Energy Efficiency Study Applied to Residual Heat Systems in the Ecuadorian Oil Industry Located in the Amazon Region

The oil sector in Ecuador represents one of the largest national energy consumers, with significant contributions to greenhouse gas and thermal emissions due to reliance on diesel-based thermoelectric generation. This study assesses the feasibility of implementing waste heat recovery processes in upstream petroleum operations, aiming to improve energy efficiency and reduce the sector’s carbon footprint. Historical production and energy consumption data (2015–2020) from the main oil blocks (43-ITT, 57-Shushufindi, 57-Libertador, 58-Cuyabeno, 60-Sacha, and 61-Auca) were analyzed, alongside experimental parameters from thermoelectric equipment. Key energy indicators, including recoverable heat potential, energy intensity, and CO2 emissions, were quantified to identify inefficiencies and opportunities for recovery. Results show that blocks with the highest crude production also exhibit the largest energy demand, with flue gas temperatures averaging 400 °C and an estimated recovery potential of up to 1.9 MWe through Rankine Cycle systems. Pre-feasibility analysis indicates a cost–benefit ratio of 1.03 under current conditions, which could reach 1.29 with higher load factors, while avoided emissions surpass 7000 tCO2 annually. The findings highlight a strong correlation between energy intensity and CO2 emissions, emphasizing the environmental relevance of recovery projects. Adoption of heat recovery technologies, coupled with regulatory incentives such as carbon pricing, offers a viable pathway to enhance energy efficiency, reduce operational costs, and strengthen sustainability in the Ecuadorian oil industry.