09_improve energy performance using aspenone energy management solutions_nattapol

Date: February, 2016

Improve Energy Performance using aspenONE Energy Management Solutions

Presented by: Nattapol A., APAC ENG Business Consultant

India Engineering Solution Seminar

© 2015 Aspen Technology, Inc. All rights reserved 2

Agenda

• Energy Challenges on Energy Management

• AspenTech Solutions for Energy Management

• Pinch Analysis Solution: Activated Energy Analysis

• Utilities Optimization Solution: Aspen Utilities

• Heat Exchanger Fouling Analysis Solution: Aspen Exchanger Design & Rating


Industry Challenges on Energy Managment

• Most industrial processes consume energy

– Many emit greenhouse gases

• Inefficiencies in energy demand and supply

– Often more energy supplied than needed

• Energy supply costs plants millions of dollars annually

– Greenhouse gases disposal, as well

• Optimization corrects inefficiencies

– Reducing energy inefficiencies saves companies money


AspenTech Energy Management Approach

Define An Optimal Strategy

to Achieve Corporate Energy Goals

Improve

Process Design

Optimize

Process Operations

Reduce Energy Demand

Improve

Utilities Design

Optimize

Utilities Operations

Reduce Supply Costs

A Holistic Approach to

Energy Management

Address both Supply

& Demand sides.

Improve Design and

Optimize Processes & the

Utilities System.

Sustain the gains.

Enable continuous

improvement.

Public Utilities/Grid

Utilities Production

Manufacturing Site

Power

Fuel


AspenTech’s Integrated Energy Management View

Design Utilities to

maximize

efficiency

Design the

process to use

less energy & be

more efficient

Operate

Operate Utilities

to deliver at the

lowest cost

Sustain the

process at

lowest energy

cost

Design

Utilities Supply

Process Demand

Process/Demand – Use less energy

Utilities/Supply – Provide at lowest cost


Pinch Analysis Solution: Activated Energy Analysis


Challenges with Process Energy Analysis

1. Identify Saving Potentials

2. Select Optimal Utilities

4. Maximize Energy and GHG

Savings

3. Generate and Evaluate Designs


1st Challenge: Identify Saving Potentials

Utilize Activated Energy Analysis to view target energy and GHG consumptions



2nd Challenge: Select Optimal Utilities


The target column shows the optimal process usage scheme for both:

Process Utilities

Carbon Emissions


3rd Challenge: Generate and Evaluate Designs

Relocate

exchangers

Modify existing

exchangers


Rapidly generate revamp scenarios and their energy savings for process with the possible options to:

Add exchangers


4th Challenge: Maximize Energy Savings

Visualize utility reduction for revamp scenarios

Compare revamp scenarios


Savings


Addressing Challenges with Process Energy Analysis




Savings



Activated Energy Analysis

Combining the rigorous pinch technology of

Aspen Energy Analyzer within the simulation

Activated Energy Analysis,

introduced in Version 8 of

both Aspen Plus and

Aspen HYSYS, is formed


WINNER: Best Energy Management Technology – Asian Manufacturing Awards 2013

“As the largest consumer of energy, the industrial sector is keenly focused on energy

efficiency and energy consumption. The Best Energy Management Technology Award went

to AspenTech in recognition of proven offerings to the process industries. Software

solutions such as Aspen Plus and Aspen Energy Analyzer allow owners of large, complex

facilities to realize significant savings that are a foundation for sustainable operations.”

– Bob Gill, Edititor-in-Chief, Control Engineering Asia


Solution Overview

Business Challenge & Objective Results & Benefits Business Challenge & Objective

Solution Overview

Results & Benefits

CASE STUDY: SCG Chemicals

Achieve Optimal Energy Savings with Activated Energy Analysis within

Aspen HYSYS

• SCG Chemicals looked to improve their existing work

by investigating a novel, or new process.

• Further, SCG Chemicals looked for a way to design

and optimize this new process.

• To build this novel process, SCG Chemicals utilized

Aspen HYSYS V8.4 to simulate the first pass of this

process.

