Title Page -- Copyright -- Dedication -- Preface -- Part 1: Basic Concepts and Theory -- Chapter 1: Overview of this Book -- 1.1 Introduction -- 1.2 Who is this Book Written for? -- 1.3 Five Ways to Improve Energy Efficiency -- 1.4 Four Key Elements for Continuous Improvement -- 1.5 Promoting Improvement Ideas in the Organization -- Chapter 2: Theory of Energy Intensity -- 2.1 Introduction -- 2.2 Definition of Process Energy Intensity -- 2.3 The Concept of Fuel Equivalent (FE) -- 2.4 Energy Intensity for a Total Site -- 2.5 Concluding Remarks -- Nomenclature -- References -- Chapter 3: Benchmarking Energy Intensity -- 3.1 Introduction -- 3.2 Data Extraction from Historian -- 3.3 Convert All Energy Usage to Fuel Equivalent -- 3.4 Energy Balance -- 3.5 Fuel Equivalent for Steam and Power -- 3.6 Energy Performance Index (EPI) Method -- 3.7 Concluding Remarks -- Nomenclature -- Reference -- Chapter 4: Key Indicators and Targets -- 4.1 Introduction -- 4.2 Key Indicators Represent Operation Opportunities -- 4.3 Define Key Indicators -- 4.4 Set Up Targets For Key Indicators -- 4.5 Economic Evaluation for Key Indicators -- 4.6 Application 1: Implementing Key Indicators Into an "Energy Dashboard" -- 4.7 Application 2: Implementing Key Indicators to Controllers -- 4.8 It is Worth The Effort -- Nomenclature -- References -- Part 2: Energy System Assessment Methods -- Chapter 5: Fired Heater Assessment -- 5.1 Introduction -- 5.2 Fired Heater Design for High Reliability -- 5.3 Fired Heater Operation for High Reliability -- 5.4 Efficient Fired Heater Operation -- 5.5 Fired Heater Revamp -- Nomenclature -- References -- Chapter 6: Heat Exchanger Performance Assessment -- 6.1 Introduction -- 6.2 Basic Concepts and Calculations -- 6.3 Understand Performance Criterion-U Values -- 6.4 Understanding Pressure Drop -- 6.5 Heat Exchanger Rating Assessment.

6.6 Improving Heat Exchanger Performance -- Appendix: TEMA Types of Heat Exchangers -- Nomenclature -- References -- Chapter 7: Heat Exchanger Fouling Assessment -- 7.1 Introduction -- 7.2 Fouling Mechanisms -- 7.3 Fouling Mitigation -- 7.4 Fouling Mitigation for Crude Preheat Train -- 7.5 Fouling Resistance Calculations -- 7.6 A Cost-Based Model for Clean Cycle Optimization -- 7.7 Revised Model for Clean Cycle Optimization -- 7.8 A Practical Method for Clean Cycle Optimization -- 7.9 Putting All Together-A Practical Example of Fouling Mitigation -- Nomenclature -- References -- Chapter 8: Energy Loss Assessment -- 8.1 Introduction -- 8.2 Energy Loss Audit -- 8.3 Energy Loss Audit Results -- 8.4 Energy Loss Evaluation -- 8.5 Brainstorming -- 8.6 Energy Audit Report -- Nomenclature -- References -- Chapter 9: Process Heat Recovery Targeting Assessment -- 9.1 Introduction -- 9.2 Data Extraction -- 9.3 Composite Curves -- 9.4 Basic Concepts -- 9.5 Energy Targeting -- 9.6 Pinch Golden Rules -- 9.7 Cost Targeting: Determine Optimal ΔTmin -- 9.8 Case Study -- 9.9 Avoid Suboptimal Solutions -- 9.10 Integrated Cost Targeting and Process Design -- 9.11 Challenges for Applying the Systematic Design Approach -- Nomenclature -- References -- Chapter 10: Process Heat Recovery Modification Assessment -- 10.1 Introduction -- 10.2 Network Pinch-the Bottleneck of Existing Heat Recovery System -- 10.3 Identification of Modifications -- 10.4 Automated Network Pinch Retrofit Approach -- 10.5 Case Studies for Applying the Network Pinch Retrofit Approach -- References -- Chapter 11: Process Integration Opportunity Assessment -- 11.1 Introduction -- 11.2 Definition of Process Integration -- 11.3 Plus and Minus (+/−) Principle -- 11.4 Grand Composite Curves -- 11.5 Appropriate Placement Principle for Process Changes -- 11.6 Examples of Process Changes -- References.

