Process unit stack and pipe racks against the sky, in black and white
CHEMICALS

Energy and carbon optimisation on the crude distillation unit.

The crude distillation unit is the largest energy user on a refinery. EntroMetrix learns the unit from your own historian and finds set points that cut energy and carbon per barrel while every product stays on spec.

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KEY RESULTS
−5.2%
energy consumed per barrel
−4.6%
carbon dioxide per barrel
−6.8%
fired heater fuel
−9.4%
stripping steam
−3.7%
product quality giveaway
01 · THE PROBLEM

Margin in hand costs energy on every barrel.

Firing, heat recovery, stripping steam, pressure and cut points all interact. A move that protects one product can quietly waste fuel elsewhere, so operators run to safe fixed set points with margin in hand.

That margin costs energy and carbon on every barrel, and the historian trends do not show where it is lost or how much could be recovered without breaching a specification.

01Where the unit destroys useful energy, and every policy against the carbon and throughput frontier.
02 · WHAT IT COSTS YOU TODAY

Fuel burned to stay safe.

Fuel and carbon: most of the heat a barrel needs is raised by burning fuel in the fired heater, so every degree of margin is fuel bought and carbon emitted.
Giveaway: products cut wide of their specification give away quality that could have been sold.
No map of the loss: routine trends show where energy flows, not where useful energy is destroyed, so effort goes to the wrong place.
02Energy, carbon, heater fuel and stripping steam per barrel, before and after.
03 · WHAT ENTROMETRIX DOES

A set of policies you choose from, not a single answer.

Learns your unit: builds a physics informed model of the unit's energy and carbon from your own historian, with no new sensors to start.
Finds where energy is lost: a second law view ranks where useful energy is destroyed, so the levers go where the loss is.
Trims the levers: firing and excess air, pump around duties, preflash and preheat, stripping steam, pressure and cut points, with every specification held.
Offers a choice: returns a set of policies that trade energy and carbon against throughput and product value, and you pick the point.
03Where the saving comes from.
04 · HOW YOU STAY IN CONTROL

Offline first, with your engineers setting the limits.

Your limits: product specifications and the safe operating window are set with your engineers before any recommendation.
Your history: the policy is tested against your operating history before any set point reaches the board.
Your control system: nothing connects to it in the proof phase; the model runs against a copy of the process.
Your operators: recommendations go to the board, and the operator decides.
Your drift check: the model flags when a crude slate change has moved the unit and a refit is due.
04Energy per barrel over a 24 month run.
05 · WHAT YOU GAIN

Lower energy and carbon per barrel.

Held Below the Run Mean

Energy per barrel stays below the run mean while current practice drifts up as heat recovery declines.

Carbon Avoided Adds Up

Avoided firing accumulates month by month to a plant scale figure.

A Few Levers Carry It

Firing and excess air is the largest lever, ahead of pump around recovery and stripping steam, so effort follows the value.

05Carbon dioxide avoided, month by month.
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