Upload
ogenioja
View
217
Download
0
Embed Size (px)
Citation preview
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 1/30
S av i n g E n er g y i n S av i n g E n er g y i n F r a c t i o n a t i o n O p e r a t i o n F r a c t i o n a t i o n O p e r a t i o n
TexasTechnologyShowcase2006
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 2/30
2006 Texas Technology Showcase
Presenter Presenter Presenter
Doug White
Principal Consultantand Vice President,APC Services
Process Systems andSolutions
Emerson Process
Management
Houston, Texas
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 3/30
2006 Texas Technology Showcase
F r ac t i o n at i o n E n e r g y F r ac t i o n at i o n E n e r g y F r ac t i o n at i o n E n e r g y
Over 40000 distillation/ fractionation columns in the USalone
Consume 40% - 60% of the total energy used inchemical and refining plants
Consume 19% of the total energy used inmanufacturing plants in the US
Reference: Office of Industrial Technology:
Energy Efficiency and Renewable Energy;
US Department of Energy
Washington, DC
“Distillation Column Modeling Tools”
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 4/30
2006 Texas Technology Showcase
Pr esentation O bjectives Pr esentation O bjectives Pr esentation O bjectives
Present general approaches to saving energyin fractionation/ distillation through improvedcontrol
Present techniques for economic analysis thatrecognize non-linear character of distillationoperation and effects of product blending
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 5/30
2006 Texas Technology Showcase
FC
LC
FC
TC
FC
LC
Feed, F
20,000 BPD$60/ Bbl
Bottoms, B 5%C4; $80/ Bbl> 5%C4; $60/ Bbl
Distillate, D 3%C5 ;$60/ Bbl>
%C5; $40/ Bbl
Reflux,
R
Reboiler,E
PC
AC
C as e S t u d y C as e S t u d y C as e S t u d y
AR
C3 – 25%nC4 – 25%nC5 – 25%nC6 – 25%
Steam
10$/MMBTU
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 6/30
2006 Texas Technology Showcase
S av i n g E n e r g y i n F r ac t i o n at i o n S av i n g E n e r g y i n F r ac t i o n at i o n S av i n g E n e r g y i n F r ac t i o n at i o n
Closer Control to Specifications
Optimize Energy Usage versus Recovery
Minimize Pressure
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 7/30
2006 Texas Technology Showcase
D is t i l lat i o n C o l u m n C o n t r o l S av i n g s D is t i l lat i o n C o l u m n C o n t r o l S av i n g s D i s t il l at i o n C o l u m n C o n t r o l S av i n g s
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
$/ Yr
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 8/30
Mat erial B alanc e Mat erial B alanc e
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 9/30
2006 Texas Technology Showcase
P r o d u c t V al u e P r o d u c t V al u e P r o d u c t V al u e
0.5 1.0 1.5 2.0 2.5
Spec
Product
Value;$/ Day
Bottom Product Composition; %
Assumptions:ConstantReflux; NoVariability in
Control
Optimum is to operateas close to the specas possible
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 10/30
2006 Texas Technology Showcase
Debut anizer – Mat er ial B alanc e Ef f ect s Debut anizer Debut anizer – – Mat er ial Balanc e Ef f ect s Mat er ial Balance Ef f ect s
Debutanizer
20000 BPD
Constant B/F
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
3 3.2 3.4 3.6 3.8 4 4.2 4.4
R/D Ratio
C o m p o s
i t o n
, %
B
D
Debutanizer
20000 BPD
Constant R/D
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
9 9.5 10 10.5 11 11.5
B/FRatio
C o m p o s
i t i o n ,
%
B
D
Material Balance Control Has Strongest Effecton Composition
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 11/30