Part 3: Process System Assessment and Optimization -- Chapter 12: Distillation Operating Window -- 12.1 Introduction -- 12.2 What is Distillation? -- 12.3 Distillation Efficiency -- 12.4 Definition of Feasible Operating Window -- 12.5 Understanding Operating Window -- 12.6 Typical Capacity Limits -- 12.7 Effects of Design Parameters -- 12.8 Design Checklist -- 12.9 Example Calculations for Developing Operating Window -- 12.10 Concluding Remarks -- Nomenclature -- References -- Chapter 13: Distillation System Assessment -- 13.1 Introduction -- 13.2 Define a Base Case -- 13.3 Calculations for Missing and Incomplete Data -- 13.4 Building Process Simulation -- 13.5 Heat and Material Balance Assessment -- 13.6 Tower Efficiency Assessment -- 13.7 Operating Profile Assessment -- 13.8 Tower Rating Assessment -- 13.9 Column Heat Integration Assessment -- 13.10 Guidelines for Reuse of an Existing Tower -- Nomenclature -- References -- Chapter 14: Distillation System Optimization -- 14.1 Introduction -- 14.2 Tower Optimization Basics -- 14.3 Energy Optimization For Distillation System -- 14.4 Overall Process Optimization -- 14.5 Concluding Remarks -- References -- Part 4: Utility System Assessment and Optimization -- Chapter 15: Modeling of Steam and Power System -- 15.1 Introduction -- 15.2 Boiler -- 15.3 Deaerator -- 15.4 Steam Turbine -- 15.5 Gas Turbine -- 15.6 Letdown Valve -- 15.7 Steam Desuperheater -- 15.8 Steam Flash Drum -- 15.9 Steam Trap -- 15.10 Steam Distribution Losses -- Nomenclature -- References -- Chapter 16: Establishing Steam Balances -- 16.1 Introduction -- 16.2 Guidelines for Generating Steam Balance -- 16.3 A Working Example for Generating Steam Balance -- 16.4 A Practical Example for Generating Steam Balance -- 16.5 Verify Steam Balance -- 16.6 Concluding Remarks -- Nomenclature -- Reference -- Chapter 17: Determining True Steam Prices.

17.1 Introduction -- 17.2 The Cost of Steam Generation from Boiler -- 17.3 Enthalpy-Based Steam Pricing -- 17.4 Work-Based Steam Pricing -- 17.5 Fuel Equivalent-Based Steam Pricing -- 17.6 Cost-Based Steam Pricing -- 17.7 Comparison of Different Steam Pricing Methods -- 17.8 Marginal Steam Pricing -- 17.9 Effects Of Condensate Recovery On Steam Cost -- 17.10 Concluding Remarks -- Nomenclature -- References -- Chapter 18: Benchmarking Steam System Performance -- 18.1 Introduction -- 18.2 Benchmark Steam Cost: Minimize Generation Cost -- 18.3 Benchmark Steam and Condensate Losses -- 18.4 Benchmark Process Steam Usage and Energy Cost Allocation -- 18.5 Benchmarking Steam System Operation -- 18.6 Benchmarking Steam System Efficiency -- Nomenclature -- References -- Chapter 19: Steam and Power Optimization -- 19.1 Introduction -- 19.2 Optimizing Steam Header Pressure -- 19.3 Optimizing Steam Equipment Loadings -- 19.4 Optimizing On-Site Power Generation Versus Power Import -- 19.5 Minimizing Steam Letdowns and Venting -- 19.6 Optimizing Steam System Configuration -- 19.7 Developing Steam System Optimization Model -- Nomenclature -- Reference -- Part 5: Retrofit Project Evaluation and Implementation -- Chapter 20: Determine the True Benefit from the OSBL Context -- 20.1 Introduction -- 20.2 Energy Improvement Options Under Evaluation -- 20.3 A Method for Evaluating Energy Improvement Options -- 20.4 Feasibility Assessment and Make Decisions for Implementation -- Chapter 21: Determine the True Benefit From Process Variations -- 21.1 Introduction -- 21.2 Collect Online Data for the Whole Operation Cycle -- 21.3 Normal Distribution and Monte Carlo Simulation -- 21.4 Basic Statistics Summary for Normal Distribution -- Nomenclature -- Reference -- Chapter 22: Revamp Feasibility Assessment -- 22.1 Introduction -- 22.2 Scope and Stages of Feasibility Assessment.

22.3 Feasibility Assessment Methodology -- 22.4 Get the Project Basis and Data Right in the Very Beginning -- 22.5 Get Project Economics Right -- 22.6 Do Not Forget OSBL Costs -- 22.7 Squeeze Capacity Out of Design Margin -- 22.8 Identify and Relax Plant Constraints -- 22.9 Interactions Between Process Conditions, Yields, and Equipment -- 22.10 Do Not Get Misled by False Balances -- 22.11 Prepare for Fuel Gas Long -- 22.12 Two Retrofit Cases for Shifting Bottlenecks -- 22.13 Concluding Remarks -- Nomenclature -- References -- Chapter 23: Create an Optimization Culture with Measurable Results -- 23.1 Introduction -- 23.2 Site-Wide Energy Optimization Strategy -- 23.3 Case Study of the Site-Wide Energy Optimization Strategy -- 23.4 Establishing Energy Management System -- 23.5 Energy Operation Management -- 23.6 Energy Project Management -- 23.7 An Overall Work Process from Idea Discovery to Implementation -- References -- Index.