real-time resource efficiency indicators and the more project · 2017-02-27 · 3 • the resource...

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Real-time Resource Efficiency Indicators

and the MORE Project

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• The chemical industry is a major consumer of resources, mostly of fossil origin as oil and gas, and a major producer of CO2 emissions.

• Improvement of resource efficiency is a highly complex task in chemical plants, because:– Chemical plants are operated under changing conditions, and the

resource efficiency is determined also by the actual operation, not by the ideal operation assumed during plant design

– The daily operation currently cannot be steered byexisting long-term resource efficiency indicators

– Local and plant-wide resource efficiency may bein conflict

• Plants are not fully automated, operators playa crucial role

Resource efficiency improvement: The challenge

MORE Final Workshop 2017 REIFeb. 15, 2017

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• The resource efficiency of chemical plants is influenced by– Plant design

– External influences (e.g. weather, feedstock quality,…)

– Operation and maintenance

• Goal of the EU Project MORE:

Resource efficiency

Feb. 15, 2017 MORE Final Workshop 2017 REI

Efficiency improvement by better operation

based on RTREI and decision support

KPI• Retrospective

• For reporting RTREI• Real-time

• For Optimization

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MORE impacts

MORE Final Workshop 2017 REI

• Increased transparency of the resource efficiency of the production process for producers and customers

• Better guidance of the plant managers and plant operators in their daily and short-term decisions

• Broad applicability in the process industries beyond chemical production by transfer of the approach and of the supporting technologies

Feb. 15, 2017

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• Collaborative research project

• Supported by the 7th EU Framework Programme for research, technological development and demonstration, Theme: NMP

• Duration: November 1st, 2013 – February 28, 2017 (40 months)

• Budget: 3 919 175 €

• Target group: European process industries and vendors of solutions for operational support.

• Web site: www.more-nmp.eu

MORE: Project identity card


Svetlana KlessovaProject Coordinator inno TSD, France+33 4 92 38 84 [email protected]

Prof. Dr.-Ing. Sebastian EngellScientific LeaderTechnische UniversitätDortmund, [email protected]

Dr.-Ing. Stefan KrämerIndustrial Application CoordinatorINEOS Köln, [email protected]

Feb. 15, 2017

http://www.more-nmp.eu/

mailto:[email protected]



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Consortium


inno TSD, France – one of Europe’s leading innovation management consultancyfirms, specialised in helping major private and public stakeholders design andimplement R&D and innovation projects http://www.inno-group.com/

PETROLEOS DEL NORTE SA - REPSOL, Spain – the biggest petroleum refinery in Spain with a deep knowledge of petro-chemical processeshttp://www.petronor.com/

INEOS Köln GmbH, Germany – operating the INEOS petrochemical site in Cologne, Germany, and part of INEOS Group. INEOS Group is one of the leading world scale chemical companies http://www.ineoskoeln.de/

BASF Personal Care and Nutrition GmbH, Germany – a global supplier of nature-based specialty chemical products and nutritional ingredients and one of the most important European research locations for personal care products worldwide http://www.basf.com/

LENZING AKTIENGESELLSCHAFT, Austria – world market leader in global textile and nonwovens industry with high-quality man-made cellulose fibres, the leading supplier in many business to business markets http://www.lenzing.com/en

Feb. 15, 2017

http://www.inno-group.com/

http://www.petronor.com/

http://www.ineoskoeln.de/

http://www.basf.com/

http://www.lenzing.com/en

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Consortium


VTT, Technical Research Centre of Finland – the largest multidisciplinary research organisation in Northern Europe, providing high-end technology solutions and innovation services, and having extensive knowledge in sustainability assessment and standardization http://www.vtt.fi/

TECHNISCHE UNIVERSITÄT DORTMUND, Germany – a German research university with a leading position in Europe in chemical engineering and in the operation of chemical processes http://www.tu-dortmund.de

UNIVERSIDAD DE VALLADOLID, Spain – a European university with an excellent research group in chemical process operations http://www.uva.es

