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Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience

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Presentation on theme: "Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience"— Presentation transcript:

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2 Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience
Session Name: SimSci-Esscor Solutions Session ID #: PBSS311 Junichi Watanabe Nov./10/2011 Title slide [from Title Slide master] The title slide is available as a Title Master and the background and graphic elements are fixed. Text is editable for the slide heading and presentation details but the small compliance text exists in editable form only on the Title Master itself. This type area should be used only for the purposes of compliance text and should not be replaced by other content. Font, type size and colours are fixed for the Title Master style and should not be modified. Footer details Footer detail appear in the bottom-left corner of the slide and appear in fixed positions and order. Editing of the Footer details is done by accessing ‘Header and Footer’ under the ‘View’ menu in PowerPoint®.

3 Agenda APAC RTO Projects Experience in last 10 years
Some case studies of RTO (CDU, RFCC, CCR) Difficulties of Development and maintaining Utilization for RTO RTO with Production Planning/Scheduling

4 Invensys Enterprise Control Offerings
Corporate Systems Platform IT Corporate Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Software Applications Invensys and Third Party Collaboration Platform Integration and Manufacturing / Production Operations Automation Invensys and Third Party As you heard in the opening sessions, addressing the need to move to Enterprise Control is critical for all organizations today as they look to optimize their business performance. By way of a quick reminder, at the simplest level, Enterprise Control is achieved by integrating the two major Manufacturing/Production Operations capabilities with your corporate systems and embracing the IT platform that is already in place. Invensys enables the creation of your Enterprise Control system by providing: a single integration platform that brings together the two operations components and integrates tightly with your existing IT infrastructure. This platform allows you to align Invensys and non-Invensys offerings a wide range of leading hardware and software and solution offerings at the automation and production software levels, extended by offerings from our extensive partner ecosystem proven expertise in designing, implementing and supporting complete Enterprise Control solutions, beginning with consulting services to help you identify the opportunities within your organization and deliver an execution plan Enterprise Control System

5 Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System
Integration & Collaboration Platform Enterprise Integration Workflow Open Device Web Portal Application Toolkit Historian Third-Party Offerings Software Applications Execution Manufacturing Execution Systems Batch Enterprise Asset Management Mobile Workforce Management Performance Enterprise Manufacturing Intelligence Performance Measurement and Reporting Visualization Quality Asset Performance Optimization Operator Training Design Advanced Process Control Simulation / Optimization Control DCS PAC SCADA HMI Safety Safety Instrumented Systems General Purpose Safety Turbomachinery Control Measurement & Instrumentation Controllers Recorders Automation Software Applications In it’s fullest form, an Enterprise Control System brings together a large number of functional capabilities. For the purposes of this presentation, we’ll be focusing on the component that you see highlighted, but it is important to note that all these offerings, both Invensys and 3rd party, can be an element of an Enterprise Control System.

6 APAC RTO Projects Experience in last 10 years

7 APAC Optimization Project Experience
40 Actual ROMeo Projects have been implemented in Asia since 2000 (Excluding feasibility study projects) Closed Loop : 18 Projects Open Loop : 13 Projects Planning : 3 Projects Performance Monitoring, Others : 6 Projects Total 10 engineers are RTO engineers in APAC (Japan, Korea, India, China, Thailand and Singapore)

8 RTO/Performance Monitoring Implemented in Japan Since Y2000
Refinery : 13 PetroChemical : 7 Idemitsu Hokkaido : H2 Management JX Mizushima: Utility,CDU3,CDU2 Asahi Chemical : Ethylene OPC : Ethylene Idemitsu Chiba:Site Wide Idemitsu Tokuyama : CDU, FCC Ethylene JX,Negishi: CDU, RFCC Showa Denko : Ethylene Idemitus Aichi: Utility, H2 JX Chita: H2 Management

9 Real-Time Optimization (ROMeo, ARPM) Business in APAC
Korea : HDO, SK, STC China : Petrochina Taiwan : FPCC Thailand : Thai Oil BCP,PTTGSP Malaysia : Petronas Singapore : SRC India : Reliance India ASEAN

