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8/14/2019 How to Save Energy through Enhanced Automation
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Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
How to Save Energy Through Enhanced Automation
AIChE Spring Meeting2008Douglas WhiteEmerson ProcessManagement
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2 2008 Emerson Process Management
Speaker
Doug White
Principal Consultant and VicePresident, APC Services
Advanced Applied Technologies
Process Systems and SolutionsEmerson Process Management
Many years experience designing, justifying, installing andcommissioning advanced real timecomputer applications in the process
industries.
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3 2008 Emerson Process Management
Natural Gas Prices
Natural Gas Prices (Henry Hub)
0
2
4
6
8
10
12
14
Jan-93 Jan-95 Jan-97 Jan-99 Jan-01 Jan-03 Jan-05 Jan-07 Jan-09
Date
$ / M M B T U
Forecast
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4 2008 Emerson Process Management
Process Energy Usage
27.238.8Styrene
2.12.9Ethylbenzene
5.07.1EG
4.36.2EO
2.84.0PVC
6.69.4EDC
4.76.7Polyethylene
5.07.1Ethylene
Chemicals
5.57.9Cement Production
20.329.0Integrated Pulp/Paper Mill3.14.4Petroleum Refining
Value; 10% EnergyReduction; $/ Ton
($7/ MMBTU)Process Energy;
MM BTU/ Ton
L a r g e s t C o
n t r o l l a b
l e C o s t
i n M o s t
P l a n t s !
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5 2008 Emerson Process Management
Session Objective
Present some case studies of the many ways thatautomation, advanced automation and assetmanagement can save energy in process plants
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6 2008 Emerson Process Management
Outline
How is energy used in process plants?
How can automation help save energy?
How do we implement an energy reduction program?
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7 2008 Emerson Process Management
PurchasedSteam
ProcessHeating/CoolingPurchased
Fuel
PurchasedPower
ProcessSteamDrives
ExportPower
ExportSteam
Export
Fuel
ProcessElectricDrives
ProcessFired
Equipment
ProcessSteamGenerated
ProcessDirect Fuel
Usage
CentralPower
Production
Central
SteamProduction
General Process Site Energy Flow
ProcessMisc Electric
Usage
Power PlantProcess and
Offsites
Raw MaterialAs Fuel
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8 2008 Emerson Process Management
PurchasedSteam
ProcessHeating/CoolingPurchased
Fuel
PurchasedPower
ProcessSteamDrives
ExportPower
ExportSteam
Export
Fuel
ProcessElectricDrives
ProcessFired
Equipment
ProcessSteamGenerated
ProcessDirect Fuel
Usage
CentralPower
Production
Central
SteamProduction
Average Chemical Site Energy Flow
ProcessMisc Electric
Usage
Power PlantProcess and
Offsites
Raw MaterialAs Fuel
63%
37% 4%
32%
22%
1%
18%
27%
%-Equivalent BTU basis (Including losses) on total input
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9 2008 Emerson Process Management
PurchasedSteam
ProcessHeating/CoolingPurchased
Fuel
PurchasedPower
ProcessSteamDrives
ExportPower
ExportSteam
Export
Fuel
ProcessElectricDrives
ProcessFired
Equipment
ProcessSteamGenerated
ProcessDirect Fuel
Usage
CentralPower
Production
Central
SteamProduction
Integrated Pulping Paper Mill Energy Flow
Process/ FacMisc Electric
Usage
Power PlantProcess and
Offsites
Raw MaterialAs Fuel
50%
42%
8%29%
25%
62%
5%
%-Equivalent BTU basis (Including losses) on total input
4%
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10 2008 Emerson Process Management
PurchasedSteam
ProcessHeating/CoolingPurchased
Fuel
PurchasedPower
ProcessSteamDrives
ExportPower
ExportSteam
Export
Fuel
ProcessElectricDrives
ProcessFired
Equipment
ProcessSteamGenerated
ProcessDirect Fuel
Usage
CentralPower
Production
Central
SteamProduction
Oil Refinery Energy Flow
ProcessMisc Electric
Usage
Power PlantProcess and
Offsites
Raw MaterialAs Fuel
64%
25%
10%
1%
15%
5%
34%
44%
%-Equivalent BTU basis (Including losses) on total input
6%
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11 2008 Emerson Process Management
Reducing Plant Energy Costs
Reduce Usage Individual Equipment
Improve Efficiencies Boilers, Heaters, kilns Maximize Useful Recovery - Preheat
Minimize Losses Cooling water Minimize Motor Losses
Unit Savings Optimize Process Unit Operations
Distillation/ Fractionation Maximize Waste Heat Recovery Minimize waste/ off spec
Site/ Multi Unit Savings Minimize Steam Losses and Downgrading Switch of steam drives for electric or vice versa Seasonal effects
Reduce Cost of Production and Purchase Fuel Substitution Generation Maximization Boiler and Turbine Allocation Electric Purchase Optimization
Automation and Advanced Automation are the keys to effective operation and minimum ongoing energy usage
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12 2008 Emerson Process Management
Process Industry Energy Saving Primary Targets
Fired Heaters
Distillation/ Fractionation
Central Power and Steam Production
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13 2008 Emerson Process Management
How can Automation Reduce EnergyUsage?
