Tuesday, June 9, 2009

Auto-Steam Load Shedding in a Petrochemical Complex

The two largest steam producers at the ExxonMobil Baytown Complex are both cogeneration units: gas-turbine generators integrated with heat-recovery steam generators (HRSGs). An automatic steam load shed (ASLS) system is utilized to allow the steam system at the Complex to survive a simultaneous trip of both these producers. Due to the dynamics of this scenario and the original configuration of the ASLS system, the combined production of these two HRSGs was limited to less than their full capacity. This required the additional steam demand at the Complex be met by firing less-efficient power boilers. In an effort to maximize the efficiency of the steam production at the Complex, two separate initiatives were launched. The first initiative involved running new dynamic steam system simulation cases. This resulted in the identification of a more efficient operating scenario, which involved the activation of a much larger high-pressure steam shed and eliminated the need to limit production from the HRSGs. The second initiative involved designing a new application to optimize the loading of the steam producers. This effort allows use of most efficient steam generators and allows the steam system at the Complex to survive a simultaneous trip of both these producers. Annualized 2007 energy savings were 153,000 MM Btu, equivalent to 0.33% of total Baytown Olefins Plant net energy consumption, with associated CO2 emissions reductions of 8,900 tons.

Waste Heat Recovery Power Generation Using Wow-Gen®

WOWGen® is our patented process for generating power from waste heat sources. The presentation will cover the technology, as well as case studies in power generation using reciprocating engines, biomass power generation, and steel industry.

Beneficial applications of heat recovery power generation can be found in Industry (e.g. steel, glass, cement, lime, pulp and paper, refining and petrochemicals), Power Generation (CHP, MSW, biomass, biofuel, traditional fuels, gasifiers, diesel engines) and Natural Gas (pipeline compression stations, processing plants).

Energy Efficiency — A journey within LyondellBasell

The presentation will describe the journey towards energy efficiency improvements within LyondellBasell starting 2006. This will be an overview of the systems developed within to create a sustainable energy management program. Discussions will also share the methodology utilized to gain understanding of current performance and identifying focus areas of performance to close gaps. Attention will be given to topics such as data analysis, key performance indicators, energy assessments, opportunity identification, and cap-ex prioritization. Tools that are being used for institutionalizing energy management systems and practices will be touched upon. Finally, efforts undertaken to promote cultural shift towards energy efficiency where ideal behaviors and practices become a part of normal business.

Process Control — A Significant Opportunity

The presentation will entail low cost opportunities being tapped within LyondellBasell associated with Process Controls. The presentation will describe the leveraging opportunities that exist within the chemical processes. This can play a significant role in continuing to make progress in energy efficiency during the economic downturn and limited capital availability. The discussion will be centered on applications of Advanced Process Controls (APC) and Controller Performance Monitoring (CPM). Several case examples will be discussed to illustrate the importance of control stability and where APC and CPM can work synergistically to achieve savings that are normally unnoticed.

Thermal Efficiency Improvement — A compelling case at LyondellBasell

This presentation will be an overview of the energy maintenance program for the LyondellBasell Chemicals Division. Focus will be on the intent of the program and best practices for maintaining saving energy through cold and hot insulation. Attention will be given to methodology of evaluation, prioritization and method of repair these items for energy conservation and cost savings. Actual results will be shared on implementation of the program. This presentation is geared toward sharing general information on the energy maintenance program and to build awareness of the critical nature of maintaining basic energy conservation of equipment and to provide tools for economic analysis for repairs.

A Small Plant’s Perspective on Implementing a Management System for Energy

Five manufacturing plants in Texas are participating in a national pilot program on plant energy efficiency called “Superior Energy Performance”. The CCP Houston plant participating in the Texas pilot project is a synthetic resin manufacturing plant and has approximately 50 employees. As a participant in the Superior Energy Performance pilot program, CCP tested the proposed ASME process heating system and steam system assessment standards being developed by DOE. In addition, the plant is implementing a Management System for Energy that meets the ANSI MSE 2000:2008 standard. Pierre will describe the results of the assessments, project implementation and management system implementation.

