Energy Management & Efficiency Improvement Optimization and Control Technologies

Sanjay Dave

Honeywell Technology Solution Labs pvt. Ltd

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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• 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

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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.