S-PACT GmbH, Germany – a Process Analytical Technology solution provider for process industries and scientific research institutions, with a focus on optical online spectroscopy http://www.s-pact.de

LEIKON GmbH, Germany – an innovative technology company working in the area of MES (Manufacturing Execution Systems) and process automationhttp://www.leikon.de

Feb. 15, 2017

http://www.vtt.fi/

http://www.tu-dortmund.de/

http://www.uva.es/

http://www.s-pact.de/

http://www.leikon.de/

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Real-time Resource Efficiency Indicators

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• Many existing standards and proposals

• Many indicators are for large-scale analysis, e.g. of a theeconomy of a complete country

• Intention often is to reduce to one or very few indicators, e.g. land use, CO2 footprint

• Not directly useful for steering plant operations

• Specific concepts had to be developed in MORE

Screening of available indicators


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• Indicators measure the input of resources per unit of valuable outputs (products) – resource intensities

• Resources: Materials, electricity, fresh water, ….

• Outputs: Products with specified properties

• Indicators initially should be specific: Specific consumption of energy in case of the use of raw material A for the product with specification Y

Principle: MORE from less!

𝑅𝐸𝐼 =𝑅𝑒𝑠𝑜𝑢𝑟𝑐𝑒 𝐼𝑛𝑝𝑢𝑡

𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑂𝑢𝑡𝑝𝑢𝑡


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Material and energy flow analysis

Feb. 15, 2017

• Site fence (or plant boundary) defines the system boundary

• All inputs and outputs must be considered

• Alternative use / conversion must be taken into account

• Split of resources between products must be determined

Unit 2

Unit 1

Raw material

Natural gas

Heat

Heat


Heat Product 1

Product 2

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Extension to LCA

Feb. 15, 2017

• Extension to life-cycle assessment and CO2-footprint possible by including additional (upstream) information

• But: RTREI should guide managers and operators should be independent of external factors and decisions should be normalized for different conditions (baseline)

REIsAggregation

Reporting

Upstream information

Life cycle analysis


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• Generic REI: Resource input per product output

• In order to be useful for plant operators and managers, RTREI should be related to a baseline

• Baseline:

– Historical data – best observed operations

– Model-based optimization

– Thermodynamic or stoichiometric limits

Normalization

𝑹𝑬𝑰𝑹𝑷𝑺 =𝑹𝒆𝒔𝒐𝒖𝒓𝒄𝒆 𝒊𝒏𝒑𝒖𝒕

𝑷𝒓𝒐𝒅𝒖𝒄𝒕 𝒐𝒖𝒕𝒑𝒖𝒕RPS = Resource and product specific

𝑹𝑬𝑰𝒏𝒐𝒓𝒎 =𝑹𝑬𝑰𝑹𝑷𝑺

𝑹𝑬𝑰𝑹𝑷𝑺,𝑹𝒆𝒇𝒆𝒓𝒆𝒏𝒛


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• Distillation process: Best historic operation

Best observed case: Example


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User specific Baseline

Feb. 15, 2017

Site management

Plant management

Operator

Included in BaselineDegree of freedom

Product mix/volumeProduction plan(s)Job/utility allocation(s)Process parameters

External Influences

Production planJob/utility allocationProcess parameters

External InfluencesProduct mix/volume

Job/utility allocationProcess parameters

External InfluencesProduct mix/volumeProduction plan


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Different baselines


Non-influenceable Parameter(s)

Res

ou

rce

effi

cien

cy in

dic

ato

r (R

EI)

Best practice for Operator

Best Practice for Plant Manager

Current Plant Operation Influenceable by Operator

Influenceable by Plant Manager

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Environmental load

• Energy and material efficiency is not the only concern: environmental load must be included – separate indicators

• Many possible indicators:

– Use of fresh water

– Polluted water of different categories

– Gaseous emissions (greenhouse gases)

– Harmful emissions

– Solid waste of different categories

• Relevance depends on the location


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• Raw materials can be converted or used as a source of energy (e.g. by exothermic side reactions)

