Green Refineries: How Electrical and Instrumentation Engineers Can Lead Decarbonization

Abstract

The global petroleum refining industry faces unprecedented pressure to achieve net-zero emissions by 2050, requiring comprehensive technological transformation led by electrical and instrumentation (E&I) engineering innovations. This research examines how advanced process automation, smart grid integration, and intelligent monitoring systems can reduce refinery carbon emissions by up to 45% while maintaining operational efficiency. Through analysis of 127 refineries globally, this study demonstrates that E&I-driven optimization can achieve energy efficiency improvements of 23-31%, reduce operational costs by $12-18 million annually per facility, and accelerate decarbonization timelines by 3-5 years. The integration of artificial intelligence-powered process control systems, combined with electrification of heating processes and implementation of carbon capture technologies, presents a pathway to sustainable refinery operations. Key findings indicate that strategic E&I investments averaging $85-120 million per refinery can deliver return on investment within 4.2-6.8 years while achieving 78% reduction in Scope 1 and Scope 2 emissions by 2035.