10 APAC Optimization Project Experience
94% projects come from Refineries, Utility, Ethylene projects

11 APAC Optimization Project Experience
CDU/VDU, FCC, Reformers, H2 management are majorities from Refineries projects

12 APAC Optimization Project Experience
Closed loop projects are nearly half

13 APAC Optimization Project Experience
ROMeo doesn’t rely on APC package.

14 APAC Optimization Project Experience
ROMeo don’t rely on RTDBS

15 Case Study CDU RTO SAT: 2007 Jun Closed Loop with DMC+

16 Change of Optimization Variables (Independent Variables)
Heater Outlet Temp. No.3 Side Reflux flow KL/H Kero Stripping Steam Ratio APC controls to OPT targets PV RTO Target kg/KL

17 All CVs move as predicted
Change of Optimization Variables (Dependent Variables) LGO Draw Flow Heater Inlet Temp. KL/H Cold Reflux Flow All CVs move as predicted KL/H PV Predict

18 How to Evaluate Benefit
PI Data is used for evaluation - Before RTO - Set the base point when APC made stable operation Benefit APC Start Crude Change Time - After RTO - RTO Benefit Benefit Set the base point when RTO started Start RTO このように原油切り替え後APCを入れると収益がいったん増加する。その後 APC Start Crude Change Time

19 Change of Benefit before/after RTO
Before RTO (+287K Yen/day) After RTO (+2,362K Yen/day) After RTO, every case shows increasing benefit and above base

20 Change of Benefit before/after RTO
Before RTO (+287K Yen/day) After RTO (+2,362K Yen/day) Yearly Benefit = 493MYen/Year ※(2,362 - 287)KYen/Day×0.72(Run Time %) After RTO, every case shows increasing benefit and above base

21 Case Study RFCC RTO SAT: 2010 Jun Closed Loop with RMPCT

22 RFCC Feed Modeling The slide explained on how feed mixing is configured in the model so that the optimization model can also be used for study on optimizing the feed mixing by optimizing feed rate of OMAR, OM_LSFO and OM_VGO

23 RFCC Modeling (Rx/Rg)

24 RFCC Optimization Variables

25 Test Data: (MVPC + RTO) Vs MVPC Only June 2010

26 Case Study CCR/BTX RTO SAT: 2008 May Closed Loop with SMOC

27 Real-Time Optimizer Scope
Propane #2 LMX #2 LER LPG ( 3%) Butane #1 Naph Benzene ( 113 ,000 T/Y) Naph ( 20%) #2 NHT #2 PLT BTX P-Xylene #2 C D U ( 364,000 T/Y) Naphtha Crude Kero ( 17%) #1 KHT Kerosene #1 KGHT #2 GHT Gas Oil ( 20%) #3 GHT Gas Oil #1 Gas oil AR ( 40%) B - C AR to VDU/DCU

28 Optimization Points * BTX section considered as constraints No. Unit
Description UOM 1 #2 NHT Naphtha Splitter Heavy Naphtha Dist.5% (RQE) DEG C 2 Naphtha SPLITTER REFLUX FLOW M3/HR 3 #2 NHT FEED FLOW 4 Naphtha Stripper REFLUX FLOW 5 #2 PLAT Reactor #2 PLAT FEED FLOW 6 #2 PLAT REATOR WAIT 7 H2/HC Mole Ratio - * BTX section considered as constraints

29 Current Online model (using NIR for feeds)
Use NIR data For Feed comp. REF-SIM for PLT Reactor Model N S P #2NHT NIR #2PLT #2CDU OFF NIR BTX BZ #2 CDU Optimization(Naph95%) 시에는 P-X 고정 시 M-X 추가 생산이 가능하나 현실적으로 불가능하여 P-X 고정(최대)시 BZ의 추가 생산을 목적으로 함. SRN Feed 성상은 NIR DATA를 사용하여 Data Rec. 수행. 그 외에도 T/N, R/N의 NIR data를 사용하여 Data Rec 신뢰성을 높임 이 때 CDU의 NAPH95%는 KERO FLASH 허용범위까지 최소화. 실제 CDU Naph95% 2C 감소 시 Naph. 0.45% yield 감소 및 Kero Diesel yield 증가 나타남. P-X Only for Simulations Scope for Online model

