Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Cutting Energy Costs and Emissions in an Integrated Petrochemical Complex
- Petrochemical
- Integrated petrochemical complex
- GCC region
Obstacles Our Experts Have Transformed into Opportunities
The client, a large integrated petrochemical complex, was under pressure to reduce both operating costs and environmental impact:
Energy costs
accounted for over one-third of total OPEX, with minimal transparency into consumption patterns
Utilities
(steam, cooling water, compressed air) were oversupplied and poorly balanced across units
No heat recovery
strategy in place—valuable thermal energy was being lost
No real-time
metering or analytics system to identify high-loss areas
Management
had set carbon footprint reduction targets but lacked the technical roadmap to achieve them
Opportunities
The facility had multiple opportunities for efficiency—hidden in plain sight.
Teec’s Expert-Led Solution
Our Team of Consultants delivered its Energy Efficiency Management service as a multi-phase transformation program:
What Our Experts Did
Conducted a plant-wide energy audit, identifying high-consumption hotspots across production and utility systems.
Applied Pinch Analysis and energy integration tools to uncover heat recovery opportunities
Rebalanced steam loads and adjusted cooling water system pressures to reduce parasitic energy losses
Implemented a Utility Optimization Dashboard to monitor real-time consumption and system performance
Proposed low-cost retrofit solutions that delivered energy savings without major CAPEX
The approach wasn’t just about cutting energy use—it was about designing smarter operations.
Execution Approach by Teec’s Experts
- Collected baseline data for energy consumption across all production and utility systems
- Mapped thermal, electrical, and mechanical energy flows using Sankey diagrams
- Benchmarked site performance against TEEC’s industrial efficiency database
- Performed Pinch Analysis to identify heat recovery opportunities across units
- Ran process and utility simulations (using Aspen Utilities Planner and TEEC tools) to assess scenarios for steam load balancing and compressor optimization
- Developed a shortlist of low- and no-CAPEX energy-saving opportunities, validated through pilot trials
- Adjusted setpoints and control strategies for steam pressure, air compressor staging, and cooling water circulation
- Integrated daily energy KPIs into plant dashboards for tracking and shift-level awareness
- Worked with operations and maintenance teams to embed adjustments into SOPs and PM routines
- Developed a Sustainability Dashboard to track emissions, water, and energy KPIs
- Created performance summary reports for internal leadership and external ESG disclosures
- Prepared a roadmap for ISO 50001 certification readiness
Results & Impact
Reduced overall energy consumption by 17% in 6 months across targeted systems
Improved Energy Efficiency Ratio (EER) by 22%, positioning the plant among regional top quartile performers
Achieved $1.6M in annualized energy cost savings through low-capital interventions
Cut carbon emissions by 14%, supporting corporate ESG and compliance objectives
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
BPM Solutions
Through this integration, energy savings became visible, traceable, and sustainable.