• SCG Chemicals then utilized Activated Energy Analysis

within Aspen HYSYS V8.4 to optimize their process, and

then further investigate this analysis with Aspen Energy

Analyzer.

• The package of Activated Energy Analysis in Aspen HYSYS V8.4 is a

powerful tool to:

– Guide solutions for energy savings

– Evaluate payback period

• Process optimization and heat integration optimization led steam optimization

– Steam usage reduction of 24%

– Saving consumption of steam (24.1 USD/T-feed)

– Debit production of steam (17.2 USD/T-feed)


Solution Overview


Solution Overview

Results & Benefits

CASE STUDY: Korea Energy Management Corporation

Achieve Energy Efficiency Using aspenONE

• Korea has a long term target for energy efficiency, and has

implemented different energy efficiency policies to help

achieve these goals, including Energy Audit Programs.

• Korea Energy Management Corporation (KEMCO) performs

energy audits on companies and must have an effective way

to reduce energy costs and GHG emissions.

• For their optimization workflow, KEMCO utilizes the

aspenONE engineering suite, including Aspen HYSYS, Aspen

Energy Analyzer, Aspen EDR, and ACCE

• In this case, KEMCO specifically looked at the optimization

for Naptha Hydro Treating (NHT) in a BTX process to

optimize process energy

• For this case of optimization for Naptha Hydro Treating in BTX process,

KEMCO made process changes and was able to reduce

– Energy Consumption by 1.9 Mcal/hr

– Energy Cost by 1.3 M$/yr

– With a 2 year payback period for the investment required for the

process changes


Solution Overview


Solution Overview

Results & Benefits

CASE STUDY: Cheil Industries Inc.

Save Energy in a Refinery Utilizing aspenONE

• Cheil Industries Inc. (CII) is a subset of Samsung

Group. In their Construction & Engineering department

they are concerned with energy management and

consulting services.

• For this case study they looked to optimize a CFU

process of “A” Refinery in R.O.Korea for: energy

efficiency and CO2 reductions, lowest cost, and

highest productivity

• Utilized a variety of products in the aspenONE

Engineering suite to reconstruct a HEN network

– Aspen HYSYS

– Aspen Energy Analyzer

– Aspen EDR (i.e. Aspen Shell and tube Exchanger

• Utilizing multiple products: Aspen HYSYS, Aspen Energy Analyzer,

and Aspen EDR, all within the aspenONE suite, enabled

improvements to the HEN reconstruction. Using these three solutions

together, the project was able to:

– Provide possible energy

savings of 6 Gcal/hr

– Reduce CO2 emissions

– Reduce operating cost

– Increase productivity


Utilities Optimization Solution: Aspen Utilities


Incorporating Energy Management into site planning and scheduling

• Operations planning (monthly/weekly) and scheduling (daily) have a big impact on overall energy use

• Energy rarely modelled accurately in the planning and scheduling tools

• Big energy savings are possible by better planning and scheduling. – Needs to consider both Process production and Utilities

operations


Utilities Production Planning and Scheduling

Utilities System Operation

Import / Export Contracts

Negotiate better contracts

Optimize make vs. buy of electricity

Reliable nomination

Investment Analysis

Exploit contract limits Use best mix of fuels

Choose most efficient operation

Optimise Switching Drives in Process Units

Target to reduce the $/kJ

Eliminate flaring

Reduce steam venting

Energy/utilities consumption planning

Optimise loads on power plant


Utility System Operation Challenges

PROCESS UNIT A

PROCESS UNIT B

PROCESS UNIT C

PROCESS UNIT D

PROCESS UNIT F

PROCESS UNIT E

PROCESS UNIT G

What drives should I use for the BFW pump?

Which boilers should I use and at what load should I run these boilers?

How is my equipment performing? When should I shut down for maintenance?

At what load should I run the GTG?

How much steam do I need to provide today, tomorrow, next week? How does Actual compare to Plan?

