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Project overview
As part of Mexico’s efforts to strengthen energy security and reduce reliance on imported fuels, a large greenfield refinery required an advanced solution to optimise energy recovery while meeting stringent environmental regulations.
TBWES partnered with the project stakeholders to deliver an integrated energy recovery approach, leveraging waste heat from key refinery processes to enhance overall efficiency. Through strong engineering capability and end-to-end execution, the project supported reliable operations, improved energy utilisation, and contributed meaningfully to the refinery’s sustainability objectives.
Challenges
- As part of Mexico’s national energy strategy to reduce dependence on imported fuels, a greenfield refinery, one of the country’s largest, was developed to strengthen domestic energy security. At this site, the key challenge was to optimise energy recovery while ensuring full compliance with stringent environmental norms.
Solution
- TBWES played an instrumental role in addressing this challenge by delivering an integrated waste heat recovery solution for the refinery’s sulphur recovery unit (SRU) and flue gas steam generator (FGSG). The scope comprised two trains of 71.4 TPH claus and oxidiser waste heat recovery boilers along with a 141.4 TPH flue gas steam generator, engineered to harness waste heat from refinery processes and convert it into high-value steam for power generation. The solution was designed with a pressure of 45 Kg/cm²g and an outlet steam temperature of 400°C, ensuring reliable energy recovery under demanding conditions. TBWES undertook a complete thermal design for the FGSG, along with engineering, procurement, manufacturing, testing, and transportation up to the Mexican port, followed by supervision of commissioning. Several innovations were built into the project to ensure efficiency and reliability. These included precise control of steam and flue gas pressure, adaptability to changing flow demands, and optimised outlet gas temperatures under all conditions. Modular fabrication allowed cost-efficient RO-RO (roll-on/roll-off) transportation, while phased shipment planning ensured the timely delivery of claus and oxidiser WHRB units. The boilers were also designed to meet strict NOx emission norms, helping the refinery stay compliant with environmental standards.
Result
- The project delivered significant operational and environmental benefits. By capturing and reusing waste heat, the solution contributed to a reduction of approximately 300,000 tonnes of CO₂ emissions per year compared to natural gas use. This achievement optimised refinery efficiency along with supporting Mexico’s broader energy and sustainability goals.