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14 2008 Emerson Process Management
Variability Potential Energy Savings
Example Heater Stack O2 Variability
2
3
4
5
6
7
8
9
10
11
12
8:00 9:00 10:00 11:00 12:00 13:00 14:00
Time
O2, %
0
100
200
300
400
500
600
700
800
Fuel Gas
Flow
Target
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15 2008 Emerson Process Management
Energy Savings Through Automation Target Areas
MassCont
DensFF
O2
PITC
FuelGas
PI
FI
DraftControl
FC3-5
FT3-5
Bottoms
FC3-5FC3-5
FT3-5
Bottoms
Device,
Loop
Equipment
ProcessUnit
Site- Wide
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16 2008 Emerson Process Management
Saving Energy Automation Examples
Better ControlValve Performance
ImprovedMeasurements
FC3-5
FT3-5
FC3-5FC3-5
FT3-5
Improved Loop/ Multi-loopControl Performance
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17 2008 Emerson Process Management
Component Heating Values
1184032010Butane
1204024320Propane
1241016820Ethane
132809520Methane
339103020Hydrogen
Heat of Combustionkcal/ kg (gross)
Heat of Combustionkcal/ NM3 (gross)
Component
Fuel Gas ComponentHeating Value
Control Fuel Flows By Mass Instead of Volume
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18 2008 Emerson Process Management
Energy Savings From Improved Measurements
Hydrogen Plant
Objective: Control S/C ratio as close to 3.2 as possible but avoid going belowDisturbance: Fuel gas C1 77 85%; C2 6.8 15; N2, CO also fluctuate
Test: Normal orifice plus GC max error 0.2; MMI max error 0.02
Benefits: Moving 0.2 ratio closer to limit worth 8 BTU/SCF of H2;
80 MMSCFD plant; $7 MM BTU gas $1.6 MM per year
Ref: MMI WP_00724Mass Measurement
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19 2008 Emerson Process Management
Energy Losses Through Bypassing
14.30.4
6.80.25
3.20.14
Heat LossIncrease -%
F1 /(F1+ F 2)
TC TC
Reference:Shinskey;
Energy ConservationThrough Automation
Fuel
F2
F1
TC
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20 2008 Emerson Process Management
MassCont
DensFF
O2
PITC
FuelGas
PI
FI
DraftControl
Improved Multi-Loop
Control AdvancedControl
Improved PerformanceMonitoring
Improved Diagnostics
Energy Savings Equipment Level
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21 2008 Emerson Process Management
Steam System Control Issues
PIC3
PIC4 PIC2
FIC2 FIC1
PIC1
750 psig
50 psig
Condensate
TGA
TGBUsers
Vent
Vent
PRC1
0 4500 9000 13500 18000Sec
745.0748.0751.0754.0757.0
psig
Mean=750.814 3Sig=3.242FRC1
0 4500 9000 13500 18000Sec
300.0305.0310.0315.0320.0
mlb/hr
Mean=212.955 3Sig=6.987
Objective:Maximum
Flow to TGA
Problem:Pressure
Instability in
Header Limited Flowto TGA
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22 2008 Emerson Process Management
Steam System Diagnosis Valves and Tuning
5%
220 sec
PRC 1 OP
4800 5200 5600 6000 6400
Sec
52.00
54.00
56.00
58.00
60.00%Out
Mean=56.0123 3Sig=9.381
Sec
FRC2
4800 5200 5600 6000 6400Sec
209.6
213.7
217.8
221.8
225.9mlb/hr
Mean=114.983 3Sig=19.7
5%
220 sec Flow controller to TGBhas 5% deadband;
induces limit cycle inpressure
Correction:Fix TGB turbine
governor/steam valve
Tune controllers assystem not
individually
PRC1
4800 5200 5600 6000 6400Sec
748.3
749.5
750.6
751.8
752.9psig
Mean=650.814 3Sig=3.242
Estimated value of increased flow to TGA - $3000/ day
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23 2008 Emerson Process Management