How much electricity should I purchase, how much could I sell and at what price?

What fuels should I use and how much should I purchase – what contract?

Is it economic to run my steam turbine generator?

What is the lowest operating cost to reliably provide the Utilities to the Processes

UTILITIES SUPPLY UTILITIES DEMAND


Model-based optimization of the utilities system (multi-period & multi-site)

Business Processes: Daily, Weekly, Monthly, Annual:

Demand Forecasting (integrated with Planning tools, LP)

Utilities Production Planning (Boiler Load Allocation, Choice of Fuels, Choice of Drives, etc.)

Import/Export Nominations

Emissions Prediction

Budgets

Investment Planning

Tariff Evaluation

Utilities Demand

(Multi Period)

Equipment

Availability

(Multi Period)

Contract Models

Time-dependant

Cost Information

Uti

liti

es

Pla

nn

er

(rig

oro

us

Mo

de

l)

Uti

liti

es

Pla

nn

er

Ed

ito

rs

Ex

ce

l-b

as

ed

GU

I

(wit

h A

dd

-In

)

Define Utilities Planning Scenario

Optimize

Show results for the specific Scenario

Planning of Energy and Utilities (Off-line) Using Aspen Utility Planner


off-line

Data Input

Equipment

Availability &

Constraints

Data Entry

through

standard

Aspen Utilities

Editors

(or Excel)

Linearized

Optimization

Model

Rigorous

Simulation

Model

Outputs

Investment

Evaluation

Budgets/

Forecasts View Results

Configured

Excel

Interface File Utility

Consumption

Planning

Demand

Forecasting

Utilities

Contract Data

Forward Planning of Energy/Utilities with Aspen Utilities

Aspen Utilities Planner


Using Aspen Utility Planner within Excel

Excel Add-

in


View Optimised Utility Production Plans


What-If Analysis

• GT-1 needs to be shutdown for maintenance, what is the optimum configuration of the

utility system ?

• Electricity price is high – does it pay to increase condensing in STG –1?

GT-1

STG-1


off-line

Real time operations of Energy/Utilities with Aspen Utility Online Optimizer

on-line Raw Data

Reconciled, Target &

Optimized Data Operations Optimization

Performance Monitoring

(process units, demand side)

Cost Allocation

Real Time Database

InfoPlus. 21, PI

On Line Link

Aspen Online GUI

for Interactive use

InfoPlus.21

Web.21 DCS

off-line

Data Input

Equipment

Availability &

Constraints

Data Entry

through

standard

Aspen Utilities

Editors

(or Excel)

Linearized

Optimization

Model

Rigorous

Simulation

Model

Outputs

Investment

Evaluation

Budgets/

Forecasts View Results

Configured

Excel

Interface File Utility

Consumption

Planning

Demand

Forecasting

Utilities

Contract Data

Demand

forecasting not

required for

online model


Utilities Operations – Online User Interface


Benefits across organization with consistent model

• Operational Decisions (hourly)

– Equipment Loads/ Choice of Fuels

– Switching equipment on/off (Motors versus turbines)

– Steam balance - venting

– Fuel gas balance - flaring

Operators; Shift Manager/Engineer

• Tactical Decisions (1-30 days)

• Demand Forecasting / Production Planning

• Maintenance scheduling

• Emissions Forecasting and Trading

• -

Shift Manager/Engineer;

Purchasing; Trading; Accounting

• Strategic Decisions (1 month to 5 years)

• Evaluation of future investment

• Budgeting

• Contract Negotiations (more and more complex)

Plant Management;

Purchasing; Accounting

• Monitoring (hourly, weekly, monthly)

• Plan vs. Target vs. Actual (Monitor if Process Energy Use is on Target)

• Cost Accounting (based on real cost) & Emissions accounting

Operators; Shift Manager/Engineer;

Purchasing; Environmental; Accounting


Challenge Solution Results

Mitsui Chemicals Operating cost reduction with closed loop utilities optimizer

Challenge

Significant business changes in the Ichihara works plant due to

– Changes in operational units

– Partial shut downs

– Fuels strategy and cost

Changes offer opportunities to operate differently

Lower boiler and turbine loads increased flexibility of the plant

– What was the new optimum operating balance?

