Refinery-wide process models can be used to identify specific areas for profit improvement, generate alternative improvement plans, and predict how each plan would impact overall profits. Such models integrate planning tools with rigorous process simulation to evaluate impacts of expansions, improvements, or unexpected events. Maintaining an up-to-date refinery-wide model through process simulation software allows refineries to optimize crude slates and product yields to maximize profits in challenging markets. The document discusses how integrating planning models with rigorous process simulation in a single flowsheet enables evaluation of strategic options and helps refineries make more profitable decisions.
The document discusses optimization solutions for oil refinery production planning and scheduling. It describes how optimization can help refineries better manage uncertainty, take advantage of market opportunities, and cope with increasing production complexity. The solutions aim to generate executable plans that meet demand while minimizing costs. Current scheduling solutions are limited as they involve manual trial-and-error search, whereas the proposed solution uses optimization to find optimal schedules. Benefits include reduced variability, improved schedule attainment, and better ability to capture spot market opportunities.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
The document is a resume for Robert T. Kendall providing summaries of his experience and qualifications for a facilities manager position. It outlines his objective to utilize leadership and mechanical experience to optimize operations. It then details over 30 years of experience in facilities management, maintenance management, and operations roles for various companies. His technical skills and experience include CMMS programs, budgeting, electrical and mechanical systems, and he has managed facilities ranging from 155,000 to 190,000 square feet.
This document outlines the work experience and responsibilities of an individual as a Maintenance Manager at two sawmills from 2000-2003. At the first mill, key responsibilities included restructuring the maintenance department, leading equipment reliability strategies, and managing capital projects. At the second mill, responsibilities involved organizing major shutdowns, leading health and safety programs, investigating incidents, and implementing work systems to improve planning and task management.
Conoco on Path to Reliability Centered Loop Management: Enhancing ROA on the WayARC Advisory Group
Conoco on Path to Reliability Centered Loop Management: Enhancing ROA on the Way
Process manufacturers have invested heavily in manufacturing plants and
automation systems. A typical manufacturing plant may have hundreds or
even thousands of regulatory control loops to enable safe and efficient operations.
The most complex units often have advanced process control and
optimization schemes implemented on top of these regulatory control
loops. All of these systems have a need for
tighter process control to enable more effective
use of assets that result in higher ROA and ultimately
better business performance and
profitability.
Unfortunately, automation effectiveness deteriorates
over time. The lack of a structured
methodology for control loop maintenance is a
contributing factor that erodes performance. A
manufacturing plant typically has only two or three control engineers who
each have responsibility for a large of number of loops, yet they often have
no means of identifying where to focus their efforts so that their work has
the largest economic impact on plant performance.
Mike Palm has extensive experience leading projects to improve reliability and reduce costs for oil and gas, aeronautic, utility, and manufacturing clients. Some of his accomplishments include facilitating GE Workouts to identify improvement projects for an oil and gas company, leading the selection of a CMMS system while working with over 60 functions at a midstream oil and gas company, and organizing a team to develop standard PMs for over 45,000 pieces of equipment across 60 locations for another oil and gas company. He has successfully led various work management and process improvement projects across multiple industries.
The document discusses optimization solutions for oil refinery production planning and scheduling. It describes how optimization can help refineries better manage uncertainty, take advantage of market opportunities, and cope with increasing production complexity. The solutions aim to generate executable plans that meet demand while minimizing costs. Current scheduling solutions are limited as they involve manual trial-and-error search, whereas the proposed solution uses optimization to find optimal schedules. Benefits include reduced variability, improved schedule attainment, and better ability to capture spot market opportunities.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
The document is a resume for Robert T. Kendall providing summaries of his experience and qualifications for a facilities manager position. It outlines his objective to utilize leadership and mechanical experience to optimize operations. It then details over 30 years of experience in facilities management, maintenance management, and operations roles for various companies. His technical skills and experience include CMMS programs, budgeting, electrical and mechanical systems, and he has managed facilities ranging from 155,000 to 190,000 square feet.
This document outlines the work experience and responsibilities of an individual as a Maintenance Manager at two sawmills from 2000-2003. At the first mill, key responsibilities included restructuring the maintenance department, leading equipment reliability strategies, and managing capital projects. At the second mill, responsibilities involved organizing major shutdowns, leading health and safety programs, investigating incidents, and implementing work systems to improve planning and task management.
Conoco on Path to Reliability Centered Loop Management: Enhancing ROA on the WayARC Advisory Group
Conoco on Path to Reliability Centered Loop Management: Enhancing ROA on the Way
Process manufacturers have invested heavily in manufacturing plants and
automation systems. A typical manufacturing plant may have hundreds or
even thousands of regulatory control loops to enable safe and efficient operations.
The most complex units often have advanced process control and
optimization schemes implemented on top of these regulatory control
loops. All of these systems have a need for
tighter process control to enable more effective
use of assets that result in higher ROA and ultimately
better business performance and
profitability.
