Client experiences of using Petro-SIM to assist with ......• Refinery in Płock classified as...

SUPERIOR RESULTS. SUSTAINED.

Client experiences of using Petro-SIM to assist with refinery optimisation Sławomir Szumacher – PKN ORLEN

Nicola Knight - KBC

29 September 2016

KBC ADVANCED TECHNOLOGIES

Proprietary Information

2

Agenda

• PKN ORLEN Overview

• KBC Overview

• What is Petro-SIM?

• How does PKN use Petro-SIM?

LP Vector updates

Energy Analysis

Heat Exchanger fouling monitoring

‘What If’ studies

• Summary

29 September 2016



3

PKN ORLEN Overview

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4

Overview of PKN ORLEN

Global presence:

4 continents, 50 export markets

The largest company

in the CEE region

Awards and distinctions:

The only Polish company in

GLOBAL 500 by Fortune magazine

Named World’s Most Ethical

Company by Ethisphere Institut

Named Best Managed

Company in Poland by Euromoney

29 September 2016



competitive advantage of PKN ORLEN

• Refinery in Płock classified as super-site (according to WoodMackenzie) due to size , complexity and integration with pet-chem

• Modernized assets in Mażejkiu and Litvinov

• Readiness for market changing trends due to

realized investments

• Leader at fuel market in CE

• The biggest pet-chem Company in CE • Attractive portfolio including PX, PTA,

polyolefins and butadiene • Strategic supplier for chemical bussines in

region • PX/PTA – one of the most modern plants in

Europe with capacity PTA of 650 kt/a

Shale gas and conventional

exploration concessions in

Poland and Canada

6 refineries in PL, CZE and

LT leading supplier of

petrochemical products in PL,

major exporter in CEE

2 new CCGT power plants

under construction

Around 2700 gas stations in

Europe

5

KBC Overview

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6

KBC is a wholly-owned subsidiary of Yokogawa’s Solution Services business

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General Meeting of Shareholders

Audit & Supervisory Board

Board of

Directors

Chairman

S. Kurosu

Solution Services Business

Headquarters

Shuzo

Kaihori

President & CEO

Takashi

Nishijima

As of April 1, 2016

7

What is Petro-SIM?

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8

Petro-SIM is an Advanced Process Simulation Platform

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Proven Engineering

Process Simulator

Easy access to SQL,

Excel & Process

Historians

Integrated Process

Modelling

Designed for real

world applications

Scalable Simulation

Solutions

Integrated with 3rd

Party Technologies

9

LP Vector updates

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10

LP Model Development

29 September 2016 1

0

LP Design Definition

Process Simulation

Model Calibration

Feeds

Inventories

Transfers

Crude

Assay

LP Tables

Process

Unit

LP Tables

Product

Blends &

Specifications

Test & Validate

Process Simulation

Model Predictions

Refinery LP

Model Assembly

LP Model Testing

& Validation

Test & Validate

Refinery Yield

Data

Process

Performance

Data

Non-linear Models

Linear Models

11

Petro-SIM - Automation of LP vector generation

Petro-SIM

contains purpose

built LP Utility to

facilitate LP data

generation and

automate the

generation of LP

Submodels

29 September 2016 1

1

Petro-SIM Process Model

Petro-SIM LP Utility

LP Submodel

Template

LP Submodel

12

VDU Case

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Better

Yields

improvement

-2.8% Vac Res

Benefit 0.2 $/bbl

Recovery

Heat integration

LP Submodel Petro-SIM Process Model

Petro-SIM Process Model Energy consumption

~10 % less

13

Energy Analysis

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14

Using Petro-SIM to improve energy performance

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Petro-SIM Process Unit Model

Reconciled Mass &

Energy Balance

Input to SuperTarget, generates

composite curves & identifies heat

integration potential

0

50

100

150

200

250

300

350

BT

Ind

ex

(%)

Client

Refinery Site BT

Input to BT benchmarking to

identify energy performance and

identify gaps to improve

Use Petro-SIM to

evaluate the impact on

yield of the energy

improvement

Use Petro-SIM to

evaluate the economic

benefit of heat integration

improvement

15

PKN Energy Efficiency Results for CDU3

0

50

100

150

200

250

BT

In

dex

Best Technology (BT) is KBC’s proprietary methodology for ranking the energy efficiency of process units BT Index of 100% is the ‘Ideal Result’

PKN 2013

Result

PKN 2010

Result

16

Heat Exchanger fouling monitoring

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17

HX Monitor – online fouling monitoring program

14 June 2012

Cleaning benefits per

exchanger and group

Fouling charts

Paybacks for single,

multiple and the entire

set of exchangers

1

7

18

HX Monitor Trial - PKN Experience

• The crude unit selected for HX monitor testing

consisted of 3 HX trains, 27 shells, a desalter,

a flash drum, a furnace

• Test run stages

3 day on site training session followed by 3 month

self-study and gaining experience with KBC

support

The Step by Step procedure easily followed

Summary of the results

Conclusions sent to KBC

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• PKN successfully completed the trial with

close co-operation with operations - learnt

many lessons:

Information on bypasses/control

Changes to HX construction compared to

design

Measurement devices malfunctioning

19

PKN – HX Monitor Results

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10

20

30

40

50

60

70

05/07/2014 25/07/2014 14/08/2014 03/09/2014 23/09/2014 13/10/2014 02/11/2014 22/11/2014

Dir

ty/c

lean

fu

rnace

heat

dif

fere

nce

per

cru

de

flo

w

[MJ/t

*h]

Crude 1 Crude 1 Crude 2

20

‘What If’ studies

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21

Site Wide Petro-SIM model

• Prompt evaluation of streams

management

• Products economical

optimisation

• Crude evaluation – identifying

process bottlenecks

• Sulphidic corrosion &

naphthenic acid corrosion

• Enables PKN optimisation

engineers to work efficiently,

embedded within work

processes

22

FCC Case (new feed evaluation)

Yields Nev/common

propane 1.02 Dry gas 0.97

propylene 1.02 H2S 0.86

C4 1.03 LCO 0.97

naphtha 1.03 clarified oil 0.86

coke 0.87

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250

350

450

550

650

0 20 40 60 80 100

Tem

pera

ture

[oC

]

Evaporated [% vol]

TBP Curves Common

NEV

1) Challenge 2) Calculations

3) Test run

Tank, pump, pipeline

0.02 $/bbl No operational changes

Petro-SIM Process Model

LP Submodel

4) Investment 5) Effect

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Summary

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Summary

• Using Petro-SIM enables the PKN ORLEN optimisation

department to:

Validate & update LP vectors

Generate & validate energy saving ideas

Validate and test >300 ideas

• Combined benefit to date is 1.14 $/bbl

29 September 2016



SUPERIOR RESULTS. SUSTAINED.

Any Questions? Thank you for listening



Sławomir Szumacher – PKN ORLEN

Nicola Knight - KBC

Client experiences of using Petro-SIM to assist with ......• Refinery in Płock classified as...

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