Isomax Heat Integration and Decarbonization
Award
Energy Project
Description
Chevron’s Isomax Heat Integration and Decarbonization project reduces CO2 emissions, restores ISOMAX plant (El Segundo Refinery) to its 1969 nameplate capacity, lowers energy use, and increases returns. The reduction in carbon emissions has been accomplished by optimizing unit heat integration and shifting steam generation to the more efficient cogeneration system. This involved replacing eight existing heat exchangers with twelve high-performance ones, converting the furnace convection section to reboiler service, installing a waste heat recovery unit (WHRU), and upgrading high-pressure piping to 9 Chrome.
The HIDE project is expected to reduce CO2 emissions by approximately 70,000 metric tons per year and achieve energy savings of 153 MMBTU/HR. These values were estimated using the PRO/II Process Engineering Simulation. The project has contributed to higher returns by restoring nameplate capacity, reducing utilities operating expenses and emissions.
The proposed configuration is distinguished by its ingenuity, as spatial constraints necessitated the substitution of eight ground-level exchangers with twelve exchangers strategically positioned on an elevated heavy-duty platform supported by deep foundations.
The construction phase of the project incorporated 42 deep piles (45.5 feet embedment), approximately 416 tons of steel, 19,013 feet of piping, 6,271 feet of welds, 26,480 feet of conduit, 76,961 feet of wire, 203 instruments, and 144 loop checks. Initial planning for the project began in 2021, with construction completed in late 2024.
The HIDE project at Chevron Refinery El Segundo is a remarkable example of collaboration, resilience, and excellence (both globally and within United States). This ambitious initiative brought together a diverse array of contracting partners of over 30 companies. Together, these partners enabled the completion of over 100,000 labor hours in the field without a single recordable injury during all pre-turnaround construction activities in a high-consequence, in-service unit.
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