Ref: “Development of an Operational Optimization System for a Utility Plant”, Kazuhisa Tsuchiya, Mitsui Chemicals, AspenTech Global Conference: OPTIMIZE 2011, Washington, D.C., May 2011




Challenge

Developed a complex-wide utilities model in Aspen Utilities Planner

Deployed an automated process to run utilities optimizer using:

– Real-time historian data

– Aspen Utilities model

– Aspen DMCplus (APC) to automatically implement optimal solution

Excel interface provided for operators to conveniently enter the non-historian data





Challenge


With increased flexibility, Mitsui Chemicals could choose

– Optimal fuel type depending on price

– Balance turbines used

This new technology enabled business process helps operators to make informed choices

– Review the optimized results for a reality check

– Transfer new settings to APC

Achieved an operational cost reduction 1.5%


Challenge Solution Result

LyondellBasell Improve efficiency with on-Line energy management

Challenge

Corporate energy goals:

− Reduce total energy by over 2% per year

− Continually improve energy intensity

Challenge:

− Complex energy supply contracts

− Site has lots of energy intensive equipment

Ref: Brian Finnegan, et. al., LyondellBasell, AspenTech User Conference, Houston, May 2009



Focus on operators and provide actionable information

Aspen Plus, Aspen Plus Optimizer, Aspen Utilities On-Line Optimizer, and aspenONE Production Management & Execution (PM&E) suite

Experience of AspenTech’s Professional Services acknowledged and appreciated by the Client





Better management of complex utility systems

Improved make or buy decisions

Improved startups & shutdowns

Accurate what-if analyses

Models used for engineer and operator training

Better cogeneration steam scheduling

Projects will meet their expected benefits target



Value

Gained

Current Practices

Energy

Management

Shorter Delay


Solution Overview


• ENI wanted an energy management system to

optimize the overall performance of the Sannazzaro

Refinery Utilities System.

• Part of ENI’s mission to improve energy efficiency at

the refinery included optimizing the process and

utility operations, by minimizing supply costs.

Solution Overview

• This project was a collaboration between ENI and

AspenTech services and developed in three phases.

• The core of the Energy Management System was the

Aspen Utilities Model, broken into two applications:

– Aspen Utilities Online Optimizer

– Aspen Utilities Planner

CASE STUDY: ENI

ENI Energy Optimization System with Aspen Utilities

Project Execution Benefits:

• Lower external software services costs by up to 66%

• Self sufficient to maintain in the future

Future Projects

Implement same project execution methodology for Taranto Refinery

Results & Benefits

• Actionable recommendations to

plant operators how to reduce

cost

• Reduction in:

– Operating cost

– Steam venting

– Fuel flaring

Evaluation of:

• Impact on utility costs when production

rates change

• Cost impacts of changes in utility prices

• New contracts

• Optimal equipment usage during

abnormal operation

Aspen Utilities Online Optimizer Benefits

Aspen Utilities Planner Benefits


Heat Exchanger Fouling Analysis Solution: Aspen Exchanger Design & Rating


Heat Exchanger Fouling Fundamental

• Fouling results from the accumulation of scale, organic matter, corrosion

products, coke, particulates or other deposits on the heat transfer surface

of heat exchangers and costs millions of dollars a year

EFFECTS OF FOULING

• The fouling layer creates an additional resistance for heat transfer, hence reduces the performance of the equipment

Thermal

• Flow area available is reduced as the deposits grow, increasing pressure drop Hydraulic

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCLym7uK2vcgCFYRXPgodtTUODg&url=http://www.process-cooling.com/articles/87263-mitigating-fouling-in-heat-exchangers&psig=AFQjCNH9xpdnHP47vFK2HXNVkhVvtwJXNQ&ust=1444756272770543


Heat Exchanger Fouling: CDU Preheat Trains

• Fouling formation in preheat exchangers of a

crude distillation unit (CDU) is identified as a main

energy consuming unit in petroleum refineries.