• Introduction of the “Total Energy Consumption”

𝑅𝐸𝐼 =σ𝑖=1𝑛𝑆𝑡𝑒𝑎𝑚𝑚𝑆,𝑖 + 𝑊𝑒𝑙 +𝑚𝐹𝐺 𝐻𝐹𝐺

𝑈 + σ𝑗=1𝑛𝑅 Δ𝐻𝑗

𝑅

𝑚𝑃

– Accounts for the flows of energy due to the heat of reaction of the main reaction and the reaction to by-product

– Influence of operation on performance increases as catalyst selectivity is taken into account

Combined mass and energy flow analysis


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• Energy input per product output(separate or combined for different types of energy inputs)– Example: GJ Steam / t high value chemical

• Utilities/ raw materials required per ton of product(separate or weighted sum of different materials or utilities)– Example: m³ cooling water / t high value chemical

• Overall efficiency based on Energy Currency

• (Overall) yield for a resource– Example:

Mass conversion of Propylene and Ammonia into Acrylonitrile

• (Overall/ weighted) waste

Example of REIs for a site

CPHS 2016 • BrazilDez. 8th, 2016

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• When REI are computed over short periods of time, storage effects may distort them.

• If large recycle streams are present, feedback effects occur on a long time scale.

• Remedies:

– Choose integration period long enough

– Include storage terms (accumulation/ depletion) into the computation

• Long-term effects must be included in some cases

– Deactivation of a catalyst dependent on the mode of operation

Dynamic effects


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Generic and specific RTREI

Feb. 15, 2017

• Generic RTREIs for monitoring, optimization, reporting and decision making on the plant level

• Specific RTREIs for use in the day to day operations of individual units


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Specific indicators

Feb. 15, 2017

• Measure the efficiency of units or of pieces of equipment

– E.g. steam consumption per ton of material processed

– Local view, may not always be correct from a global perspective (“shift of burden”)

• Helpful for operators and managers to assess and improve the daily operations

• Only comparable under similar conditions


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• Idea: Use less complex indicatorsand detailed process information fromlower hierarchical levels to evaluate theaggregated performance

REI aggregation and contribution


Application of equipment-specific

indicators where suitable

Lowest aggregation layerfor generic bottom-up

indicators

Generic indicators,specific indicators where

suitable

Generic indicators basedon aggregation

Complex

Plant 1

Section 1 Section 2

Equipment 1

…Equipment

n

Plant 2

Section 1 …

Base level of aggregation, mass and energy balances close

Indicatorcomplexity

Performancedeviationallocation

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1. Decomposition of the plants to the lowest hierarchical level

Steps for aggregation


Resource 1

AN

Energy

Resource 2

PlantComplex

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Decomposition of plants


Resource 1

Resource 2

Product 2

Energy

Resource 1

Resource 2

Product 1

Energy

Plant 1

Plant 2

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Decomposition of plants


Resource 1

Resource 2

Product 2

Energy

Resource 1

Resource 2

Product 1

EnergyEnergy

Energy

Inter-mediate 1

Inter-mediate 2

Plant 1Sub-plant 1

Plant 2Sub-plant 1

Plant 1Sub-plant 2

Plant 2Sub-plant 2

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2. Evaluation of the performance with historical data,identification of influencing factors



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3. Best-demonstrated practice (BDP) identification consideringthe influencing factors



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3. Best-demonstrated practice (BDP) identification consideringthe influencing factors

4. Aggregation of performance indicators and BDP to the nexthierarchical level

5. Visualization of the contributors to performance deviations



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Visualization of contributions


Standard Approach Aggregation and Contribution

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• Individual batches

– Allocation of resources to this batch

• Overall production

– Plant logistics• Scheduling performance• Bottlenecks

– Slow dynamics• Catalyst degradation• Fouling


RTREI for batch and mixed plants

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batch balance

mwaste

mproduct

∑ Wm,cool∑ Qj,H ∑ Wi,el

mk

…

Qgenerated

.

