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Energy Management & Efficiency Improvement Optimization and Control Technologies
Sanjay Dave
Honeywell Technology Solution Labs pvt. Ltd
2
Content
• Overview - Opportunities for Energy and GHG Savings
• Get Cheaper Energy – Planning and Scheduling
• Get Cheaper Energy – Industrial load management system
• Produce Energy Cheaper – APC & O in CPP
• Consume less energy: APC & O in refinery units
• Consume less energy: APC & O in Offsite
• Sustaining benefits
• Conclusion
3
Overview - Opportunities for Energy and GHG Savings
Process Design Improvement
Opportunity Analysis• Benchmarking• Pinch Analysis
Adv. Process Technology• High Flux Exchangers/
Heat Integration• High Efficiency Distillation• Power Recovery Turbines• Advanced Catalysts• Improved Process Design
Managing Emissions• Ecofining• Rapid Thermal Pyrolysis• Callidus/Maxon Burners
Online / Offline Monitoring & Control & OPT
Online Monitoring• Energy/Emissions
Dashboard• Wireless Solutions
Control/Opt• Supply Side APC & Opt
•Get energy cheaper•Produce energy cheaper
• Demand Side APC & Opt•Refinery APC & Opt•Offsite APC & Opt
Sustain Benefits
Sustaining Benefits• Remote Performance
Monitoring• Continuous Improvement• Technology Refresh
Maintain / Operation• Attend steam traps• Insulation • Maintain rotating
machines
4
Get Cheaper Energy – Planning and Scheduling
1# atmosphere tower
2# atmosphere tower
1# Ethylene
Crude oil Naphtha
Naphtha
Buy naphtha
AGO
AGO
Oil from bottom of HCU
AGO feed to diesel
Crude oil
Crude oil
2# Ethylene
2# atmosphere tower
• Planning and Scheduling– Plan and schedule for energy efficient feed stock and fuels
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Planning and Scheduling
• Development and analysis of LP models of refining and petrochemical facilities
• Planning integrates:– Products’ demand and prices– Raw material availability and cost– Feedstock and product qualities– Process unit configuration– Blending correlation and
specifications
• Provides a feasible optimal solution:
– Which raw materials to purchase– Which products to sell– How to operate the process units– Blending recipes– Maximized profit– Minimize Energy
6
Get Cheaper Energy – Industrial load management system
• Forecast demand and Plan
electricity/ energy
• Optimize between different power
sources, Inhouse, External
• Avoid peak tariffs
• Constrain to contracted value
7
Produce Energy Cheaper – APC & O in CPP
Boiler Optimization
Accept steam loads and allocate according to efficiency and constraints
Turbine Optimization
Accept electrical loads and balance according to efficiency and price
Supply/Demand Optimization
Meet forecast demand accounting for price, emissions, availability, contracts, etc.
Performance Monitor
Monitor performance of boilers and turbines.
Combustion Control
Tight Fuel/air ratioControl excess O2
8
Power plant optimization
• Non linear optimization
• Adaptive control and optimization , adapt to the changing quality
of fuel and fouling conditions
• Fault detection : Ability to detect faulty instruments , CO , O2,
NOx
• Allocation of load to the boilers and turbines, after adjusting for
efficiency and price of fuel
• Unmeasured disturbance detection : Use of state of art
techniques to estimate false air and unmeasured steam flows
• Stability and agility . Control should be stable , but also quick to
respond to changes in steam or power.
9
Consume less energy: APC & O in refinery units
VGOHT
DHDT
DCU
FCC
KEROMerox
NSU
H2 Unit + PSA
CCR
CDUVDU
Gasoline
LPG
Kerosene
Diesel
Gasoline
Coke
CDU/VDU
Preheat optimization Furnace ControlDistillation Control
DCU
Furnace ControlDistillation ControlWGC Control
FCC
Furnace ControlDistillation ControlWGC ControlImproved Heat recovery
CCR
Reformer ControlRegenerator ControlDistillation ControlImproved Heat recovery
H2 optimization
Reformer ControlHydrogen network optim
Hydrotreater / HCU
Preheat optimizationFurnace ControlDistillation ControlReactor Control / H2 red
Crude
10
Refinery/ petrochemical plant optimization
• Unit level optimization using multivariable model based predictive control and optimization. – Short time to implementation to reap quicker benefits and sustain
benefits by leveraging true closed loop step test and model ID
• Global Dynamic optimization of group of units– Refinery: Hydrogen Units, CCR, VGOHT, DHDT, HCU etc
– Petrochemicals: Naphtha/ Gas cracker complex
• Nonlinear first principle model based control and optimization for Polymer plants
• State of the art techniques for sensing the product qualities – Unisim
– Advanced statistical methods
– Grey box models
11
Consume less energy: APC & O in Offsite
Crude
Refinery
Component Tanks
Blend Tanks
Marketing
MARKETSIGNALS
Octane
RVP
BenzeneOxygen
ASTM D86
Blend control and Blend optimization
Giveaway Energy = $$Reduce the number of reblends
12
Blend control and optimization
• Blend control
– Manual or pre-configured recipe specification
– Pacing control due to inadequate component flow
– Support for property analyzers – linear average and property error
calculations, signal validation
• Blend Optimization
– Multi blender optimization
– Instantaneous or tank property control
– Minimum cost or Minimum giveaway
– Accurate blend models
13
• Remote Performance Management– Sustain benefits of Advanced
applications such as APC & Opt, MES
– Check process and catalyst performance
• Life Cycle Management– Keep system current to ensure
highest availability– Leverage capabilities of modern
system to improve safety. Reliability and efficiency
Sustaining Benefits
14
Conclusion
• Improving energy efficiency is an effective way to reduce operating costs and CO2 emissions
• Solutions include low capital cost operational improvements plus a wide variety of technology solutions
• Energy savings of 3-8% are possible• Technology and capability are key success factors• Benefits achieved decline rapidly unless they are sustained.