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IndustrialEnergyManagementwithVisualMESAatBPLingenrefinery
AvailabilityDepartment BPLingen refinery
Soteica
ERTCAnnual Meeting Vienna 2012
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Outline
Introduction BPLingenrefinery VisualMESA
Energysystemdescription Projectobjectives Projectscheduleandmodelsummary Benefits Conclusions
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Introduction(I)
BPLingenrefinery Oneofthemostcomplexrefineriesintheworld LocatedinNorthWestGermany ConsideredoneofEurope'sleadingconversionrefineries Inkeepingwitheffortstoprotecttheenvironment,allofthegasoline
anddieselfuelproductsareessentiallyfreeofsulphur Refiningcapacityof93thousandbarrelsperdayofcrudeoil
VisualMESAenergymanagementsystemimplemented
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Introduction(II)
HydrogenFuelSteamWaterElectricityUtilitiesSystems
ExternalUtilitiesContracts
EmissionsRegulations
ProcessIndustrialSite
RealTimeandWhatifPlanningOptimizerthatfindstheoptimalwaytooperateutilitiessubjecttocontractual,environmentalandoperationalconstraints
OptimumUtilitiesOperationsReport
Measurements OptimumSetPoints
KPIMonitoringandAccountingReports
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Introduction(III) VisualMESAisa1st PrinciplesModelingandOptimization(SQP
MINLP)programforfuels,steam,BFW,condensate,hydrogenandelectricalsystems,includingemissions
Fieldsofapplication: RealTimeOptimization Monitoring,AuditingandAccounting Engineering Planning RealTimeValidatedEnergyandEmissionsKPICalculationServer
Currentlyinuseinmorethan70refineriesandpetrochemicalsites
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Energysystemdescription
Setoffiredboilersandprocessfurnacesburningfuelgas Steamnetworkwiththreesteampressurelevels Setofsteamturbogenerators Twocogenerationunits
Productionof50MWofelectricityfromtwonaturalgaspoweredgasturbines,foruseonsiteandforsaleoftheexcessenergy
Thegasturbineshavesteaminjectionandheatrecoverysteamgeneratorwithpostcombustion
Differenteconomictradeoffs(amongelectricity,steamandfuelnetworks)
Manychallengestooperatetheenergysystematminimumcost,withintheconstraints(e.g.emissions)
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ProjectObjectives
Monitoringandreductionoftherefinery'stotalenergycosts
Monitoringequipmentperformance Balancingthevariousenergycosts Developing"Whatif"studies
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ProjectSchedule
Datacollection Softwareinstallation(August2010) FunctionalDesignSpecifications Modelbuildingandoptimizationconfiguration Training(January2011) Modelreview Burningperiod Projectandmodeldocumentation(July2011)
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Modelscope
Steam,fuels,emissions,boilerfeedwater,condensatesandelectricitysystem
OptimizationObjectivefunction:TotalEnergycosts=Fuels+Electricity+Othercosts
(FuelOil/NaturalGas/LPG(Propane/Butane)/Electricity/Water)
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VisualMESAGUI(mainview)
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Powerplantmodelview
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Optimizationvariables Cogeneration
GTsloads SteaminjectiontoGTs FuelGastopostcombustion
Steamproductionatboilers FuelGas/FuelOiltoafiredboiler FuelGastotheotherfiredboilers
Turbogeneratorsmanagement TGsloads
Pumpswaps(steamturbines/electricalmotorsswitches) 6possibleswitchesfor401.5barsteamturbines) 36switches111.5barsteamturbines CondensingTurbines
Electricityexportation(orimportation) NaturalGas/Butane/PropanemakeuptoFGsystem Steamletdownandvents
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Constraints
Equipmentrelated(i.e.burnerscapacity) Operationalconstraints Utilitiesprocessplantsdemand Contractual Environmental
NOxandSO2emissionslimits CO2emissions(monitoring)
85Optimizationvariables(54discretevariables)29Constraints
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Benefits
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DaytoDayOptimization Steamproductionbalance GasTurbinesloadsandsteaminjection Turbogeneratorsloads NaturalGas/Butane/PropanemakeuptoFGnetwork
Pumpswaps Theremainingvariables(forexample,steamletdownflow
rates)areconsequencesofthechangesmentionedbefore,beingmanipulatedautomaticallybythecontrolsystem
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Energycostsreductionexamples
NaturalGas/Butane/PropaneadditiontoFGnetwork
GasTurbineloads Pumpswaps
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Example1:MinimizationofbutaneadditiontoFGnetwork
Butane reduction
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Example1(cont):MinimizationofbutaneadditiontoFGnetwork
Energy cost reductionaround 5% on total energy cost
Butane reductionto FG networkaround 3 t/h
Delta Cost (Current minus Optimized)
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Example1(cont):Effectonheaters(furnaces)
FG flow increase at a furnace(around 0.15 t/h)
Burners FG pressure(around 0.25 bar increase)
below the constraint of 1.5 bar
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Example2:OptimizationofGasTurbinesloads
Although electricity exportation penalty increase
Gas turbine load increase operating at higher efficiency
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Example3:OptimizationofPumpswaps
Steam vent eliminated
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Example3:OptimizationofPumpswaps
Several pump swapsA maximum pump swaps constraint required
Economic impact of 1.4% cost reduction on total energy cost
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Performancemonitoring(equipmentefficiency)
Gas turbine heat rate
Deviation
Gas turbine theoretical heat rate
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Performancemonitoring(equipmentefficiency)
Fired boiler efficiency
Turbogenerator efficiency
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Systemauditing(steamimbalances)
Steam imbalance 1,5 bar header
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Casestudies
GasTurbineOfflinewashingevaluation Effectofstart/stopofequipment:
Firedboilers Turbogenerators Largesteamcondensingturbines
UseofNGlinesinfiredboilers
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Differentmodeluses
Clientservermodel Shiftsupervisors,Operators,Engineers Optimizationonshiftbasis
Standalonemodeluse Engineeringandplanningstudies
Sustainabilityoftheuptodatemodel KeyPerformanceIndicatorsserver Instrumentationreview
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Conclusions
VisualMESAimplementedatBPLingenrefinery Asaresultoftheproject,abetterknowledgeofutilities
systeminteractionshasbeenacquired,understandingalldecisionvariablesandtheassociatedconstraintswhichsometimesarehidden
Abilitytoreactonlinetocapturebusinessopportunitiestoreduceenergycostsandimproveemissionsmanagement,gettingsignificantenergysavings