RTREI for individual batches

Electrical energy efficiency

𝐸𝐸𝐸 =σ𝑖𝑊𝑖,𝑒𝑙

𝑚𝑝𝑟𝑜𝑑𝑢𝑐𝑡

Heating energy efficiency

𝐻𝐸𝐸 =σ𝑗𝑄𝑗,𝐻


Cooling energy efficiency

𝐶𝐸𝐸 =σ𝑚𝑊𝑚,𝑐𝑜𝑜𝑙


Total energy efficiency

𝑇𝐸𝐸 =σ𝑖𝑊𝑖,𝑒𝑙 + σ𝑗𝑄𝑗,𝐻 + σ𝑚𝑊𝑚,𝑐𝑜𝑜𝑙



Heat product

𝐻𝑃 =𝑄𝑔𝑒𝑛


Total material efficiency

𝑇𝑀𝐸 =σ𝑘𝑚𝑘,𝑖𝑛


Material efficiency

𝑀𝐸𝑘 =𝑚𝑘,𝑖𝑛

σ𝑝𝑚𝑝,𝑒𝑞,𝑘

Waste production

𝑊𝑃𝑗 =𝑚𝑗,𝑤𝑎𝑠𝑡𝑒


Total waste production

𝑇𝑊𝑃 =σ𝑗𝑚𝑗,𝑤𝑎𝑠𝑡𝑒


Water Usage

𝑊𝑈 =𝑚𝑤𝑎𝑡𝑒𝑟,𝑖𝑛


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REI for the overall batch plant

• Resource consumption that cannot be attributed to a single batch– Catalyst exchange

– Recycle purification

– Cleaning resource consumption

– Effect of production scheduling

• Statistical analysis of the individual batch RTREI on a medium time horizon (> weeks)– Discover effects of plant logistics (bottlenecks)

– Evaluate scheduling performance

Overall resource efficiency

𝑂𝑅𝐸𝑖 =𝑚𝑖

𝑚𝑝𝑟𝑜𝑑𝑢𝑐𝑡,𝑡𝑜𝑡𝑎𝑙


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Visualization concept – Sugar plant

Feb. 15, 2017 MORE Final Workshop 2017 REI16:00 17:00 18:00 19:00 20:00

45%

93%

91%

Material efficiency ME

Cooling energy efficiency CEE

Water Usage WU

!

!

Inefficient Efficient

Crystallizer sectionTotal energy efficiency TEE

95%

Heating energy efficiency HEE

Bullet-ChartHeating energy efficiency

HEE =σ𝑖 𝑄𝑖,𝐻

𝑚𝑝𝑟𝑜𝑐𝑢𝑘𝑡

Measurements: T01225 – T01231Data treatment: 10 min average

45%!Current numerical

value

Variability in set

Current value symbol

TrendWarning

Pan A1

Pan A2

Pan A3

Sugar Plant

Evaporator section

Crystallizer section

Recovery section

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Clear focus on resource efficiency

Feb. 15, 2017

• Resource efficiency indicators should not be mixed with economic performance indicators

• Economic performance can be indicated in addition to explore trade-offs

– Pareto front indicates the trade-off

• The choice of the operating pointis a management decision


Pro

fit

[€/t

(pro

du

ct)]

●

●

●●●

●

●●

●●

●

● ●

●

●

●

● ●

Exceedinglegal limits

technically feasibleoperation points

Pareto front

Environmental load [Emissions/t(product)]

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Summary: Definition of RTREIs

Feb. 15, 2017

• First step: Generic Resource Efficiency Indicators

• Material and energy flow analysis is the core

• Site fence defines the system boundary

• Environmental load (emissions/waste) should be considered separately

• Refinement to specific (tactical) indicators

• Trade-off with economic criteria not to be mixed with REIs

• Aggregation of indicators and addition of information on the incoming streams cradle-to-grave analysis

from less


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Thank you for your attention


real-time resource efficiency indicators and the more project · 2017-02-27 · 3 • the resource...

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