2006 Texas Technology Showcase
Effec t of Variabi l i ty Effec t of Variabi l i ty – – S t an d ar d A n al y s i s S t an d ar d A n a ly s i s
Time
SpecificationLimit
Average
Composition
Composition
y(x)= 1
2
1
2
2
e
x mean
6
1 %
o f p e a k h e i g h t
1 4 %
16% of area
2% of area
Frequencyof
Occurrence
y
Mean
1 SD
2 SD
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 12/30
2006 Texas Technology Showcase
Effect of Reduced Var iabi l i ty Effect of Reduced Var iabi l i ty
IMPROVED PROFITBY CHANGING
TARGET
REDUCEDVARIABILITY
POOR CONTROL
$PROFIT
SPECIFICATION LIMIT
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 13/30
2006 Texas Technology Showcase
R ed u c e d V ar i ab i l i t y O p t i o n s
2-Sigma 2-Sigma
NewSet Point
OriginalSet Point
2-Sigma 2-Sigma
Upper LimitPV distribution for original control
PV distribution for improved control
Extra margin withoutimproved control
value
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 14/30
2006 Texas Technology Showcase
P r o d u c t V al u e w i t h V a r iab i l i t y P r o d u c t V a lu e w i t h V ar i ab i l i t y P r o d u c t V al u e w i t h V a r iab i l i t y
0.5 1.0 1.5 2.0 2.5
SpecProductValue;$/ Day
Bottom Product Composition; %
MeanValue
Initial
Variability
Initial OperatingTarget
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 15/30
2006 Texas Technology Showcase
P r o d u c t V al u e w i t h V a r iab i l i t y R e d u c e d – S am e S et p o i n t P r o d u c t V a lu e w i t h V ar i ab i l i t y P r o d u c t V al u e w i t h V a r iab i l i t y
Reduced R e d u c e d – – S am e S et p o i n t S am e S et p o i n t
0.5 1.0 1.5 2.0 2.5
SpecProductValue;$/ Day
Bottom Product Composition; %
New
Mean Value
Reduced
Variability
Initial OperatingTargetOld Mean
Value
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 16/30
2006 Texas Technology Showcase
P r o d u c t V al u e w i t h V a r iab i l i t y P r o d u c t V a lu e w i t h V ar i ab i l i t y P r o d u c t V al u e w i t h V a r iab i l i t y
0.5 1.0 1.5 2.0 2.5
SpecProductValue;$/ Day
Bottom Product Composition; %
NewMeanValue
ProfitIncrease
OldValue
ReducedVariability
For any givenstandard deviationit is possible tocalculate the
optimum setpoint.
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 17/30
2006 Texas Technology Showcase
Debu tanizer - Net Pr ofi t Cur v e Debutanizer Debutanizer - - N et P r o f i t C u r v e N et P r o f i t C u r v e
D e b u t a n i z e r
2 0 0 00 B P D
5 % B t m C o m p
0
5 0 0 0 0
1 0 0 0 0 0
1 5 0 0 0 0
2 0 0 0 0 0
2 5 0 0 0 0
0 .0 0 1 .0 0 2 .0 0 3 .0 0 4 .0 0 5 .0 0 6 .0 0
D i s t il la t e C o m p o s i t io n s , %
N
e t P r o
f i t , $ / D a y
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 18/30
2006 Texas Technology Showcase
Debutanizer – O p t i m u m S et p o i n t W i t h Variabil i ty Debutanizer Debutanizer – – Op t i m u m S et p o i n t W i t h O p t i m u m S et p o i n t W i th
Variabil i ty Variabil i ty
Debutanizer
20000 BPD
5% Btm Comp
Variability Effect on Optimum Setpoint
150000
175000
200000
225000
250000
0 0.5 1 1.5 2 2.5 3
Distillate Compositon, %
P r o f i t , $ / D a y
0
0.3
0.6
Standard
Deviation
Optimum Setpoint Depends on Variability
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 19/30
2006 Texas Technology Showcase
E ff ec t o f B l en d i n g E ff ec t o f B l en d i n g E f fec t o f B l en d i n g
Column Product
Shipped Product
Proposition: Since actual specification is on shippedproduct rather than column product directly, smallexcursions over the specification don’t matter andcan be handled by blending.Is this correct?
