Asset Decarbonization: Electrification and Energy Efficiency

Asset decarbonization projects provide an opportunity to reduce emissions and increase energy efficiency all while providing economic returns.

Clients rely on Fluor's experience to design and build asset decarbonization projects on either new or existing facilities. Fluor brings to each project its expertise in process and electrical engineering proven during 100 years of engineering, procurement and construction projects.

Asset decarbonization takes two primary forms: electrification and improving energy efficiency.

Electrification in the Energy Transition

Electrification of industrial facilities is the design or retrofit of a facility to use electricity instead of steam or fuel gas. Most facilities can be electrified, reducing their carbon footprints.

While electrification is simple in concept, there are many considerations that must be addressed for a project to be successful. Fluor helps clients consider aspects such as which equipment provides the largest reduction to carbon emissions if electrified and whether the facility’s electrical distribution system has sufficient capacity and reliability for the potential changes in electrical loads.

Fluor helps clients realize the many benefits of electrification projects:

  • Improved energy efficiency
  • Lower emissions of NOx, SOx and particulates
  • Reduced water consumption and water treating requirements
  • Reduced capital and operating costs
  • Increased operating reliability
  • Reduced fuel gas demand of a facility

High-impact Electrification Methods

The electrification methods with the largest impact to emission intensity and energy efficiency are electric motors instead of steam turbines, electric heaters and heat pumps on columns. Fluor has more than 30 years of experience electrifying industrial facilities using these methods.

Energy Efficiency Optimization

Energy efficiency optimization reduces a facility's required energy consumption. Reducing energy consumption delivers decarbonization benefits while providing economic returns.

As with electrification, Fluor has decades of experience working on energy efficiency projects. Fluor helps clients implement high-impact methods to improve a facility's energy efficiency:

  • Optimizing heat recovery systems
  • Selecting equipment and technologies based on their energy intensity
  • Applying energy optimization best practices
  • Comparing designs to known benchmarks

Fluor takes a systematic, rigorous approach to understand a client's existing assets and energy needs. By leveraging technical expertise in process and electrical engineering, Fluor can readily determine the best options for each project and facility. Project teams employ the following process design enhancements and design practices to achieve maximum benefit.

Process design enhancements:

  • Applying flare gas recovery, mechanical vapor recompression, high-performance heat transfer and distillation equipment and optimum energy sources
  • Designing for recovery of waste heat and ideal integration of waste streams
  • Implementing effective process control strategies to achieve unit objectives while reducing energy consumption
  • Working with equipment and technology suppliers to enhance their designs
  • Using nested layers of optimization and proven, best available technology

Design practices:

  • Executing value-improving practices such as energy optimization, process intensity and process simplification
  • Designing to an appropriate balance between operating cost and energy inputs versus capital expenditures, such as optimizing insulation thicknesses or pipe sizes
  • Finding potential energy efficiency value by modeling systems and using heat integration analysis software that develops composite curves and clearly shows pinch points
  • Determining energy intensity by process unit and benchmark against best-in-class designs

Fluor's expertise, proven tools and processes and operations-driven mindset help optimize a facility’s energy efficiency to meet economic and environmental needs.