aspen Energy Analyzer, Ingenero mapped the HEN and proposed pinch-based adjustments to improve thermal efficiency.
Outcome
- 9% desalter temperature increase
- 13% heater duty reduction
- 40% vapor flow gain
- $700,000/year potential savings
ImpactX
Hydrocarbon Loss Study Reduces F&L by 0.7%
Challenge
A Mumbai-based refinery had unaccounted hydrocarbon losses up to 7% due to outdated SOPs and incomplete tracking.
Solution
Ingenero conducted gap analysis, field audits, and process reviews, including witnessing crude tank sampling and reviewing F&L reports.
Outcome
- Losses reduced by 0.5–0.7%
- SOPs and operational philosophy optimized