Fired Heater Controls
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24 2008 Emerson Process Management
Combustion Control
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25 2008 Emerson Process Management
Heater/ Boiler Combustion Control Savings
$/ Yr Savings
100 MM BTU/ Hr $7/ kSCF Gas400 F Stack Gas Rise
$0
$100,000
$200,000
$300,000$400,000
$500,000
$600,000
2 3 5 7 10
% O2
$/ Yr
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26 2008 Emerson Process Management
Typical Heater APC Package
FIC101
H306
FIC102
TI069
TIC
361
FIC361
TI071
CO
CombustionControl
HIC353D
PIC359D
TIC362D
AIC354D
AIC356D
O2
FIC103
TI069
(Up to 4)
FIC104
TI070
TI073
TI
072
TI043
TI075
TI067
MPC Block
FuelDemand
Air Demand
PIC357D
PassBalance
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27 2008 Emerson Process Management
Excuses For Not Improving Heater Controls
Damper/ Air controls are not reliable Answer: Add positioners to dampers, with feedback to
control system; Analyze and fix controller problems
Dont have online analyzer/ cant maintain them Answer: Analyzers are cheaper and more reliable
particularly mass flow meters. With higher fuel costs, theyare well justified.
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34 2008 Emerson Process Management
Distillation Controls
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35 2008 Emerson Process Management
FCLC
FC
TC
FC
LC
Feed, F20,000 BPD
$50/ Bbl
Bottoms, B< 5 %C4 ; $70/ Bbl> 5%C4; $50/ Bbl
Distillate, D< 5%C5 ;$45/ Bbl> 5%C5; $38/ Bbl
Reflux,R
Reboiler,
E$36/ Bbl FOE
PC
AC
Typical Distillation Column
AR
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41 2008 Emerson Process Management
Distillation Column Control Savings
Cost Per Year Excess Reflux
20000 BPD Stabilizer Column$10/ MM BTU Steam
$0$100,000$200,000$300,000$400,000$500,000$600,000$700,000
5 10 25 50
% Excess Reflux
$/ Yr
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42 2008 Emerson Process Management
Column Pressure Effect
Relative Reboiler Cost Per Year Column Pressure Effect
20000 BPD Stabilizer
0%
20%
40%
60%
80%
100%
120%
100 120 140 160 180 200
Pressure, PSIA
Basis: Constant SeparationModeled With ChemSepPeng Robinson Equation of State
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43 2008 Emerson Process Management
Energy Savings Site Wide
Site Energy/ Utility Management
Steam System Control
Fuel System Control
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44 2008 Emerson Process Management
Energy Management and OptimizationSystem
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45 2008 Emerson Process Management
Plant Utility Systems Many Opportunities for Savings
MPS
HPS
Many interactingdecision variables
Large number of constraints
Unit 1 Unit 2
Unit 5
HRSG
DeminPlant
Condensate
LPS
BFW
FG
FB1FB1 FB2FB2 FB3FB3 WHB1WHB1 GT1GT1WHB2WHB2
ST1ST1 ST2ST2
Make-Up
PRVPRV
PRVPRVUnit 4
Vent
Vent
Vent
Unit 3
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46 2008 Emerson Process Management
Optimizer Decisions
Which boiler(s) should I run? What load? How much electricity should I produce? Buy? Sell?
Is it economic to run the steam turbine? Which fuel should I buy? How much? Should I be using more steam drives or more electric
drives? When will efficiency gain from maintenance balance
the cost of shut down for this equipment? How does my actual compare with plan corrected to
standard conditions?