Energy Optimization of a Large Central Plant Chilled Water System

This presentation will present the methodology and findings of a recently concluded central plant chilled water assessment at the Freescale Semiconductor, Inc’s Oak Hill (Oak Hill) plant in Austin, TX. The main objective of the chilled water assessment was to take a “systems approach” to optimize the entire system and thereby increase the overall energy efficiency of the chilled water system. Although this is a semiconductor manufacturing facility, its central chilled water plant is very similar to typical large industrial manufacturing plants such as petrochemicals, pharmaceuticals, etc. Secondly, the assessment methodology used in the optimization process here can be applied across the board to other industrial central chilled water and refrigeration plants.

This paper will present the bestpractices that are already in existence at the Oak Hill site including site level integration, use of high efficiency chillers, use of variable-speed drives, periodic maintenance, etc. Additionally, this paper will justify the need for having a high degree of instrumentation, data collection and monitoring in plants that do not currently have that capability.

The Oak Hill site chilled water assessment resulted in several findings that can be done to further optimize the chilled water system. Some of these findings were truly “out of the box” and the plant’s ability to monitor and collect critical parameters (flows) has allowed the assessment team to accurately quantify the potential savings opportunities. Each of these potential savings opportunities will be described in the paper along with what quantifiable impact it would have on the energy system. In addition, some of these opportunities are currently being implemented at the Oak Hill plant and possible actual results that may be available will also be reported.

New Approach to Improving Heater Efficiency

Fired Heaters are major consumers of energy in refining and petrochemical industries. Owners have been trying to improve the efficiency of fired heaters to reduce their fuel bill. A conventional approach to improve the efficiency of the heaters is adding heat transfer surface in series to the existing heat transfer surface. Addition of heat transfer surface in series causes fluid side pressure drop to go up leading to feed pump or compressor limitations. We have developed a new approach to efficiency improvement by using parallel or split flow approach. In this scheme fluid is split in two parallel streams in accordance with the additional surface provided for efficiency improvement. We have executed four projects in the last seven years and will present three case studies demonstrating this new approach. The split flow revamp cost is almost 1/3 to 1/2 of the conventional revamp cost, thus improving the payout substantially.

NOX Reduction with a Return on Investment

Lean premix based combustion systems have proven to be capable of achieving the stringent HGA requirements with NOx production continuing to operate below the 0.01 lb/MMBtu target without sacrificing other emissions performance.

The story of how thorough project attention to detail, communication and cooperation, along with the application of proven Ultra Low NOx and mixing technologies, enabled the end user to lower NOx further than expected, save fuel, increase efficiencies, and lower maintenance costs, will be presented with the end user.

The applications to be presented are two large Ultra Low NOx lean premix retrofits of existing air heaters at a petrochemical plant in the Houston area.

These two application types illustrate the achievability of sub 8 ppm NOx using preheated air without FGR or other diluent, and how modern mixing technologies in conjunction with lean premix products of combustion allow for greater heat inputs into processes.

A BEST PRACTICE APPROACH to Planning, Executing and Thriving in the “Changing” World of Energy Management, Energy Efficiency and Climate Change

It is vitally important for companies today to link strategies for climate change and energy management. Modular Process Control and Trinity Consultants will present a case study on how leading edge chemical companies are integrating these joint strategies. They will cover the implementation process, challenges, and successes from companies taking this approach.

Reducing Your Energy Footprint Without Capital

Energy intensive utility equipment is run by plant operators to meet shifting process demands, energy costs, ambient conditions or environmental limits. Industry best practice is to keep utility service or availability high, respond to process alarms and follow your operating guidance and rules based on historic studies and intelligent rules for leveraging efficient and inefficient units and thermal storage. Plant operators do this through available supervisory control systems and graphical user interfaces. But today, equipment performance curves can be running in real time and correcting energy costs based on available equipment operating measurements through that same supervisory control system.

A hybrid modeling framework integrates the predicted energy demand model with the economically-optimum supply model of the utilities helps operations achieve the lowest-cost supply within environmental limits. Leveraging modern plant/utility dashboards can provide guidance across a facility on current, actual utility and environmental costs to enable informed, intelligent decisions beyond pure energy systems to support production decisions. Five different systems have been deployed and will be described which resulted in between 5-20% reduction in energy costs.