Leverage Pinch Analysis to Reduce Refinery OPEX

Global refining is entering a decisive decade. According to the U.S. Energy Information Administration’s Outlook on Global Refining to 2028, global refining capacity in 2023 reached ~103.5 million barrels per day, with an additional 2.6–4.9 million b/d expected by 2028. This expansion signals intensifying competition, utilization pressure, and rising OPEX risks across global operations.

In this landscape, efficiency is a strategic necessity. With energy costs representing up to 60% of refinery OPEX, forward-looking refiners are embracing advanced process optimization and pinch analysis to unlock deep energy savings and operational resilience.

Pinch analysis, a proven energy integration technique, systematically identifies the minimum possible energy consumption in process plants by analyzing heat recovery opportunities across units. When combined with AI-driven control systems, predictive maintenance, digital twins, and hydrogen integration, it enables smarter, leaner, and cleaner refining operations.

Our latest executive report reveals how leading refiners are merging data, digitalization, and decarbonization to reshape cost structures, enhance process efficiency, and accelerate progress toward sustainable competitiveness. View the full report and uncover how to turn disruption into long-term advantage.

Contact us to learn how FutureBridge helps refiners optimize OPEX, reduce emissions, and enhance performance.