Utility / Service Analysed Project Type Industry (year) Determined Original Efficiency Determined CAPEX Savings % of total investment Determined OPEX Savings Determined New Efficiency Our Recommendation (in brief)
$M $M/yr
Water Green Field Oil and Gas (2002) N/A $25 1% $5.0 N/A We found a way to better utilise the water, allowing the process to better fit the utility system.
Thermal Green Field Coal Gasification (2008) N/A $100 4% N/A N/A We found numerous pieces of equipment that could be eliminated by integration, in addition to system improvements.
Exergy Green Field Oil and Gas (2002) N/A $80 3% $5.0 N/A We used an extra heat exchanger, reducing the size of a number of gas compressors, and eliminating a number of high pressure vessels.
Thermal Green Field Petrochem (2008) N/A $20 1% N/A N/A Pinch analysis showed this was one of the few facilities where the demand on the Low Pressure steam system was governing, which eliminated the economic justification for on site electricity generation.
Exergy Debottlenecking Gas Processing (1984) N/A $1 30% N/A N/A An exergy analysis showed how intelligent placement of compression interstage cooling eliminated the need for an additional compressor, allowing intensification.  This application was normally required 2-stage compression, but we accomplished the same task with 3-stages of compression, and avoided the need for additional equipment.
Thermal Debottlenecking Oil and Gas (2000) 94% $0 0% $0.1 100% Two systems were optimised independently of each other.  We found how 5 metres of pipe could integrate the two systems with excellent benefit.
Water Green Field Oil and Gas (2002) N/A $30 1% N/A N/A After performing a water pinch, we found ways to economically unfreeze and modify the process, resulting in new investment saving opportunities.
Exergy Debottlenecking Gas Processing (1999) N/A N/A N/A N/A N/A Exergy analysis showed how seasonal production could maximise seasonal production in a manner no one else considered.  Production was increased by 5% during seasonal variations.
Thermal Expansion Oil Refining (2007) 76% $50 9% $1.5 99% We found a solution that used two small pumps to significantly reduce heat requirements
Thermal Expansion Gas Processing (2006) N/A N/A N/A N/A N/A Our pinch analysis found a way to economically improve the total safety of the hot utility system.  By de-integrating one small exchanger and making it electrically heated (it was not a continuous load, and the load was less than 100 kW), we were able to change the heating medium from a semi-toxic hot oil to inhibited water, with significant reductions in environmental risk.
Thermal Debottlenecking Gas Processing (1984) N/A $2 70% $0.05 N/A We recommended using a separator in the process to unload the refrigeration system
Thermal Brown Field Power Generation (2004) N/A N/A N/A N/A N/A Using pinch analysis, we demonstrated that a method of measuring boiler efficiency that had been successful for years would no longer work.  The analysis saved weeks of arguing.