IndustrialEnergyManagementwith VisualMESAatBPLingenrefinery

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

VisualMESAenergymanagementsystem implemented

Introduction(II)
RealTimeandWhatifPlanningOptimizerthatfindstheoptimalwaytooperate utilitiessubjecttocontractual,environmentalandoperationalconstraints
Measurements Optimum SetPoints Optimum Utilities Operations Report KPI Monitoring and Accounting Reports

Emissions Regulations

HydrogenFuelSteamWaterElectricity

UtilitiesSystems

ExternalUtilities Contracts

Industrial Site

Process

Introduction(III)
VisualMESAisa1st PrinciplesModelingandOptimization(SQP MINLP)programforfuels,steam,BFW,condensate,hydrogen andelectricalsystems,includingemissions Fieldsofapplication: RealTimeOptimization Monitoring,AuditingandAccounting Engineering Planning RealTimeValidatedEnergyandEmissionsKPICalculation Server Currentlyinuseinmorethan70refineriesandpetrochemical sites

Energysystemdescription
Setoffiredboilersandprocessfurnacesburningfuelgas Steamnetworkwiththreesteampressurelevels Setofsteamturbogenerators Twocogenerationunits
Productionof50MWofelectricityfromtwonaturalgaspoweredgas turbines,foruseonsiteandforsaleoftheexcessenergy Thegasturbineshavesteaminjectionandheatrecoverysteam generatorwithpostcombustion

Differenteconomictradeoffs(amongelectricity,steamand fuelnetworks) Manychallengestooperatetheenergysystematminimum cost,withintheconstraints(e.g.emissions)

ProjectObjectives
Monitoringandreductionoftherefinery's totalenergycosts 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 FuelGas/FuelOiltoafiredboiler FuelGastotheotherfiredboilers TGsloads 6possibleswitchesfor401.5barsteamturbines) 36switches111.5barsteamturbines CondensingTurbines

Steamproductionatboilers

Turbogeneratorsmanagement

Pumpswaps(steamturbines/electricalmotorsswitches)

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/PropanemakeuptoFG network Pumpswaps
Theremainingvariables(forexample,steamletdownflow rates)areconsequencesofthechangesmentionedbefore, beingmanipulatedautomaticallybythecontrolsystem

Energycostsreductionexamples
NaturalGas/Butane/PropaneadditiontoFG network GasTurbineloads Pumpswaps

Example1:
MinimizationofbutaneadditiontoFGnetwork

Butane reduction

Example1(cont):
MinimizationofbutaneadditiontoFGnetwork
Delta Cost (Current minus Optimized)

Energy cost reduction around 5% on total energy cost

Butane reduction to FG network around 3 t/h

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

Gas turbine load increase operating at higher efficiency

Although electricity exportation penalty increase

Example3:
OptimizationofPumpswaps

Steam vent eliminated

Example3:
OptimizationofPumpswaps

Several pump swaps A 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)

Turbogenerator efficiency

Fired boiler 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,understandingall decisionvariablesandtheassociatedconstraintswhich sometimesarehidden Abilitytoreactonlinetocapturebusinessopportunitiesto reduceenergycostsandimproveemissionsmanagement, gettingsignificantenergysavings