holistic approach to capturing and sustaining energy savings · holistic approach to capturing and...
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©2006 Aspen Technology, Inc. All rights reserved
Holistic Approach to Capturing and Sustaining EnergySavings
December 7th, 2006
2©2006 Aspen Technology, Inc. All rights reserved
Outline
•What is energy management?
•Advanced Process Design
•Sustainability
•Holistic approach
•Summary
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Energy Flow and Profitability
Supply Profile
Demand Profile
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Energy Management Components
Supply SideSupply Side
(Utilities)(Utilities)
DesignDesign
OperationsOperations
Demand SideDemand Side
(Processes)(Processes)
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Energy Management –Time Horizons
Supply SideSupply Side
(Utilities)(Utilities)
Demand SideDemand Side
(Processes)(Processes)
Strategic Planning
Tactical Planning
Scheduling
Operating Decisions
Control
Years
Months/Weeks
Days
Hours
Minutes
DesignDesign
OperationsOperations
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Utilities system modeling
Total Site Pinch Analysis
Optimize utilities system design
Cogeneration Feasibility
GHG Planning
Energy/yield/purity/throughputtrade-off
Process/Column Pinch Analysis Catalyst Replacements Process re-sequencing &
optimization Establish energy targets
Energy Management Components
Supply SideSupply Side
(Utilities)(Utilities)
Operator Decision SupportSystem
Performance management Dynamic targeting & alerting Heat Exchanger Monitoring Advanced Control Real time Optimization
Fuel, Steam & Poweroptimization
Performance Management Utilities Contract Management Emissions management Reduce flaring & venting
Demand SideDemand Side
(Processes)(Processes)
DesignDesign
OperationsOperations
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RawMaterials
DesiredProductsProcess?
The objective of process design is the creation of a process toconvert raw materials into desired products
What is Process Design?
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Feed Heat Cool
Reactor
Process design starts with the Reactor
What is Process Design?
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FEED RECYCLE
Cool
CoolCoolHeat
Heat
Heat
Heat
ReactorFEED
PRODUCT
BYPRODUCT
The reactor design dictatesthe separation and recycle problem
What is Process Design?
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Cool
Cool
Heat
Heat
Heat
Reactor
FEED
FEED
PRODUCT
BYPRODUCT
The reactor and separator system dictate the heating and cooling dutiesof the streams, so the heat exchanger network can be developed
FEED
What is Process Design?
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CW
CW
Steam
Steam
Steam
ReactorFEED
FEED
PRODUCT
BYPRODUCT
Those duties which cannot be satisfied by heat integrationdictate the need for .external utilities
Steam Mains
CoolingTower
FEED
What is Process Design?
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Reactor
Separation Scheme
Heat ExchangerNetwork
Utility Selection
Base Case
Different possibilitiesfor heat recovery
Type, SequencePressure, Feed ConditioningSide Reboiler / Condenser
Steam, Hot OilFlue gas, Refrigerant
Type, Phase, CatalystPressure, Temperature
Once a base case design has been developed, this can then beimproved by considering Structural and Parametric Changes
Process Improvement
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Engineer Modeling
Quantify real impact
Idea # 3 ......Idea # 2Idea # 1,
Traditional Approach to Process Improvement
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SynthesisGenerate Ideas
ModelingEvaluate Ideas
Engineer
Quantify real impact
Set targetsIdentify critical designchanges
Key Ideas
AspenTech Advanced Process Design
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Modeling
ModelingExistingProcess
ExistingProcess
ImprovedProcess
ImprovedProcess
Reduced Modeling EffortBetter Improvement Option
Impact on ProcessConfiguration
Why use Process Synthesis?
