IndustrialEnergyManagementwithVisualMESAatBPLingenrefinery

AvailabilityDepartment BPLingen refinery

Soteica

ERTCAnnual Meeting Vienna 2012

Outline

Introduction BPLingenrefinery VisualMESA

Energysystemdescription Projectobjectives Projectscheduleandmodelsummary Benefits Conclusions

Introduction(I)

BPLingenrefinery Oneofthemostcomplexrefineriesintheworld LocatedinNorthWestGermany ConsideredoneofEurope'sleadingconversionrefineries Inkeepingwitheffortstoprotecttheenvironment,allofthegasoline

anddieselfuelproductsareessentiallyfreeofsulphur Refiningcapacityof93thousandbarrelsperdayofcrudeoil

VisualMESAenergymanagementsystemimplemented

Introduction(II)

HydrogenFuelSteamWaterElectricityUtilitiesSystems

ExternalUtilitiesContracts

EmissionsRegulations

ProcessIndustrialSite

RealTimeandWhatifPlanningOptimizerthatfindstheoptimalwaytooperateutilitiessubjecttocontractual,environmentalandoperationalconstraints

OptimumUtilitiesOperationsReport

Measurements OptimumSetPoints

KPIMonitoringandAccountingReports

Introduction(III) VisualMESAisa1st PrinciplesModelingandOptimization(SQP

MINLP)programforfuels,steam,BFW,condensate,hydrogenandelectricalsystems,includingemissions

Fieldsofapplication: RealTimeOptimization Monitoring,AuditingandAccounting Engineering Planning RealTimeValidatedEnergyandEmissionsKPICalculationServer

Currentlyinuseinmorethan70refineriesandpetrochemicalsites

Energysystemdescription

Setoffiredboilersandprocessfurnacesburningfuelgas Steamnetworkwiththreesteampressurelevels Setofsteamturbogenerators Twocogenerationunits

Productionof50MWofelectricityfromtwonaturalgaspoweredgasturbines,foruseonsiteandforsaleoftheexcessenergy

Thegasturbineshavesteaminjectionandheatrecoverysteamgeneratorwithpostcombustion

Differenteconomictradeoffs(amongelectricity,steamandfuelnetworks)

Manychallengestooperatetheenergysystematminimumcost,withintheconstraints(e.g.emissions)

ProjectObjectives

Monitoringandreductionoftherefinery'stotalenergycosts

Monitoringequipmentperformance Balancingthevariousenergycosts Developing"Whatif"studies

ProjectSchedule

Datacollection Softwareinstallation(August2010) FunctionalDesignSpecifications Modelbuildingandoptimizationconfiguration Training(January2011) Modelreview Burningperiod Projectandmodeldocumentation(July2011)

Modelscope

Steam,fuels,emissions,boilerfeedwater,condensatesandelectricitysystem

OptimizationObjectivefunction:TotalEnergycosts=Fuels+Electricity+Othercosts

(FuelOil/NaturalGas/LPG(Propane/Butane)/Electricity/Water)

VisualMESAGUI(mainview)

Powerplantmodelview

Optimizationvariables Cogeneration

GTsloads SteaminjectiontoGTs FuelGastopostcombustion

Steamproductionatboilers FuelGas/FuelOiltoafiredboiler FuelGastotheotherfiredboilers

Turbogeneratorsmanagement TGsloads

Pumpswaps(steamturbines/electricalmotorsswitches) 6possibleswitchesfor401.5barsteamturbines) 36switches111.5barsteamturbines CondensingTurbines

Electricityexportation(orimportation) NaturalGas/Butane/PropanemakeuptoFGsystem Steamletdownandvents

Constraints

Equipmentrelated(i.e.burnerscapacity) Operationalconstraints Utilitiesprocessplantsdemand Contractual Environmental

NOxandSO2emissionslimits CO2emissions(monitoring)

85Optimizationvariables(54discretevariables)29Constraints

Benefits

DaytoDayOptimization Steamproductionbalance GasTurbinesloadsandsteaminjection Turbogeneratorsloads NaturalGas/Butane/PropanemakeuptoFGnetwork

Pumpswaps Theremainingvariables(forexample,steamletdownflow

rates)areconsequencesofthechangesmentionedbefore,beingmanipulatedautomaticallybythecontrolsystem

Energycostsreductionexamples

NaturalGas/Butane/PropaneadditiontoFGnetwork

GasTurbineloads Pumpswaps

Example1:MinimizationofbutaneadditiontoFGnetwork

Butane reduction

Example1(cont):MinimizationofbutaneadditiontoFGnetwork

Energy cost reductionaround 5% on total energy cost

Butane reductionto FG networkaround 3 t/h

Delta Cost (Current minus Optimized)

Example1(cont):Effectonheaters(furnaces)

FG flow increase at a furnace(around 0.15 t/h)

Burners FG pressure(around 0.25 bar increase)

below the constraint of 1.5 bar

Example2:OptimizationofGasTurbinesloads

Although electricity exportation penalty increase

Gas turbine load increase operating at higher efficiency

Example3:OptimizationofPumpswaps

Steam vent eliminated

Example3:OptimizationofPumpswaps

Several pump swapsA maximum pump swaps constraint required

Economic impact of 1.4% cost reduction on total energy cost

Performancemonitoring(equipmentefficiency)

Gas turbine heat rate

Deviation

Gas turbine theoretical heat rate

Performancemonitoring(equipmentefficiency)

Fired boiler efficiency

Turbogenerator efficiency

Systemauditing(steamimbalances)

Steam imbalance 1,5 bar header

Casestudies

GasTurbineOfflinewashingevaluation Effectofstart/stopofequipment:

Firedboilers Turbogenerators Largesteamcondensingturbines

UseofNGlinesinfiredboilers

Differentmodeluses

Clientservermodel Shiftsupervisors,Operators,Engineers Optimizationonshiftbasis

Standalonemodeluse Engineeringandplanningstudies

Sustainabilityoftheuptodatemodel KeyPerformanceIndicatorsserver Instrumentationreview

Conclusions

VisualMESAimplementedatBPLingenrefinery Asaresultoftheproject,abetterknowledgeofutilities

systeminteractionshasbeenacquired,understandingalldecisionvariablesandtheassociatedconstraintswhichsometimesarehidden

Abilitytoreactonlinetocapturebusinessopportunitiestoreduceenergycostsandimproveemissionsmanagement,gettingsignificantenergysavings