Energy Management System National Energy Efficiency Conference September 2012
PCMSB Company Name Petronas Chemical MTBE Sdn Bhd Product Methyl Tertiary Butyl Ether (MTBE) Propylene (C3=) Capacity 300,000 MT/year MTBE 80,000 MT/year propylene Build 1992 Location Gebeng Industrial Area, Kuantan, Pahang Specialty The only dual feed plant in the world
Agenda • Needs of EMS • Background • EMS Framework • Energy Operating Parameters • Energy Optimization Case Study • Monitoring Cycle • Benefits • Key Success Factors • Alignment to ISO 50001
The Needs of Energy Management System • To have an online energy monitoring system • Cost effective plant operation (optimizing energy) • Create awareness among staff on the importance of energy efficiency • To monitor instantaneous energy optimization condition of the plant.
Background • 2007 PCMSB Management initiative for systematic drive to improve Energy Performance – Definition of Energy KPIs – Identification of Energy Parameters and Optimization of Targets – Online Energy Dashboards – Training of Process Engineers and Operators • 2008 Mecip Malaysia / Actsys Consortium awarded project to implement Energy Management System • Jan 2009 Completion of Project
EMS Framework Plant Energy Index (Overall Site, Utilities) Unit Level Energy Indices (Individual unit boundaries) Actual Target Energy Index Deviation Mass Balances Monetary Loss (Ensures healthy measurements) Individual Energy Operating Parameters (Energy parameters for each unit level) Identification of deviating parameters and root cause analysis
EMS Framework – Petronas Chemical MTBE Sdn Bhd (PCMSB) EMS Actual energy consumption (TSRF) Theoretical energy consumption (TSRF) Overall Complex Mass Balance Utility Optimizer Energy Index Process Mass Process I Process II Process III Utilities Balance Aimed to minimize the Energy Index Energy Index Energy Index Energy Index total plant utilities operating cost. Fuel Gas Mass Balance Steam Mass Balance To ensure accurate measurement Individual Energy Operating Parameters inputs to EMS Flare Mass with Actual values, Target values and the Balance respective Energy Index Deviation
Energy Operating Parameters EQUIPMENT PARAMETERS EFFECT Reboiler Ratio Steam Usage Column Column Pressure Inlet Temperature Steam Usage at charge Reactor heater HC H2 Ratio HC Feed Isentropic Efficiency Steam flow to turbine Steam Turbine Exhaust to bypass stack Fuel Gas Flow Gas Turbine Heat Rate Polytropic Efficiency Fuel Gas Flow Compressor Spillback Excess Oxygen Fuel Gas Flow Boilers Stack Temperature Excess Oxygen Fuel Gas Flow Heaters / Furnace Stack Temperature
Case Study Optimization WHB Economizer BFW Inlet temp Aim : To determine the target heater stack temperature Observation : Stack temp and corresponding HPS production is » a function of the load » a strong function of the controlled BFW temperature. Oleflex Heater Stack Temp & HPS Flow vs Flue Gas Flow For Varying Econ inlet BFW Temp (TIC2018) 280.0 24.0 270.0 22.0 260.0 T stack (Deg C) 20.0 250.0 HPS (T/H) T Stack (177) T Stack (Deg C) T Stack (160) 18.0 T Stack (140) 240.0 T Stack (121) HPS (177) 16.0 HPS (160) 230.0 HPS (140) HPS (121) HPS Flow (T/H) 14.0 220.0 12.0 210.0 10.0 200.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 130.0 Flue Gas Flow (T/HR)
