*Sustainable Energy Efficient Industrial Facility Design DOI: http://dx.doi.org/10.5772/intechopen.108829*

drop in the PHT is changing, the necessity for adding new heat exchangers units, the requirement for changing units' sequence, the necessity to streams splits, the requirement even for brand new streams matching, the requirement to alteration the atmospheric and/or vacuum towers internals, the need to change crude pumps and then on. Such situations will bring hard constraints to any plant owner to start out any retrofit on the premise of energy saving or energy-based GHG emissions reduction particularly, unless it's absolutely necessary for unit de-bottlenecking via the furnace debottlenecking to permit throughput increase. In such situations usually, many good opportunities to avoid wasting energy consumption and reduce energy based-GHG emissions are going to be overlooked.

The feasibility of pre-heat train design modifications within the fossil oil distillation plant depends not only on the retrofit needs of the pre-heat train but also on the constraints associated with distillation towers. The interaction between the atmospheric and vacuum distillation towers, products and inter-coolers (top, middle and bottom pump-arounds) of both columns' conditions beside its hydraulic situations create a multifarious problem to the process owners that forces them to significantly re-consider on the premise of energy saving only and/or emissions reduction any design modification especially if the desired modifications need long downtime of the plant, to be implemented. Such constraints make the choice makers of any petroleum distillation plant avoid completely any try to change the pre-heat train design and only considering the modifications which mostly accept the initial pre-heat train design with minimal changes. The petroleum refineries owners have very valid point to behave this manner.

The moves of the heat exchangers units within the crude distillation plant pre-heat train from one location to a different for re-sequencing heat exchangers units, as an example, even between the same streams, will need a crane work inside the process area and definitely a crude distillation plant down time to implement it as a project. To maneuver one heat exchanger unit within the crude distillation plant pre-heat train to a new location to be matched with another stream will even be harder not only because it needs crane work and down time but another more involved engineering project to design the new pipework required and also the pipe rack capability to accommodate the new portion of the piping system including the pre-heat train re-piping required, civil work, instrumentation and control modifications material of construction selection, safety study/HAZOP. In many situations within the crude distillation plant's pre-heat train area, congestion will not allow such modifications in the slightest degree and if it allows it; the pipework modifications could be very expensive. Besides, in such situations the re-use of existing heat exchangers units, a minimum of from surface area point of view and/or materials of construction are going to be another unfeasible situation to contemplate for enhancing the pre-heat train energy efficiency.

Adding of new heat exchangers to reinforce the energy efficiency of the crude distillation plant pre-heat train via re-matching of streams between the crude oil cold stream and also the hot products for instance or the splitting of crude stream in one side and/or the towers products or pump around streams on the opposite side, whether or not the initial/original design may find it to be beneficial from energy saving point of view, most of the times the prevailing topology of the original design does not allow it because of the previous constraints and no way to proceed on the premise of energy saving merits alone. In many other situations the original/ grassroots design of the pre-heat train does not have any merit in doing modifications to avoid wasting energy without revisiting completely the crude distillation

plant pre-heat train grassroots design plot plan and re-do the design from scratch. Therefore, if we miss the "right" crude distillation plant pre-heat train grassroots design from the beginning, we are going to be constrained with the existing distillation towers and pre-heat train grassroots design plot and there'll be very limited opportunity to boost the pre-heat train energy performance. In conclusion, the initial design cannot be improved in the least along its lifetime. Therefore, it'll be beneficial to the petroleum refineries to form the pre-heat train design of the crude oil "right" from the beginning with inherent capability to capture waste energy with no topological modification of its original design. The inventions [US Patent 10,494,576 B2 (2019) & US Patent 10,822,551 B2 (2020)] renders energy efficient healthy aging design of crude oil refineries distillation units' Pre-Heat Trains. The invention is related to new energy efficient configuration of integrated crude oil atmospheric and vacuum distillation units' pre-heat train. The invention renders novel pre-heat sustainable design from energy consumption efficiency and fossil fuel-based GHG emissions' points of view along the fossil oil refinery lifetime solely; through the pre-heat train heat exchangers' surface areas manipulation (**Figure 6**). The novel pre-heat topology design is fixed and "right" from the star of the petroleum refinery commissioning up to the refinery end-of-service. It enables the cold crude oil stream of medium grade and mixed grade crude oils uses the identical topology with minimum energy consumption, compared with prior art, within the crude furnace before the atmospheric distillation column with none structural modifications along the petroleum refinery lifetime through some heat exchangers surface areas manipulation only.

This invention enables the crude oil refineries to know ahead of time their plot plan needs for future crude distillation units furnace debottlenecking and/or energy saving projects. The invention shown embodiment exhibits the small print of the pre-heat train's design for the Minimum Approach Temperatures Range of 30 C to 15 C and further the thermal duties of heat exchangers (Q ) in MW and temperatures in degree C (the recommended values for these designs). The energy saving compared with state-of-art brand new refineries pre-heat train configuration is up to about 30 MW of fuel saving. This saving can increase even more by up to about 50% to save up to about 50 MW of fuel using the identical invention configuration with more surface area manipulation only as mentioned above while the prior art designs do not have this capability. Taking into consideration that oil refineries can live about 50 years, the missed opportunity in both fossil fuels saving and fuel-based GHG emissions reductions are huge. Taking also into consideration that every barrel of oil going to petroleum refineries worldwide goes through this pre-heat train, the worldwide missed opportunity will be significant and increasing with time.

The developed designed shall be further developed till the end of its life-time and shall be designed for every interval of Minimum Approach Temperatures which suits normal shutdown for instance 5 C i.e. Minimum Approach Temperatures of 30 C, 25C, 20C and 15 C for a life-cycle of 20 years with a shut-down cycle of each 5 years. Because the detailed design is completed and provisions were made during the initial design, during planned shut-down exchangers areas/shell shall be installed to induced the desired energy efficiency. The design is prepared to be implemented with an awfully short cycle and might be called "off the shelves design", as all requirements to be energy efficient supported on capital and energy values trade-off may be fulfilled with none hindrance. As ADU-VDU plant heat demand is almost constitutes of its all energy requirement, the propose design can be assumed to be sustainable energy

*Sustainable Energy Efficient Industrial Facility Design DOI: http://dx.doi.org/10.5772/intechopen.108829*

efficient design. For a whole sustainable design all energy elements i.e. heating, cooling, shaft power and waste energy recovery technologies has to be designed in the same manner [3–5].
