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The only one & The largest Integrated Olefin Petrochemical Company in Indonesia
In Cilegon – Banten Province - Indonesia
Kesiapan Industri Kimia Dalam Implementasi Industri 4.0 (Case study PT. Chandra Asri Petrochemical Tbk)
Indonesia Industrial Summit 2018April 4-5, 2018, Jakarta Convention Center
Prepared by
Helmilus Moesa
(Advisor PT. Chandra Asri Petrochemical Tbk )
1. Company Introduction PT. Chandra Asri Petrochemical Tbk. a. Site Location (Where We are & What We are doing)b. Business Process, supply & demand and multiplier efek.
2. Road map peningkatan Kapasitas Produksi (2018 – 2030).
3. Peningkatan Effektivitas , Produktivitas, Efisiensi, Quality & Safetymelalui process control dan digitalisasi.
4. Pemakaian Teknologi Process Control & Digital.a. PI Coreseight.b. Optience.c. Advanced Process Control (APC) & Real Time Optimizer (RTO)d. OCSe. Machine learning.
5. Summary
Agenda
3
1a. Site Location
PT. Chandra Asri Petrochemical Sites Locations In Cilegon (120 KM from Jakarta)
Consists of 3 Locations, 9 Plants with total area=156 Hectares
LOCATION-1(120Hectares-Anyer)
4 Plants
Location-320 Hectares
(Bojanegara)2 Plants
Head Office(Jakarta)
CAP
Gasoline
Acetic Acid
Plant
EDC
Plant
EO/EG
Plant
Ethyl Ben
Plant
Ethyl Acete
Plant
VCM
Plant
SM
Plant
PVA
Plant
PVC
Plant
Polystyrene
Plant
VAM
Plant
Polyethylene
Plant
Polypropylene
Plant
Butadiene
PlantSBR
Plant
MTBE
Plant
Ethylene
Propylene
Crude C4
Acrylic Acid
Plant)
BUTENE-1
Plant
1c. Multiplier Effect OfPT. Chandra Asri Petrochemical Tbk
CrudeOil
Blue Sky
Plant
Balongan &
Cilacap
Kerosine
Diesel
Residu
LPG & Lighter
OlefinPlant
Ethylene
Cracker
Plant
LNG
PLANTNaturalGas
LNG
Export
Naphtha
Condensate
REF
INER
Y
BBM
Crude C5
Aromatic
Plant
PET/PES
Plant
Benzene
Plant
Alkyl-Benz
PlantAl-Benz
Sulfo-Plant
Pygas
Piperylene
Plant
Application OfPetrochemical Products
PT. Chandra AsriPetrochemical Tbk
Formulation
Plant
Packaging
Glass aqua
Cling rap film
Dash board/Automotive parts
Battery case
Tyre
Refrigerator CPU Comp Remote Control
Insulation cable
Bottle
Pempers
Infus TextilesPipes Polyester
Super Absorbent
Plant
DCPD
Plant
3,301 3,458 3,938 4,171
6,500
8,000
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
2016 2018 2019 2020 2025 2030
Tota
l Pro
du
ctio
n (
KTA
)2. Peningkatan kapasitas PT. Chandra Asri Petrochemical Tbk
(2018 - 2030)
New SSBR = 120 KTAExpansion BD= 37 KTA
New PE = 400 KTAExpansion PP = 80 KTA
Debottle necking - Ethylene = 40 KTA- Propylene = 20 KTANew MTBE =130 KTANew Butene-1 = 43 KTA
Second Complex CAP - Ethylene = 1000 KTA- Propylene = 550 KTA- C4 = 262 KTA- BD = 175 KTA- Benzene = 363 KTA
New Plant Coal to Pet-Chem = 450 KTANG to Pet-Chem = 850 KTAPX, PET, PES = 200 KTA
KTA KTA KTA KTA
KTA
KTA
Note:KTA : Kilo Ton per Anum1 KTA : 1,000 Tons/Year
3. Peningkatan Produktivitas dan Effisiensi
(Through Optimization of Process Control & Digitalisation)
DISTRIBUTED CONTROL SYSTEM
(DCS)
TRANSMITTERSCONTROL VALVES
REGULATORY CONTROL
DISTRIBUTED CONTROL SYSTEM (DCS),
COMPRESSOR SURGE CONTROL (CCC)
TURBINE SPEED CONTROL (TRISEN TS410),
EMERGENCY SHUTDOWN SYSTEM (TRICONEX),
FIRE & GAS DETECTION SYSTEM
PLANT & EQUIPMENT
TRANSMITTERS, CONTROL VALVES,
FRACTIONATION COLUMNS,
COMPRESSORS , TURBINES, PUMPS
REACTORS, CRACKING FURNACES
PID CONTROLLER
SEQUENCE CONTROL
MOTOR START/STOP
INTERLOCK LOGIC CONTROL
ADVANCED PROCESS CONTROL
REAL TIME OPTIMIZER
APC :