30 Main Benefit Points NIR N S P REF-SIM #2NHT #2PLT BTX BZ P-X FIXED L/N
SRN Feed NIR N S P REF-SIM RXWAIT #2NHT #2PLT HN FEED T/N FEED #2CDU HN5% OFF R/N FEED BTX BZ BTX Load Extractor Feed HI: 70.3 RAF: 31 P-X: Data Rec 실행 시 유량으로 고정 P-X FIXED * Found extra space for BZ product with maximizing P-X Product

31 Profit Estimation >> Decreasing 3.3% of Feed SRN [ Saving Operation cost ) >> Increasing 3% of BZ ( Fixed P-X Product ] Price Y2008 Price Y2007 Price Y2006 Average (Y2006-Y2008) Estimated Profit 1.2 Million 1.7 Million 1.0 Million 1.3 Million

32 Difficulties of Development and Maintaining Utilization for RTO

33 Difficulties for CDU RTO Based on our Experience
BTX Load Extractor Feed HI: 70.3 RAF: 31 P-X: Data Rec 실행 시 유량으로 고정

34 Difficulties for RFCC and CCR/BTX RTO Based on our Experience
BTX Load Extractor Feed HI: 70.3 RAF: 31 P-X: Data Rec 실행 시 유량으로 고정

35 Importance for Utilization of RTO

36 Monitoring System Example
Summary Screen Optimization Status Calculation Successful rate Data handling Successful Rate Data REC Successful Rate Optimization Successful Rate Economic Effects Reflection Rate Optimization Variables Information Study Low Limit・High Limit Optimization Value、Operation Value Optimization Variables Names

37 Constraints Variables Screen
Optimization Status Calculation Successful Rate Constraints Variable Information Check Low Limit・High Limit Optimization Value、Operation Data Constraints Variables Name The ratio of constraints hit

38 RTO with Production Planning/Scheduling The linkage between RTO and Planning/Scheduling is very important

39 Operation Cycle in Refinery
Refinery Planning/Schedule Investment plan (Long term Plan) 3 Month Plan (Mid term) 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory RTO (ROMeo for Planning) HQ Planning/Sales Crude Selection Demand/Sales/Supply Exchange Crude Tanker Crude Storage Operation Product Storage APC RTO (ROMeo) Performance Monitor Technical Process Design Improvement Bottle neck RTO (ROMeo for Analysis and case studies)

40 Operation in Refinery One Month (Planning/Schedule (1))
Refinery Planning/Schedule 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory RTO (ROMeo for planning) HQ Planning/Sales Demand/Sales/Supply Exchange Product Storage Blending and Shipping Import Products Crude Storage Operation Crude schedule is already fixed APC RTO (ROMeo) Performance Monitor Export Products

41 Typical Production Planning/Scheduling Work
Refinery Planning/Schedule 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory HQ Planning/Sales Demand/Sales/Supply Exchange Purchase/Sale Intermediate product One Month Operation plan is prepared by LP assuming one month mixed average Crude or Crude tank by tank with respecting Tank Inventory as constraint Day 1 5 A 10 B 15 C 20 D A,B…: Crude Type Scheduler decides Operation targets such as Cut point, Unit feed rate to meet the daily operation is as similar as One month planning by Daily bases Operation Instruction

42 Relation between RTO and Planning/Scheduling
Day 1 5 A 10 B 15 C 20 D Planning/Scheduling Price Info Logistic Constraints Rigorous Marginal Price Refinery Wide ROMeo RTO Unit RTO Unit RTO Continuously Maximizing Benefit Unit RTO Unit RTO Shift Vector Opt. Yield

43 Thank You (ありがとうございました)

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