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Case study FCC model with integrated energy and yield

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Case study FCC model with integrated energy and yield

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Case study FCC model with integrated energy and yield

  1. 1. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17 January 2018 Confidential Information Case Study FCC Model with Integrated Energy and Yield
  2. 2. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Demo FCC unit constrainedby turbine drivingwet gas compressor • Client use of model:  FCC-SIM™ model used for unit monitoring  FCC-SIM optimiser used each morning to determine specific unit operating targets not provided in LP • Situation on unit:  Unit runs to wet gas compressor limit – set in optimiser as a fixed flow  WCG driven by condensing steam turbine. Inlet valve fully open. - Variations in cooling water temperature impact shaftwork generated by the turbine and therefore vary capacity of the unit • Combined process and utility model with BT utility used to:  Optimise to true constraint accounting for steam system performance  Monitor unit BT energy index, accounting for varying yield and throughput
  3. 3. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Steam Header Balance • Objectives: MP Header  MP header demand is set by users  First take steam from STG extraction - Up to max 75 T/h  Then take steam from letdown valve - But need a minimum of 3 T/h • Objectives: HP Header  Send FCC generated steam to users - MP header steam demands - Satisfy MAB turbine power requirements  Export any excess  Import any deficit
  4. 4. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Results • Variation in cooling water temperature  Small difference in energy- US $80K per year  Big difference in process yield – US $10.4m per year Output Base Energy Benefit Yield Benefit Comment Cooling Water Temperature °C 20 15 15 Yield Impacts FCC Feed m3/h 249 249 249 Fixed for this example Yield 200 Minus wt% 79.6 79.6 80.4 UP Energy Impacts Total Energy Use Gcal/h 189.0 188.5 189.9 UP Steam Import T/h 23.7 22.8 21.3 Specific Energy Consumption Gcal/T Feed 0.827 0.825 0.834 UP - More energy used (More Coke, but less steam import) BT Index % 115 115 114.6 DOWN - Better Yield is worth spending the extra energy Economic Impacts Operating Profit US $ m/y 225.4 225.5 235.8 Saving US $ m/y 0.08 10.4
  5. 5. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Conclusions • Energy systems have a large impact  Direct energy cost reduction  Energy systems constrain process performance • With Petro-SIM™ KBC is working towards a truly unified view  HX Monitor: process and heat exchange  Petro-SIM Energy: process and utilities  BT Index Utility: smart energy KPIs that account for yield and feedstocks • Design – Revamp – Monitoring – Optimisation

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