Case Study Optimization WHB Economizer BFW Inlet temp • BFW Initial Set point : 170 C Acid Dew Point vs H2S in Fuel Gas • Design Set Point : 177 C Source : Gatecycle Verhoff-Banchero correlation (based on Fuel Gas with 76 mol% H2) 150 • Acid Dew Point Design Basis : to protect against dew point 145 corrosion in case of high H2S content in the 140 fuel gas supply degC 135 • 130 H 2 S Analysis : maximum H2S content in fuel gas to be less than 30 ppm 125 120 • Fuel gas with only 30 ppm H2S will 0 100 200 300 400 500 600 700 800 produce flue gases with an acid dew point ppm H2S in fuel gas temperature around 120 degC EB220 Performance Testrun • WHB Testrun TI2094 TC2081 Setpoint was lowered to 140 degC 242.000 165.000 240.000 160.000 • TC2081 DegC TI2094 DegC Result 238.000 155.000 – stack temperature reduction from 236.000 150.000 240 to 234 degC. 234.000 145.000 232.000 140.000 – increased HP steam production 230.000 135.000 of almost 1 T/H 228.000 130.000 • Savings 2/3/2008 3/2/2008 3/9/2008 1/27/2008 2/10/2008 2/17/2008 2/24/2008 3/16/2008 Fuel savings of RM350K/year
Energy Management System Monitoring Cycle Engineers Managers Operators Energy Other Plant Info Applications Management System System Application & Business Model Layer Database Lab DCS Info Layer
Energy Management System Monitoring Cycle • Design • Historical best performance • Simulation equations • Performance Test Runs Current Plant Operation Target Energy Actual Energy Operating Parameter Operating Parameter • Changed energy index deviations • Improved plant performance Energy Index Plant Adjustments Deviation (EID) and improvements Excess Utility Consumption (Steam / FG / Electricity) Operator Action • Changing set points • Adjusting control parameters
Realized Benefits from EMS MTBE Energy Specific Consumption & Energy Cost (2008-2012) Savings 8,000,000.00 14.00 RM 2 7,000,000.00 Million/month 12.00 Energy Cost 6,000,000.00 10.00 Energy Cost, RM ESC, mmBTU/MT 5,000,000.00 MTBE Energy 8.00 Specific 4,000,000.00 Consumption 6.00 3,000,000.00 4.00 2,000,000.00 2.00 1,000,000.00 - 0.00 Nov-07 Mar-09 Aug-10 Dec-11 May-13
Other Initiatives • Based on Utility Optimizer, – Change turbine driven pumps to motor driven (7Nos) – reduces LP steam venting by 10t/h – estimated savings of RM 2.5 million • Benefits – Minimize Steam Loss – Minimize FG consumption – Reduced maintenance cost on turbines – Savings on turbine hot stand by steam consumption
Key Success Factors • Real time monitoring • Automated process calculations • Increased interaction between operators and managers • Reliability of instruments (Mass Balance) • Equipment performance (Efficiency) • Continuous Energy Improvement • Open and transparent communication between departments
ISO 50001 Energy Management System Top Mgmt provides the framework for setting and reviewing energy objectives and targets Continuously revising targets to ensure high energy Allocating resources and setting up plant energy performance indices for continuously monitoring energy usage Operating and maintaining energy parameters in accordance with operational target values viewed in the EMS screens Energy performance team For all Energy Indices and Energy Operating conducting energy audits and Parameters, review non-conformities => check follow-up actions Energy Index Deviation (Actual versus Target) Real time calculation runs using plant historian Real time monitoring & monthly reporting Determining and implementing the appropriate action needed
Thank you AUXILIARY POWER (0.22%) SHAFT POWER GT SHAFT POWER (34.23%) ROTOR COOLING LOSS (2.09%) WORK ( … .% of GT HP TURB POWER (2.18%) COMPRESSOR COMBUSTOR LOSS (0.49%) Shaft Power) PIPE LOSS (0.08%) I N L E T A I R IP TURB POWER (6.68%) DUCT LOSS (0.35%) ( 1 . 4 LP TURB POWER (10.87%) RADIATION LOSS 5 % ) RADIATION LOSS CONDENSER LOSS 33.53% RADIATION LOSS (0.06%) (0.04%) RADIATION LOSS (0.09%) CHEMICAL (0.34%) ENERGY (97.32%) HP STEAM (34.39%) IP STEAM (8.6%) LP STEAM (4.03%) STACK LOSS (8.97%) FUEL SENSIBLE HEAT 1.00%
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