MAXIMIZE CAPACITY, PUSH CAPACITY UNTIL REACHES CONSTRAINT, STABILIZE QUALITY
RTO :
MAXIMIZE PROFIT, DRIVEN BY ECONOMIC
SET POINTS
CONSTRAINTS
ADVANCED PROCESS CONTROL
(APC) REAL TIME OPTIMIZER
CONFIDENTIAL
9
Year
Pro
du
ct Y
ield
WORLD CLASS Product Yield
2013 65.5 %
2014 66.3 %
2015
64.6 %
2016 68.0 %
2017 68.1 %
2025
Q2(Quartile-2)
Q1(Quartile-1)
Yield Optimization
APCImplementation
3 a. Peningkatan Yield
201564.6 %
201565.5 %
201466.3 %
201668.0 %
201768.1 %
TAM
CONFIDENTIAL
10
2013 18 GJ/T-HVC 2016
17.9 GJ/T-HVC
WORLD CLASSEnergy Consumption
Year
201717.2 GJ/T-HVC
APC Implementation
Furnace Revamping
Utility Optimization
Ener
gy C
on
sum
pti
on
2025
Q1
3 b. Pengurangan pemakaian energy
SP Qty Rank
Naphtha A 10 55 KT 1
Naphtha B (20) - 5
Naphtha C (5) - 3
Naphtha D - 7 KT 4
Naphtha E 9 35 KT 2
Naphtha D (14) - 6
LPG 1 30 -
LPG 2 40 -
LPG 3 60 -
It optimizes Operating Rate & Max Profit
Feedstock Ranking
Main Product Yield
CAP complex simulation by optience
MaximumProfit
Margin
3 c. Optimalisasi Profit margin
3d. Peningkatan kualitas produk(dengan teknologi OCS)
CONTINUOUS READING100% sample is inspected
Pelletizer machine (Field)
BATCH READING12 pc film ~ 30 gr~0.2% sample is inspected
CONTINUOUSSAMPLINGTrickle 100 g/10 sec~36 Kg/Hr
BATCH SAMPLING1 sample of 15 Kg every 4 Hr3.75 Kg/Hr
0
20
40
60
80
1 2 3 4 5 6 7 8 9 10
Tota
l Def
ect
Are
a (m
m2)
Bad Good Limit
Real Time Monitoring Mobile Tool
Chandra Asri has been utilizing such apps enables data analyzing in multiple ways
supporting fast data-driven decisions and provide insights
into operations and business
“Seeing plant data on any device, wherever we are, whenever we need it”
4. Pemanfaatan Teknologi4 a. PI Coreseight apps (Memonitor secara real time operasi pabrik melalui komunikasi mobile)
Eye CatchingDashboard
4. Pemanfaatan Teknologi4 b. Contoh tampilan monitoring pabrik secara real time melalui komunikasi mobile
16
Plant Condition
OPTIENCE
Plant data link( PI-System )
Actual plant operating condition
Laboratory data Market Price(fluctuate dynamic market price
Plant Constraint
(Frequently change)
Raw Materials Specification
P : Paraffin contents
O : Olefin contents
N : Naphthene contents
A : Aromatic contents
Sg :Specific Gravity
ASTM-Boiling point
4 c. OPTIENCE(Mengoptimalkan operasi pabrik berdasarkan perubahan input)
MaximumProfit
Yield Simulator(Spyro apps)
4 d. Advance Process Control (APC) & Real Time Optimizer (RTO) apps
Mengoptimalkan proses produksi secara otomatis berdasarkan perubahan imput
4c. Learning Machine “Finding the Patterns Humans Can’t See”
Having numerous high valuable assets,
Chandra Asri will utilize machine learning as
advanced early warning & risk detection software
that identifies process & equipment problems
Contamination
Fouling
Corrosion
Vibration
Cavitation
Flooding
Emission
Conclussion
1. PT. Chandra Asri Petrochemical Tbk merupakan industri huluyang bahan bakunya dari Oil & Gas, dimana produk-produknyamerupakan bahan baku untuk industri-industri hilirnya, yangakan menghasilkan produk yang bernilai tambah tinggi(semua jenis bahan baku plastic dan synthetic rubber)
2. Untuk meningkatkan produktivitas, effisiensi, profit margin,quality & Safety, Perusahaan (sudah/akan) menerapkanteknologi process Control & digitalisasi dengan memakai.a. Pi Coreseight b. Optience c. APC/RTO d. DCSe. SAP f. OCS g. Machine learningyang merupakan rangkaian road map menuju industri 4.0
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