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47 2008 Emerson Process Management
Unit 2Unit 1
LPS
ST1ST1 ST2ST2PRVPRV
PRVPRVDemin
Plant
Condensate
Make-Up
Unit 5Unit 3 Unit 4
HRSG
MPS
GT1GT1FB1FB1
HPS
BFW
FG
FB2FB2 FB3FB3 WHB1WHB1 WHB2WHB2
Full Utility Optimization
Many interactingdecision variables
Large number of constraints
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48 2008 Emerson Process Management
Overall Energy Optimization Strategy
Continuously Calculate Production Costs Over Load Range withCurrent Fuel Mix
Incorporate Constraints on All Equipment Decisions Made Through Rule Based Logic Boiler Load Allocation
Distribute Steam Production Based on Cost and Constraints
Turbine Load Allocation Distribute Steam for Minimum Cost with Constraints
Tie-Line Control Control Electrical Purchase Based on Economic Decision and
Constraints
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49 2008 Emerson Process Management
Boiler Load Allocation
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50 2008 Emerson Process Management
Load Allocation
50,000 75,00025,000Boiler Load, lb/hr
Boiler Efficiency
No. 1
No. 2
No. 3
80
85
90How to provide 200 kpph steam?
LoadMost
Efficient
Equal
Loads
MinimumCost
No. 4
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51 2008 Emerson Process Management
Energy Savings via Site Energy Balance
Blow-Down
Make-Up
Power
Fuel
1600 psia; 940 F
Flue Gas;200 F
200 psia
Steam;
125 psia
Condensate
1000 KW384pph
384pph
24,393kBTU/ hr
19200 pph
20,200pph
0kBTU/hr
Make-Up
Blow-
DownPower
Fuel
1600 psia; 94 0 F
Flue Gas;200 F
200 psia
Steam;
125 psiaCondensate
1000 KW271pph
271pph
18510kBTU/ hr
13550 pph
10,100pph
3754kBTU/hr 9600 pph
Reference: Kinney;Energy Conservation inProcess Industries
Nave calculation, value 125 psia steam reduction =
1000 x (1031 Btu/ lb ( Hv) 0.7(eff))x $7/MMBtu (Fuel) =$10.31 per klb
Actual site value 125 psia steam reduction =$4.08 per klb
i l S
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56 2008 Emerson Process Management
Typical Energy Management SystemBenefits
1 3 % Overall site utility costsavings!
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57 2008 Emerson Process Management
Example
Utilities Example Biomass Power
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58 2008 Emerson Process Management
Utilities Example Biomass Power Boiler
Paper mill 160k PPH Fluidized-bed Boiler Fuels:
Sludge Wood waste Tires Fuel gas
Incentives: Maximize use of cheap fuels (Tires & Wood) Burn all the sludge to minimize land fill Maximize steam production
S lid F l C i i C l
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59 2008 Emerson Process Management
Solid Fuel Composition Control
Sludge Presses
M
Sludge Bin
M
SludgeRecoveryHopper
VSM
HCSilo 1
Bark Yard
VSM
HC
FC
FC
WS WS
RSP RSP
WS
SolidFuel Bin
FC
HC
RSP
HCRSP
SludgeTarget
BarkTarget
Tire DerivedFuel (TDF)
VSM
Solid
Fuel ToBoiler
TDFTarget
Silo 2
FC
B il C t l
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60 2008 Emerson Process Management
Boiler Control
Boiler
Lance Burners (16)
FC
Load Burners (4)
FC
TI A-F
TC
HS M HSMAsh Screws (2)
Primary AirBlower
Air Preheater
TI
To ID Fan
PC
RSP
Fuel Gas
SecondaryAir Blower
FC
FCOverfire
Air Ports(18)
CombustionControl
To AshHanding
NCAvg
To ID Fan Speed Control
Solid Fuel
FC
Solid Fuel
FC
B il P C t l I
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61 2008 Emerson Process Management
Boiler Process Control Issues
Varying water in sludge Long delay & lag times (20 60 minutes) to
change fuel composition Fuel composition time constants are a
function of fuel bin level
Solid fuel composition in fuel bin isunknown
Bed temperature constraints (max & min) Multiple operators controlling same unit Different operating philosophy used by each
shift
Solid Fuel Composition Control
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62 2008 Emerson Process Management
Solid Fuel Composition Control
Sludge Presses