• Almost half of the overall operational cost of the

refineries is due to the energy loses resulted from

fouling formation in the preheat exchangers1

1 S. Asomaning, C.B. Panchal, C.F. Liao Heat Transfer Engineering, 17 (2000), p. 21

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCO3L_6iOrMgCFcGdgAodMQQPbg&url=http://chem409-fouling.wikispaces.com/Introduction&bvm=bv.104317490,d.eXY&psig=AFQjCNH8twLQLu0Ha6Jo3qaznW-W-84yWA&ust=1444161325805932

http://www.google.com.mx/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCIrJnd3XrsgCFYImPgodh5cCYQ&url=http://mykosan.com/en/articles/no-medicinal-mushroom-drugs-in-the-west/&psig=AFQjCNHSMUC_0fzW0U52lqlcFwmE3v2QKg&ust=1444249740614649


Parametric Studies with Aspen Simulation Workbook

• Aspen Simulation Workbook provides easy and robust integration between Aspen Tech’s

Engineering tool (Aspen Plus, Aspen HYSYS, Aspen Exchanger Design and Rating, etc.)

& Microsoft Excel

• Among its features are:

– Copy and paste functionality to bring input and output variables to Excel

– Run Scenarios & Parametric Studies. With this feature you can easily and quickly run hundreds of

scenarios to analyze process sensitivity, check design cases,etc.

– Rapidly develop user interfaces

– Workflow automation: Automate repetitive tasks through VBA code


Parametric Studies with Aspen Simulation Workbook

Aspen Shell & Tube or

Aspen HYSYS

Aspen Simulation Workbook

Parametric Study


Heat Exchanger Fouling Monitoring

Can specify

any number

of buy or

sell

contracts

TI

FI

TI

FI

TI

TI

Historian

(e.g., IP.21)

Heat Transfer Coefficient

0

10

20

30

40

50

9/20 11/9 12/29 2/17 4/8

Date

Ove

rall

U

ASW

• Tag history pulled into MS Excel by IP.21

• Linked to HX model using Aspen Simulation

Workbook

• HX model predicts U or fouling factor

• Enables operating decisions

Clean

Tags Vars

HX

Model


Specify rigorous Heat Exchanger Models from the simulator Activated EDR

Improve fidelity of process simulation by specifying rigorous heat exchanger models within

Aspen Plus or Aspen HYSYS


Business Challenge & Objective

Heat exchanger fouling was impacting energy consumption & unit capacity

Needed a way to easily monitor performance & guide maintenance decisions to reduce down-time

Solution Overview

Aspen HYSYS with rigorous Aspen EDR models

Results & Benefits

Built an automated performance modeling tool that

monitors & reports heat exchanger fouling &

performance on a daily basis

Optimized cleaning schedules and reduced plant

down time– a $3-4MM/year savings

INEOS: HX Performance Monitoring

Ref: Robert Pes & Pierre Séré Peyrigain, INEOS Lavera, Aspen HTFS Annual User Group Meeting, Cologne, Dec. 2006


Business Challenge & Objective

Monitor crude pre-heat exchanger fouling and it’s impact on refinery performance

Solution Overview

Built a model of the pre-heat train in Aspen HYSYS

using rigorous Aspen EDR models

Used Aspen EDR to calculate fouling resistances and

assess impact of these on the process performance

Results & Benefits

Developed a tool for regular use by operators to

avoid overscheduling cleaning

Increased process uptime increasing refinery

profitability and avoiding extra costs

Saudi Aramco & InProcess: Hx Performance Monitoring

Ref: Stephan Wagner, Saudi Aramco

Manel Serra & Maria Jesus Guerra, Inprocess AspenTech OPTIMIZE, Boston, MA, May 2013


Thank you Q&A

09_improve energy performance using aspenone energy management solutions_nattapol

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