Steam network operation stability and reliability is vital for any industrial branch. A combined steam network model comprising a balance and a coupled thermo-hydrodynamic model, including seasonal variations impact and system specificities, is presented. A balance model can readily be used by a refinery’s operators. The thermo-hydrodynamic model identifies system bottlenecks and cold spots and evaluates proposed operation and investment measures including heat loss reduction. A three-pressure levels refinery steam network served for model testing and validation. Balance model results reveal significant misbalance in steam production and consumption, reaching 30.5% in the low-pressure steam system, and heat balance differences in the range of 9.2% to 29.5% on individual pressure levels, attributable both to flow measurement accuracy issues and to heat losses. The thermo-hydrodynamic model results differ from the measured steam parameters by less than 5% (temperature) and by less than 4% (pressure), respectively, with the estimated operational insulation heat conductivity exceeding 0.08 W/m/K. Its comparison with that of 0.03 W/m/K for dry insulation material yields the need for pipelines re-insulation and a partial revamp of the steam network. The model is sufficiently general for any type of industry, pursuing the goal of cleaner and energy-efficient steam transport and consumption.

Steam crackers (ethylene plants) belong to the most complex industrial plants and offer significant potential for energy-saving translated into the reduction of greenhouse gas emissions. Steam export to or import from adjacent units or complexes can boost the associated financial benefit, but its energy and environmental impact are questionable. A study was carried out on a medium-capacity ethylene plant using field data to: 1. Estimate the energy savings potential achievable by optimizing internal steam management and optimizing steam export/import; 2. Quantify the associated change in air pollutant emissions; 3. Analyze the impact of the increasing carbon price on the measures adopted. Internal steam management optimization yielded steam let-down rate minimization and resulted in a 5% (87 TJ/year) reduction in steam cracker’s steam boiler fuel consumption and the associated cut of CO₂ emissions by almost 4900 t/year and that of NO_x emissions by more than 5 t/year. Steam import to the ethylene plant from the refinery proved to be purely economic-driven, as it increased the net fuel consumption of the ethylene plant and the refinery complex by 12 TJ/year and resulted in an increase of net emissions of nearly all considered air pollutants (more than 7000 t/year of CO₂, over 15 t/year of NO_x, over 18 t/year of SO_x) except for CO, where the net change was almost zero. The effect of external emissions change due to the associated backpressure electricity production surplus (over 11 GWh/year) was too low to compensate for this increase unless fossil fuel-based electricity production was considered. The increase of carbon price impact on the internal steam management optimization economics was favorable, while a switch to steam export from the ethylene plant, instead of steam import, might be feasible if the carbon price increased to over 100 €/tCO₂.