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Energy Optimization with Pinch Analysis McMullan

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Optimization in the conceptual or feasibility stage provides:
Specifications for the Licensor Process Design Package (PDP) before design begins and opportunities to minimize utilities capital costs

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Energy Optimization with Pinch Analysis McMullan

  1. 1. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Energy Optimization Early in Design Process Minimizes Process Energy Consumption – and Minimizes Total Projects Costs Andrew McMullan KBC (A Yokogawa Company) Proprietary Information
  2. 2. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Compelling justifications for investment Switches to Gas Changing crude slates Push into petrochemicals and chemicals Regulatory changes – emissions standard, such as IMO2020 Proprietary Information
  3. 3. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Investments are under pressure from vigilant stakeholders Proprietary Information
  4. 4. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Traditional design process needs to respond Proprietary Information
  5. 5. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Cost of change increases but data, information and insight are added Cost of Design Changes Proprietary Information
  6. 6. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Wait for more definition or make changes before design starts? Early In Design • Limited Data • Many Interacting Options • Hard to understand overall picture Later In Design • Modification Costly • Changes lead to delays • Complex Impacts on multiple systems Proprietary Information
  7. 7. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 CapEx and OpEx savings are in the Gap Early In Design • Limited Data • Many Interacting Options • Hard to understand overall picture Later In Design • Modification Costly • Changes lead to delays • Complex Impacts on multiple systems Case Study GAP worth IRR improvement = 1% CapEx = $103MM OpEx = $66MM per year 14% less energy Proprietary Information
  8. 8. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 CapEx and OpEx savings are in the Gap Early In Design Later In Design Case Study GAP worth IRR improvement = 1% CapEx = $103MM OpEx = $66MM per year 14% less energy Early development of technology models Requirements captured in the PDP Almost no re-work as improvements are designed in from the beginning Proprietary Information
  9. 9. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Breaking the Vicious Cycle Simulation to “patch up” uncertain data Plant Wide Model to model global impacts Pinch and TotalSite Analysis to optimise inter unit interactions Detailed Pinch to improve heat integration Utility Model to understand steam/fuel/power balances Optimise driver selection and utility design Experience & Expertise – anticipate what the design will look like Best Practice and smart ideas from other plants Proprietary Information
  10. 10. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Plant Wide, pinch, utility, best technology (BT) now all in Petro-SIM Model Simulation to “patch up” uncertain data Plant Wide Model to model global impacts Pinch and TotalSite Analysis to optimise inter unit interactions Detailed Pinch to improve heat integration Utility Model to understand steam/ fuel/power balances Optimise driver selection and utility design Experience & Expertise – anticipate what the design will look like Best Practice and smart ideas from other plants Proprietary Information
  11. 11. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Develops into the Operations Digital Twin Early In Design Later In Design Proprietary Information
  12. 12. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Case Study Client Situation • Planning a significant plant expansion Objectives • Minimize Capex • Reduce Capex in utility system by reducing energy provided and removed from new units • Ensure adequate utility sizing for both new units and the existing refinery for all required normal and abnormal operating cases Improve the integration between the new units and the existing refinery • Maximize energy efficiency • Build improvements with <5 year paybacks into design • Ensure suitable integration with existing refinery Project Goals • Minimize Capex • Reduce energy use by maximizing the efficiency of each new unit • Improve the integration between the new units and the existing refinery Proprietary Information
  13. 13. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Procedures Performed: • Before FEED • Process Simulation, to fill-in missing data and determine opportunities for process improvements • Site wide utility strategy, including power generation/import philosophy and steam conditions to maximise integration potential • DT min analysis to optimise capital/energy trade- off for heat recovery design • In Parallel with PDP/FEED • Kick-off meetings with licensors to discuss and agree to proposed improvements • Pinch analysis for heat integration improvement • Utility/reliability modelling to optimise sparing and utility generation design • BT Benchmarking to assure efficiency of design Objectives • Before FEED • Changed utility strategy to motor-centric rather than turbine-centric, modified electrical design accordingly • Opportunities identified in all licensed units • In Parallel with FEED • 14 ideas agreed for implementation • 14% energy reduction in final design • – 66 MM USD/Y saving • 103 MM USD Capital cost reduction • Significantly Exceeded Target Savings • Improved overall project IRR by more than 1% Proprietary Information
  14. 14. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Net Impact of Energy Changes Units Items Cost Increase (MM USD) RHDS Switching to a motor -6 HS-FCC Driver selection -112 ERU Driver selection -22 RHDS Pinch improvement 21.5 HS-FCC Pinch improvement 8 C4 block Pinch improvement 3 C4 Block Distillation column improvement 3.1 NHDS Pinch improvement 4 Alkylation Distillation column improvement 14 SRU Pinch improvement 1 Utility Smaller boiler & associated system sizing -19.9 Utility LLP header 2 Total -103.3 409 74 13 8 313 0 50 100 150 200 250 300 350 400 450 Gcal/h • Overall Steam generation reduced by 130 T/h • Fewer boilers required to meet demand Proprietary Information
  15. 15. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 Optimisation in the conceptual or feasibility stage provides: • Specifications for the Licensor Process Design Package (PDP) before design begins • Identify suggested process design features • Number of pumparounds on columns • Use of hot separators on hydrotreaters • Suggested new heat integrations and exchanger approach temperatures • Suggested process operating conditions • Equipment specifications for key equipment • Process operating conditions, including specifications for product transfers between units • Opportunities to minimize Utilities Capital Costs • Recommended driver selection to give the best fit with the overall steam balance • Recommendations for additional utilities, such as intermediate or low-low pressure steam headers, to allow units to be cross integrated Proprietary Information
  16. 16. 11th AIChE Southwest Process Technology Conference | October 1-2, 2019 ANDREW MCMULLAN AMCMULLAN@KBCAT.COM WWW.KBC.GLOBAL Thank You

Optimization in the conceptual or feasibility stage provides: Specifications for the Licensor Process Design Package (PDP) before design begins and opportunities to minimize utilities capital costs

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