Sustainable Energy
Case Studies
Green Hydrogen Plant
Eichleay conducted a low carbon road mapping study to evaluate the techno-economic merits of potential decarbonization opportunities for a refiner across 3 different site locations. The study identified 125 potential decarbonization opportunities, which were subsequently refined down to 33 options for further evaluation.
One of the opportunities identified was a new 48 ton/day green hydrogen production facility to supply hydrogen to a new sustainable aviation fuel (SAF) operation.
Eichleay’s scope included:
- Electrolyzer technology evaluation and vendor selection
- Early engagement with key suppliers to support a fast-paced schedule
- Executed FEL 1 and FlexFEED (FEL 2/3) Engineering & Design
- Developed plant layout within a constrained footprint
- Close coordination with the selected electrolyzer vendor and the utility provider to align design
- Equipment specification for the electrolyzers, hydrogen purification and compression systems, and high-pressure hydrogen storage
- Developed a comprehensive TIC estimate
125
Decarbonization Opportunities Identified
48
Tons/day Hydrogen
$400 MM
Total Installed Cost
Renewable Diesel Blending
Project to cost effectively blend renewable diesel and regular diesel for compliance with California low carbon fuel standard (LCFS) and federal renewable fuel standard (RFS) obligations for carbon credits.
Eichleay’s scope included:
- Marine receiving of renewable diesel (RD) and routing of new piping on existing pipeways to existing storage tanks
- Modifications to existing tanks for storage of non-RD diesel, RD, and blended RD products (8 tanks total)
- Design of a new injection system with 2 new centrifugal pumps, control valves, and custody transfer flow meters to control the amount of RD injected in each blend
- Modifications to existing diesel tank manifold for flexibility to connect each tank product to pipelines, rail, and truck loading facilities
2,750
LF of New Piping
$9.2 MM
Total Installed Cost
20%
Renewable Diesel Blend
Green Ammonia Production
Eichleay completed a FEL 1 study to evaluate the feasibility and design of two gigawatt-scale green ammonia plants. The project focused on optimizing ammonia production by integrating advanced technologies and ensuring operational efficiency. The study highlights Eichleay’s ability to handle complex, large-scale ammonia production initiatives while ensuring alignment with sustainability goals.
Key process units evaluated included:
- Desalination systems
- Electrolysis systems
- Air separation technology
- Hydrogen compression
- Ammonia synthesis and storage capacity
Our scope included a technology evaluation for the key process units, development of plot plans to optimize design efficiency and high-level TIC estimates.
$4-5 Billion
Total Installed Cost
Renewable Energy Plaza
This project developed a new facility dedicated to dispensing compressed natural gas (CNG) and hydrogen (H2) fuels for light and heavy-duty transportation fleets in Northern California. The initiative supports California’s strategic transition toward zero emission vehicles and the expansion of alternative fuel infrastructure.
Eichleay provided comprehensive design, project management, and consulting services, driving critical project activities including:
- Design management
- CEQA/EIR requirements
- Land use permits
- Project schedule and cost control
- Site soil remediation
- Vendor selection and management
- Fire protection requirements
- Site security
“Service Station of the Future”
Greenhouse Gas Study
Eichleay performed energy efficiency assessments for two refineries in California and identified opportunities to reduced greenhouse gas (GHG) emissions through the use of electrification, waste heat recovery, combustion controls and process optimization.
A total of 61 opportunities were identified across both sites. For each opportunity, Eichleay developed a project scope description, major equipment requirements, identified implementation challenges, determined estimated energy savings (electricity, natural gas, steam, and water) and developed a +/-50% TIC estimates with supporting documentation.
Example project scopes included:
- Replacing existing 1,500 – 5,000 horsepower steam turbine drivers with electric induction motors
- Modifying an existing steam turbine to withdraw 40,000 lb/hr of 300# steam for use on site
- Consolidating 3 vacuum towers and 4 furnaces into a single vacuum tower with preheat train and furnace
- Upgrading a crude preheat train to improve heat recovery from intermediate streams
- Adding air preheat systems, enhanced combustion controls, and new SCRs to inefficient furnaces and reboilers
- Installing pressure swing adsorption (PSA) system to recover hydrogen from off-gas stream
- Sitewide electrical power infrastructure upgrades to provide redundant and independent main feeds to the refinery