Value•5-30% energy savings with 1-2 years payback (energy and emissions reduction)•5-15% capacity increase with 10-30% less capital (plant debottlenecking)
Value•5-30% energy savings with 1-2 years payback (energy and emissions reduction)•5-15% capacity increase with 10-30% less capital (plant debottlenecking)
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Design for Energy EfficiencySamsung General Chemicals, Daesan (Korea)
Site Profile
•Energy costs had risen
dramatically since plant start-up
(oil price $17 $29 $40 )
•By 2000, the annual energy bill for
the complex was over $60MM
•SGC began to study radical
revamp plans to significantly
reduce energy costs
Business Challenges
How AspenTech Helped•Joint project executed by Samsung General Chemicals / Samsung
Engineering / AspenTech.•Several SGC’s ideas were used, together with new ideas generated from
modelling and energy system optimization analysis.•Practical project ideas developed and costed.($9.1MM)•20%+ energy savings achieved. ($12MM/year)
•SGC operates a large aromaticscomplex in Daesan, Republic ofKorea
•Built in 1997•Capacity:
480,000 MTA Paraxylene240,000 MTA Benzene100,000 MTA Toluene
Complex-wide revamping for energy optimization
Aromatic Complex Revamping
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Design for Energy EfficiencyZero Capital Opportunities
Site Profile
•Rigorous, predictive Aspen plus model
•Detailed analysis and specific
operational modifications of:
•Ethane-propane feed splitter
•Cold box- Demethaniser
•Ethylene splitter / fractionator
•Rigorous acceptance testing of all
modifications
Deliverables
Results•Changes were easily implemented and tested within a 4 month period.•Energy savings in excess of $500,000 / year with no capital
expenditure.•Many other potential improvements and debottlenecking opportunities
identified for future development.•Unit personnel gained more knowledge, which has helped improve
operation and optimization efforts
•Ethylene Plant•Capacity - 1 billion lb per annum•Ethane/propane feedstock
Aromatic Complex RevampingCrackingFurnaces
GasSweetening Quench
Diln Steam
Compression1-3
NaOH WashDrying
Cold Box
Chilldown
Companders
EthyleneReFridge
DeEthaniser
DePropaniser
Stabiliser
EthyleneSplitter
DeMethaniser
C3's
C5's
C4's
H2
Methane
Ethylene
Ethane r/c
EthaneFeed
PropaneReFridge
Steam System
Comp-4
AcetHydro
PropaneFeed
PyGas
Water
Framework•Pay-for-performance fee basis
•Zero capital expenditure
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Design for Energy EfficiencyZero Capital Opportunities (cont.)
Demethanizer Operational Improvements–Cold Box refrigeration loads / profile shifted
•Make better use of higher level refrigeration and lower duty on colder
refrigeration levels
–Methane Circulation maximized
Hydrogen purity
Hydrogen intrusion into demethanizer
Recycles to methane refrigeration compressor (MRC)
Pressure required at PGC and Demethanizer
–Methane in Bottoms Reduced to 50 ppm, Side Reboiler Duty Reduced
& Pre-heater Flow Increased
•Properly balanced tray loading
•Maximized separation efficiency
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Sustainability
A year later….
Most of the operational improvements had regressed to their
original state
Why?–Inadequate follow-up by process engineering to train operations
–“But we’ve always run it that way”mentality
–Staff turn-over
–Lack of management attention
–No on-line performance management system
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Energy Investment Plan &
Program Management
Energy Investment Plan &
Program Management
Energy Management AnalysisEnergy Management AnalysisAssess Current State of site energy managementAssess Current State of site energy managementMap improvement needs to AspenTech capabilitiesMap improvement needs to AspenTech capabilitiesPlan the Energy Management ProgramPlan the Energy Management Program
Holistic Approach
Supply SideSupply Side(Utilities)(Utilities)
Demand SideDemand Side(Processes)(Processes)
DesignDesign
OperationsOperations
Energy / yield / purity / throughputtrade-off
Process/Column Pinch Analysis Catalyst Replacements Process re-sequencing & optimization Establish energy targets
Operator Decision Support System Performance management Dynamic targeting & alerting Heat Exchanger Monitoring Advanced Control Real time Optimization
Utilities system modeling Total Site Pinch Analysis Optimize utilities system design Cogeneration Feasibility GHG Planning
Fuel, Steam & Power optimization
Performance Management
Utilities Contract Management
Emissions management
Reduce flaring & venting
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Month 1 Month 2 Month 3 Month 4 Months 5 & 6 Months 7 to 9 10 to 12 13 to 18
Typical Sequence of Events
EnergyManagement
Analysis
Program Management
Engineering Design, Construction &CommissioningAdvanced Process
Design
Utilities ManagementUtilities Planning Utilities Operations
Energy
TargetsOperationalImprovements
CapEx Projects
Operational Improvements
Advanced Process Control / Real-time Optimization
Performance Management
Base-lining Targeting Continuous Improvement
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SummaryV
alu
e
Time
=
Syn
erg
y+
Su
stai
nab
ility
Consulting report
No Knowledge transfer
Implement Point Solutions
Transfer Know-how & models
Investment Plan
Program management
Performance Management
Deliverables
SYNERGY –Design, Operation, Supply & Demand workingtogether towards the same goal
SUSTAINABILITY –Capture improvements, then “Sustain the Gains”