Industrial Energy Management with Visual MESA at BP Lingen refinery Availability Department – BP Lingen refinery Soteica ERTC Annual Meeting – Vienna ‐ 2012
Nov 25, 2015
IndustrialEnergyManagementwithVisualMESAatBPLingenrefinery
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
VisualMESAenergymanagementsystemimplemented
Introduction(II)
HydrogenFuelSteamWaterElectricityUtilitiesSystems
ExternalUtilitiesContracts
EmissionsRegulations
ProcessIndustrialSite
RealTimeandWhatifPlanningOptimizerthatfindstheoptimalwaytooperateutilitiessubjecttocontractual,environmentalandoperationalconstraints
OptimumUtilitiesOperationsReport
Measurements OptimumSetPoints
KPIMonitoringandAccountingReports
Introduction(III) VisualMESAisa1st PrinciplesModelingandOptimization(SQP
MINLP)programforfuels,steam,BFW,condensate,hydrogenandelectricalsystems,includingemissions
Fieldsofapplication: RealTimeOptimization Monitoring,AuditingandAccounting Engineering Planning RealTimeValidatedEnergyandEmissionsKPICalculationServer
Currentlyinuseinmorethan70refineriesandpetrochemicalsites
Energysystemdescription
Setoffiredboilersandprocessfurnacesburningfuelgas Steamnetworkwiththreesteampressurelevels Setofsteamturbogenerators Twocogenerationunits
Productionof50MWofelectricityfromtwonaturalgaspoweredgasturbines,foruseonsiteandforsaleoftheexcessenergy
Thegasturbineshavesteaminjectionandheatrecoverysteamgeneratorwithpostcombustion
Differenteconomictradeoffs(amongelectricity,steamandfuelnetworks)
Manychallengestooperatetheenergysystematminimumcost,withintheconstraints(e.g.emissions)
ProjectObjectives
Monitoringandreductionoftherefinery'stotalenergycosts
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
Steamproductionatboilers FuelGas/FuelOiltoafiredboiler FuelGastotheotherfiredboilers
Turbogeneratorsmanagement TGsloads
Pumpswaps(steamturbines/electricalmotorsswitches) 6possibleswitchesfor401.5barsteamturbines) 36switches111.5barsteamturbines CondensingTurbines
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/PropanemakeuptoFGnetwork
Pumpswaps Theremainingvariables(forexample,steamletdownflow
rates)areconsequencesofthechangesmentionedbefore,beingmanipulatedautomaticallybythecontrolsystem
Energycostsreductionexamples
NaturalGas/Butane/PropaneadditiontoFGnetwork
GasTurbineloads Pumpswaps
Example1:MinimizationofbutaneadditiontoFGnetwork
Butane reduction
Example1(cont):MinimizationofbutaneadditiontoFGnetwork
Energy cost reductionaround 5% on total energy cost
Butane reductionto FG networkaround 3 t/h
Delta Cost (Current minus Optimized)
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
Although electricity exportation penalty increase
Gas turbine load increase operating at higher efficiency
Example3:OptimizationofPumpswaps
Steam vent eliminated
Example3:OptimizationofPumpswaps
Several pump swapsA 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)
Fired boiler efficiency
Turbogenerator 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,understandingalldecisionvariablesandtheassociatedconstraintswhichsometimesarehidden
Abilitytoreactonlinetocapturebusinessopportunitiestoreduceenergycostsandimproveemissionsmanagement,gettingsignificantenergysavings