Enhancing sustainability: The role of carbon capture technologies in refineries for a cleaner future

The intense global focus on climate change and corresponding carbon dioxide (CO₂) emissions targets have put refineries under increasing pressure to become more efficient and sustainable. Achieving carbon neutrality to meet these targets is one of the biggest challenges facing this sector today.

The challenge is complex: how to support rapidly growing energy demands, meet emissions standards, and build towards a sustainable future. Such a complex challenge can’t be solved by any one solution.

In fact, a combination of technologies and new fuels is required to reach carbon neutrality. Reducing emissions requires investment in energy efficiency and renewables, as well as in technologies such as carbon capture, utilization, and storage (CCU/S).

The biggest challenge facing oil refineries is the fact that it takes a lot of energy and water to operate, with energy costs adding up to 50% of total operating expenses for some refineries. Plus, they account for approximately 6-8 % of all global industrial energy consumption. In this landscape, improving energy efficiency is therefore becoming increasingly critical.

The Benefits of Carbon Capture in Refineries

Carbon capture, utilization, and storage (CCU/S) is one way for refineries to achieve sustainable development. While small-scale CCU plants have been around for decades, large-scale facilities are becoming more common. Once captured, CO₂ is typically stored in geological formations, preventing its emission into the atmosphere. In many industries, there are also solutions to re-use the captured carbon as a way of boosting productivity and, thereby, profitability. 

However, capturing carbon dioxide is an energy-intensive process, and efficient heat exchanger technologies are fundamental to making CCU/S commercially viable. At Alfa Laval, our proven high-efficiency heating and cooling technologies can play a vital role in minimizing energy consumption while operating your refinery and in the carbon capture process.

Alfa Laval has been an integral partner in the development of numerous pre- and post-combustion CCU/S installations. With our broad portfolio of heat exchangers, we support our customers to meet the demands of this energy-intensive process, maximizing CO₂ capture while minimizing steam consumption and utility requirements. 

Opportunities Beyond Just Carbon Capture

Refineries use a lot of heat in the refining process, and this makes looking for waste heat and recovering it a great way to start saving money and also reduce your CO₂ emissions from the start. Your refinery will become more efficient, and your savings in operating costs will be realized from day one.

For example, crude preheating is the most energy-intensive part of the refining process. An inefficient crude preheat train will cause more fuel consumption in the fired heater, increasing operating costs and carbon emissions. This, coupled with the average age of most refineries being in excess of 50 years, means that there is an opportunity for improvement. Installing more advanced technologies will make this process more efficient. The more wasted heat that can be recaptured, the better the bottom line and the more sustainable your refinery’s operations will be over the long term.

Depending on the specifics of your refinery, other things that you may want to consider include crude distillation, blue hydrogen, and crude oil desalting, to name a few.

Maximizing your refinery’s efficiency and sustainability takes planning and time. It’s a process that requires ongoing commitment to make it enduring. Many factors can come into play for this to happen, including things like conducting an energy audit, educating your employees, and building team support.

Alfa Laval Can Help Move Your Refinery Toward a More Sustainable and Profitable Future

Wherever you are on the sustainability journey — if you are already actively planning or still just thinking about taking your next steps — Alfa Laval is ready to partner with you. Carbon capture is just one important part of a holistic approach to energy efficiency in refineries.

There is no other company that has the array of technology solutions and the corresponding energy efficiency expertise like Alfa Laval. We have the ability to offer customized end-to-end solutions specific to your needs.

Learn more about how you can rise to the sustainability challenge and remain profitable.