Crude Oil conversion to Gas Boiler and its impact on Company Sustainability and Energy Performance

SABIC aims to reduce greenhouse gas emissions by 2030 globally by 20% compared to 2018 baseline. In alignment with Kingdom Vision 2030 strategic objectives, Saudi Kayan adapted crude oil liquid fuel swap to gas fuel (Natural Gas) which will help to reduce CO2 emission by 200 KMT per year by enhancing energy intensity and firing efficiency.

Project Scope:

Modification of the existing COB (Crude oil Boiler) and Flue Gas Treatment System to fire fuel gas include

• Modification / replacement of existing COB Burners, flame scanners, ID Fan impeller, Flue gas duct, stack, control valves etc.
• Modification of the piping to fire PFO (Pyrolysis Fuel Oil)
• Installation of new Fuel Gas line from existing SK Fuel Gas header
• Installation / modification of metering skid, filter, KO Drum etc.
• Demolition of crude oil system

Project completion:

First Boiler commissioning after revamping was done in Sept-2023 and second boiler was commissioning in Aug 2024.

Realized Benefits:

• GHG: 200,000 MTCO2 / Year (4% of SK GHG)
• Energy Saving: Fuel – 0.5M GJ/Y & Electricity – 30k MWH (1% of SK)
• Water Saving: 112,657 m3/Y (2 % of SK )
• Material : FLYASH – 5,000 MT/Y, Gypsum – 17,000 MT/Y (6.2% of SK Waste)

In addition the project improved the reliability of the boiler and reduced the maintenance cost by 1.5 MSAR per annum.

Moreover, Boiler efficiency increased from 80% to 92% and boiler capacity utilization increased from 60% 100%.