SUPERIOR RESULTS. SUSTAINED.
Client experiences of using Petro-SIM to assist with refinery optimisation Sławomir Szumacher – PKN ORLEN
Nicola Knight - KBC
29 September 2016
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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
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PKN ORLEN Overview
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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
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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
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KBC Overview
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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
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What is Petro-SIM?
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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
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LP Vector updates
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LP Model Development
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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
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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
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1
Petro-SIM Process Model
Petro-SIM LP Utility
LP Submodel
Template
LP Submodel
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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
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Energy Analysis
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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
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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
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Heat Exchanger fouling monitoring
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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
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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
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PKN – HX Monitor Results
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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
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‘What If’ studies
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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
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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
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SUPERIOR RESULTS. SUSTAINED.
Any Questions? Thank you for listening
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Sławomir Szumacher – PKN ORLEN
Nicola Knight - KBC