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

externalCustomer

1b. Overall Block Diagram Business ProcessPT. Chandra Asri Petrochemical Tbk.

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

1d. Indonesian Polypropylene & Polyethylene supply and Demand

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

Field

CCR

DCS

3 e. Continuous Emission Monitoring System (CEMS)

Gas Turbine Exhaust

DCS-Console

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

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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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