This presentation includes forward-looking statements. Actual future conditions (including economic conditions, energy demand, and energy supply) could.

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Presentation transcript:

This presentation includes forward-looking statements. Actual future conditions (including economic conditions, energy demand, and energy supply) could differ materially due to changes in technology, the development of new supply sources, political events, demographic changes, and other factors discussed herein (and in Item 1 of ExxonMobil’s latest report on Form 10-K). This material is not to be reproduced without the permission of Exxon Mobil Corporation. ExxonMobil Baton Rouge Chemicals: Energy Optimization in a Turndown Environment 2010 Industrial Energy Technology Conference New Orleans, Louisiana May 21, 2010

2 Overview Scene Set 2009 ExxonMobil Baton Rouge Chemicals ACC Awards Exceptional Merit 1: Elastomers Block Operations Exceptional Merit 2: BELA-5 Dynamic Matrix Control Conclusion

3 Scene Set The current chemicals market is constantly changing… Improve energy efficiency = reduce Greenhouse Gas emissions Maintain stability in all market environments ExxonMobil energy program Foundation = “Global Energy Management Systems” (G-EMS) Resource and support improve projects by business Set and steward continual improvement targets Importance of structured program Inherent system to sustain progress Ownership by business teams to demonstrate progress Plan developed regardless of business environment

BRCP ACC Awards Elastomers Block Operation Butadiene DMC Steam system efficiency improvements Aromatics SWAT / Energy Initiatives Intermediates KEV Implementation Energy Critical Heat Exchanger Program TLE Chemical Cleaning Refinery Gas Recovery G-EMS projects Phthalic Anhydride Incinerators Plasticizer Batch Reactor Delay Isopropyl Alcohol Vat Reboiler TOTAL SITE CONTRIBUTIONS MBtu/yr savingsT CO2/year 850,00051, ,0006,500 1,340,00078, ,0008, ,00015, ,00026, ,0008, ,000100,000 90,0005,000 20,0001,000 30,0002,000 Total: 3,950,000 Mbtu/yr Total: 300 kTons CO 2 /year Foundational G-EMS Activities Business Improve Projects Exceptional Merit 11 Awards, including 2 exceptional merit

5 Elastomers Block Operations Background Elastomers unit is energy intensive and has little energy conserving turn- down capability 2009 supply surpassed demand resulting in lower production volumes Business wanted to maintain originally forecasted efficiencies and maintain a steady supply of product to customers Team challenged existing paradigm of turndown vs. block operations Theory: Block Operation is more efficient than production at reduced rates Data analysis: Energy intensity per pound of production at different rates Definition of Block Operation Running the unit at its most energy efficient rate regardless of market conditions and completely shutting down once all of demand has been met.

6 Elastomers Block Operations Why Block Operation? Regardless of market conditions, units must remain at maximum efficiency to be competitive Outcome of analysis Elastomers similar to pink line, not blue Gap becomes block operations credits Challenges with Block Operation Manufacturing unit start ups & shut downs Equipment must be monitored for reliability impacts Critical factor: accurate demand forecast to eliminate early start-up/loss of efficiencies Who should consider Block Operations? Units that do not have a linear efficiency vs production curve Units with refrigeration requirements, compressors, solvents, etc. Any high base energy requirement compared to incremental increase associated with rate Energy consumed per pound product

7 Elastomers Block Operations Results: Delivered a 24% improvement over operating at reduced rates Realized 850,000 MBtu/yr savings, 51 kT CO 2 reduction Keys to Successful Block Operation Determining if Block Operation is an option Does the unit have good turndown capabilities? Determining how long unit must be down to see positive impact Determining energy losses associated with start up and shut downs Communication between all sides of the organization Marketing / Sales – manage inventories during downtime Technical / Engineering – determining credits & potential losses Process – Safely managing unit s/u and s/d

8 Butadiene Dynamic Matrix Control Background on Dynamic Matrix Control (DMC) Multivariable, predictive process control Based on model of the plant On-line control and optimization every minute Benefit of DMC on butadiene unit Process optimization Maximization of heat recovery Other production optimizations achieved Console operator tool Quicker reaction time to changing parameters Teaching tool for new operators Predict Move Optimize Operations Variable

9 Butadiene Dynamic Matrix Control Team Composition: 2 process control engineers 2 DMC experts Several supporting technical disciplines Step Process: Scoping study – 1 day Pre-test – 2 weeks Plant test and commissioning, AspenTech SmartStep TM software – 3 weeks Post-project “tuning” and improvements – 4 weeks Continual upkeep and maintenance to deliver results Results: Annual savings – 112,000 MBtu/yr Approximate annual emissions reduction - 6,500 Tons CO 2 Matrix Grid

10 Conclusions Success factors Sustainable activities through changing environments Continual development of business ideas Foundational program to support base site work Management support of energy projects and programs Path forward Continue to set and meet efficiency targets Learn from project successes – “don’t reinvent the wheel” Stay the course – continual funding and support Thank you to ACC for the recognition and opportunity to present