M
Sludge Bin
M
SludgeRecoveryHopper
VSM
HCSilo 1
Bark Yard
VSM
HC
FC
FC
WS WS
RSP RSP
WS
SolidFuel Bin
FC
HC
RSP
HCRSP
SludgeTarget
BarkTarget
Tire DerivedFuel (TDF)
VSM
Solid
Fuel ToBoiler
MPC BlockTDFTarget
Silo 2
PredictedBTU
Content
Boiler Control
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63 2008 Emerson Process Management
Boiler Control
Boiler
Lance Burners (16)
FC
Load Burners (4)
FC
TI A-F
TC
HS M HSMAsh Screws (2)
Primary AirBlower
Air Preheater
TI
To ID Fan
PC
RSP
Fuel Gas
SecondaryAir Blower
FC
FCOverfire
Air Ports(18)
CombustionControl
To AshHanding
NC
MPCOutputs
Avg
To ID Fan Speed Control
Solid Fuel
FC
Solid Fuel
FC
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64 2008 Emerson Process Management
Power Boiler Sludge
0
1020
30
4050
60
1 2 / 2
0 / 0 0
1 / 9 / 0
1
1 / 2 9
/ 0 1
2 / 1 8
/ 0 1
3 / 1 0
/ 0 1
3 / 3 0
/ 0 1
4 / 1 9
/ 0 1
T P H
SLDG
Key
Current Average
New Average
Max Sustainable
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65 2008 Emerson Process Management
Power Boiler Bark Fuels
05
101520253035
4045
1 2 / 2
0 / 0 0 1 /
9 / 0 1
1 / 2 9
/ 0 1
2 / 1 8
/ 0 1
3 / 1 0
/ 0 1
3 / 3 0
/ 0 1
4 / 1 9
/ 0 1
T P H
BARK
Key
Current Average
New Average
Max Sustainable
Power Boiler APC Benefits
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66 2008 Emerson Process Management
Power Boiler APC Benefits
Difference inHourly Costs
Power Boiler & (Savings)
Natural Gas $2.22
Sludge Disposal ($23.04)
Sludge Ash Disposal $9.18
TDF $0.46
TDF Ash Disposal $0.00
Waste Wood $26.91
W Wood Ash Disposal $0.77
Total $16.50
Package BoilersDisplaced Natural Gas ($98.42)
Net Savings, $/Hr ($81.92)
Total Savings
$56k / mo
$672k / yr
Project Justified:
Replacement of requiredpneumatic instruments
DCS Hardware / Software
APC Tools Turnkey Engineering Services
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67 2008 Emerson Process Management
Issues in Evaluating Plant Energy Usage
Unit energy usage depends on production rate
Unit energy usage variance dependent on productionrate
Need to correct to standard unit conditions
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68 2008 Emerson Process Management
Unit Energy Usage
Throughput - % Max Capacity
0 10050
EnergyUsageBtu
SpecificEnergyUsageBtu /Bbl
Energy Usage - Example
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69 2008 Emerson Process Management
Energy Usage Example
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00Production
T/Hr
MMBTU/Hr
Unit Energy Usage
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70 2008 Emerson Process Management
gy g
Throughput - % Max Capacity
0 10050
SpecificEnergyUsageBtu /Bbl
x
x
x
xx
x
x
x
x
x
x
x
x
x
x
x
x
x
x
xx
x
x
x
x
xx
x
x
ConfidenceLimits
VarianceIncreases at
Lower Rates
Unit Energy Usage - Example
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72 2008 Emerson Process Management
gy g p
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
Production
M M B T
U / T o n
Excuses for Doing Nothing
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76 2008 Emerson Process Management
g g
Not enough manpower - Too busy doing other things
Our plant is special analysis based on other sitesdoesnt apply
We run our plant well already, there wont be any bigsavings found
Ostrich - (If we find something obvious,
management will ask why we didnt find it before)
Summary
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77 2008 Emerson Process Management
y
Energy is the largest controllable cost in processoperation its efficient production and use are keys to
plant profitability
Automation and Advanced Automation are keys toeffective use and management of energy in the plant
Implementation of a program to save energy requires adisciplined approach to evaluation and analysis
Questions? Comments?
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78 2008 Emerson Process Management
Q
More material on subject:http://www.emersonprocess.com/solutions/services/aat