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 20/30
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 21/30
2006 Texas Technology Showcase
Non -Lin ear Effects No n No n - - Lin ear Effects L inear Effects
EnergyCost
Composition
For nonlinear relationship, theexpected value of the energy cost isNOT at the value equivalent to themedian of the composition; It’svalue depends on the standarddeviation of the composition
Less PureMore Pure
ProbabilityDistribution
ExpectedValue
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 22/30
2006 Texas Technology Showcase
Var iabi l i ty Vs Ener gy Var iabi l i ty Vs Ener gy Var iabi l i ty Vs Ener gy
Debutanizer 20000 BPD
5% Btm Co mp; 3% Distil Com p
Variability Effect on Energy Usage
12300
12400
12500
12600
12700
12800
12900
13000
13100
13200
0 0.2 0.4 0.6 0.8 1
Distillate Composition Standard Deviation, %
E
n e r g y
C o s
t , $ / D a y
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 23/30
E n er g y B al an c e E n er g y B al an c e C o n t r o l C o n t r o l
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 24/30
2006 Texas Technology Showcase
LowEnergyCostOptimum
Profi tabi l i ty Prof i tabi l i ty Prof i tabi l i ty
Reflux
$/ Day
Low Energy Cost,$/day
Product Value,$/day
Low EnergyCost Profit$/day
High EnergyCost, $/day
High EnergyCost Profit$/day
HighEnergyCostOptimum
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 25/30
2006 Texas Technology Showcase
P r o f i t ab i l i t y w i t h v ar i ab i l i t y P r o f i t ab i l i t y w i t h v a ri ab i l i t y P r o f i t ab i l i t y w i t h v ar i ab i l i t y
RefluxBPD
$/ Day
Profit
$/day
Optimum
Assumptions:ConstantBottomsComposition
MeanValue
Current
Variability
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 26/30
2006 Texas Technology Showcase
P r o f i t ab i l i t y w i t h v ar i ab i l i t y P r o f i t ab i l i t y w i t h v a ri ab i l i t y P r o f i t ab i l i t y w i t h v ar i ab i l i t y
RefluxBPD
$/ Day
Profit
$/day
Optimum
Assumptions:ConstantBottomsComposition
OldValue Reduced
Variability;
Same Mean
NewValue
ProfitIncrease
For locally quadraticobjective functionthe benefits of reduced variabilitycan be calculatedanalytically
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 27/30
P r es s u r e E f f ec t s P r es s u r e E f f ec t s
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 28/30
2006 Texas Technology Showcase
C o l u m n P r es s u r e E ff ec t C o l u m n P r es s u r e E ff ec t C o l u m n P res s u r e E ff ec t
Relative Reboiler Cost Per Year
Column Pressure Effect
Constant Separation
20000 BPD Stabilizer
$0
$1
$2
$3
$4
$5
$6
100 120 140 160 180 200
Pressure, PSIA
$ MM/ Yr
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 29/30
2006 Texas Technology Showcase
S u m m ar y - Sa v i n g E n e r g y i n F r ac t i o n a t i o n S u m m a r y S u m m a r y - - S a v i n g E n e r g y i n F r a c t i o n a t i o n S a v i n g E n e r g y i n F r a c t i o n a t i o n
Closer Control to Specifications
Optimize Energy Usage
Minimize Pressure
8/10/2019 White TexasEnergy DCW SavingEnergyFractionation 06126
http://slidepdf.com/reader/full/white-texasenergy-dcw-savingenergyfractionation-06126 30/30
2006 Texas Technology Showcase
Q u e s t i o n s ? C o m m e n t s ? Q u e s t i o n s ? C o m m e n t s ? Q u e s t i o n s ? C o m m e n t s ?
More material on subject:http://www.emersonprocess.com/solutions/services/aat