1. Sanjay Dave Honeywell Technology Solution Labs pvt. Ltd
Energy Management & Efficiency Improvement Optimization and Control Technologies

2. Content Overview - Opportunities for Energy and GHG Savings
Get Cheaper Energy – Planning and Scheduling
Get Cheaper Energy – Industrial load management system
Produce Energy Cheaper – APC & O in CPP
Consume less energy: APC & O in refinery units
Consume less energy: APC & O in Offsite
Sustaining benefits
Conclusion

3. Overview - Opportunities for Energy and GHG Savings
Process Design Improvement
Online / Offline Monitoring & Control & OPT
Sustain Benefits
Opportunity Analysis
Benchmarking
Pinch Analysis
Adv. Process Technology
High Flux Exchangers/ Heat Integration
High Efficiency Distillation
Power Recovery Turbines
Advanced Catalysts
Improved Process Design
Managing Emissions
Ecofining
Rapid Thermal Pyrolysis
Callidus/Maxon Burners
Online Monitoring
Energy/Emissions Dashboard
Wireless Solutions
Control/Opt
Supply Side APC & Opt
Get energy cheaper
Produce energy cheaper
Demand Side APC & Opt
Refinery APC & Opt
Offsite APC & Opt
Sustaining Benefits
Remote Performance Monitoring
Continuous Improvement
Technology Refresh
Maintain / Operation
Attend steam traps
Insulation
Maintain rotating machines
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Work with Jacobs if not using UOP.
One of the major areas for capturing energy savings is by improving the design of the process. This can take the form of improving heat recovery from waste heat streams and using it to provide preheat to process streams that are heated using fossil fuels as in those fired in furnaces or boilers.
More efficient conversion of fuel to heat and power may be realised when combined heat and power cogeneration units are installed instead of power generation where waste heat is not recovered.
While improved heat recovery is a very common type of capital project implemented to improve energy efficiency, recent work by UOP has identified others areas less commonly explored that may provide significant opportunities. Many of these areas make use of advanced process technology offered by UOP such as enhanced heat exchangers, high capacity fractionator internals, new reaction internals, power recovery turbines, improved catalysts and other design features.
Aside from improving energy efficiency to reduce CO2 emissions, one can also tackle the problem by focusing on increasing the amount of renewable energy processed.
Process revamps require capital funding to implement energy efficiency solutions. There are also a variety of operational improvements that can be applied to ensure the process is operated as efficiently as possible. These can be done by a combination of monitoring applications, that help direct a user to areas where energy consumption is higher than expected and online control applications that move to directly drive the process to a more energy efficient state. Honeywell has a broad suite of solutions that can be applied to improve energy efficiency from dedicated firing controls, multivariable control and optimization and broad MES applications that connect the control room to the business.
When all of these solutions are implemented , improved business performance is only achieved by sustaining and improving these solutions over time. Honeywell brings together all the required intelligence of both UOP and HPS into its real-time systems to help manage the operation while maximizing return on equipment investments.
So lets take a closer a look at some examples.

4. Get Cheaper Energy – Planning and Scheduling
Plan and schedule for energy efficient feed stock and fuels

5. Planning and Scheduling
Development and analysis of LP models of refining and petrochemical facilities
Planning integrates:
Products’ demand and prices
Raw material availability and cost
Feedstock and product qualities
Process unit configuration
Blending correlation and specifications
Provides a feasible optimal solution:
Which raw materials to purchase
Which products to sell
How to operate the process units
Blending recipes
Maximized profit
Minimize Energy

6. Get Cheaper Energy – Industrial load management system
Forecast demand and Plan electricity/ energy
Optimize between different power sources, Inhouse, External
Avoid peak tariffs
Constrain to contracted value

7. Produce Energy Cheaper – APC & O in CPP
Turbine Optimization
Accept electrical loads and balance according to efficiency and price
Boiler Optimization
Accept steam loads and allocate according to efficiency and constraints
Combustion Control
Tight Fuel/air ratio
Control excess O2
Supply/Demand Optimization
Meet forecast demand accounting for price, emissions, availability, contracts, etc.
Performance Monitor
Monitor performance of boilers and turbines.

8. Power plant optimization
Non linear optimization
Adaptive control and optimization , adapt to the changing quality of fuel and fouling conditions
Fault detection : Ability to detect faulty instruments , CO , O2, NOx
Allocation of load to the boilers and turbines, after adjusting for efficiency and price of fuel
Unmeasured disturbance detection : Use of state of art techniques to estimate false air and unmeasured steam flows
Stability and agility . Control should be stable , but also quick to respond to changes in steam or power.

9. Consume less energy: APC & O in refinery units
CCR
Reformer Control
Regenerator Control
Distillation Control
Improved Heat recovery
CDU/VDU
Preheat optimization
Furnace Control
Distillation Control
H2 optimization
Reformer Control
Hydrogen network optim
Crude
Hydrotreater / HCU
Preheat optimization
Furnace Control
Distillation Control
Reactor Control / H2 red
FCC
Furnace Control
Distillation Control
WGC Control
Improved Heat recovery
DCU
Furnace Control
Distillation Control
WGC Control

10. Refinery/ petrochemical plant optimization
Unit level optimization using multivariable model based predictive control and optimization.
Short time to implementation to reap quicker benefits and sustain benefits by leveraging true closed loop step test and model ID
Global Dynamic optimization of group of units
Refinery: Hydrogen Units, CCR, VGOHT, DHDT, HCU etc
Petrochemicals: Naphtha/ Gas cracker complex
Nonlinear first principle model based control and optimization for Polymer plants
State of the art techniques for sensing the product qualities
Unisim
Advanced statistical methods
Grey box models

11. Consume less energy: APC & O in Offsite
Component Tanks
Blend Tanks
MARKET
Crude
SIGNALS
Marketing
Blend control and Blend optimization
Giveaway  Energy = $$
Reduce the number of reblends
Refinery
Octane
Benzene
Oxygen
RVP
ASTM D86

12. Blend control and optimization
Manual or pre-configured recipe specification
Pacing control due to inadequate component flow
Support for property analyzers – linear average and property error calculations, signal validation
Blend Optimization
Multi blender optimization
Instantaneous or tank property control
Minimum cost or Minimum giveaway
Accurate blend models

13. Sustaining Benefits Remote Performance Management
Sustain benefits of Advanced applications such as APC & Opt, MES
Check process and catalyst performance
Life Cycle Management
Keep system current to ensure highest availability
Leverage capabilities of modern system to improve safety. Reliability and efficiency

14. Conclusion
Improving energy efficiency is an effective way to reduce operating costs and CO2 emissions
Solutions include low capital cost operational improvements plus a wide variety of technology solutions
Energy savings of 3-8% are possible
Technology and capability are key success factors
Benefits achieved decline rapidly unless they are sustained.