Unfortunately, automation effectiveness deteriorates
over time. The lack of a structured
methodology for control loop maintenance is a
contributing factor that erodes performance. A
manufacturing plant typically has only two or three control engineers who
each have responsibility for a large of number of loops, yet they often have
no means of identifying where to focus their efforts so that their work has
the largest economic impact on plant performance.
Mike Palm has extensive experience leading projects to improve reliability and reduce costs for oil and gas, aeronautic, utility, and manufacturing clients. Some of his accomplishments include facilitating GE Workouts to identify improvement projects for an oil and gas company, leading the selection of a CMMS system while working with over 60 functions at a midstream oil and gas company, and organizing a team to develop standard PMs for over 45,000 pieces of equipment across 60 locations for another oil and gas company. He has successfully led various work management and process improvement projects across multiple industries.
Refineries use planning models to guide operational decisions, but changing conditions require frequent model updates to ensure profitability. Aspen HYSYS simulation software helps planning models stay accurate by transferring calibrated process data. Its integration with Aspen PIMS planning software streamlines model updating through shared tools and easy data transfer, helping refineries optimize profits.
The Evolving Landscape of Semiconductor Manufacturing to Mitigate Yield Losse...yieldWerx Semiconductor
Semiconductor manufacturing, often described as a labyrinth of complex and multi-layered processes, is central to the production of integrated circuits. These circuits, already intricate, are becoming progressively more complex with each technological leap. This evolution intensifies the requirement for robust performance metrics, such as defect rate, semiconductor yield improvement, and cycle time. Through rigorous monitoring and analysis of these parameters, manufacturers can make significant enhancements to their performance, yielding a substantial impact on operational efficiency and profitability. This detailed exposition presents a comprehensive examination of yield modeling, dynamic capacity re-allocation mechanisms, yield competitiveness, and yield prediction models, offering invaluable insights for the semiconductor manufacturing industry.
Efficient and Effective CFD Design Flow for Internal Combustion EnginesReaction Design
1) Traditional IC engine CFD simulations use simplified chemistry models that are insufficient for designing new high-efficiency engine concepts where kinetics effects dominate.
2) Detailed chemical kinetics models have been developed through the Model Fuels Consortium but cannot be directly incorporated into CFD due to high computational cost.
3) Reaction Design's CFD software uses novel parallel chemistry solvers that dramatically reduce simulation times, allowing the use of detailed chemical kinetics models for predictive 3D engine simulations.
Apply model predictive control to reduce batch cycle time and increase consis...ARC Advisory Group
Model predictive control (MPC) can reduce batch cycle times and improve consistency for batch manufacturing processes. When applied to batch distillation at a pharmaceutical plant, Baxter was able to reduce the batch cycle time by 20% by using MPC instead of PID control. Other companies like BASF and Kaneka have also successfully applied MPC to batch reactors and seen benefits like reduced variability and increased capacity. While MPC requires more initial investment, the improvements in cycle time, quality, and consistency can significantly outweigh the additional costs for suitable applications.
Petro-SIM is an industry-leading process simulation software for hydrocarbon industries. It contains rigorous simulation models and an intuitive interface. The open platform architecture allows for integration with other technologies and team collaboration. Petro-SIM supports improved process modeling, optimization, and business transformation through its superior simulation capabilities and integration features.
This article presents the discrete event simulation developed with Northwestern University to optimize an injector production line. This article was presented at the recent Winter simulation Conference (held in December 2008)
Generalized capital investment planning of oil-refineries using MILP and sequ...optimizatiodirectdirect
Abstract
Performing capital investment planning (CIP) is traditionally done using linear (LP) or nonlinear (NLP) models whereby a gamut of scenarios are generated and manually searched to make expand and/or install decisions. Though mixed-integer nonlinear (MINLP) solvers have made significant advancements, they are often slow for industrial expenditure optimizations. We propose a more tractable approach using mixed-integer linear (MILP) model and input-output (Leontief) models whereby the nonlinearities are approximated to linearized operations, activities, or modes in large-scaled flowsheet problems. To model the different types of CIP's known as revamping, retrofitting, and repairing, we unify the modeling by combining planning balances with the scheduling concepts of sequence-dependent changeovers to represent the construction, commission, and correction stages explicitly. Similar applications can be applied to process design synthesis, asset allocation and utilization, and turnaround and inspection scheduling. Two motivating examples illustrate the modeling, and a retrofit example and an oil-refinery investment planning are highlighted.
ARTIFICIAL INTELLIGENCE AND COMPUTATIONAL FLUID DYNAMICS AbhishekPatil387
This document discusses the applications of artificial intelligence and computational fluid dynamics in the pharmaceutical industry. It begins with introducing AI and how it is being used for drug discovery through deep learning techniques. It then discusses various applications of AI in healthcare such as disease identification, personalized treatment, drug discovery/manufacturing, and clinical trial research. The document next discusses computational fluid dynamics and how it can be used to analyze and optimize unit operations in pharmaceutical industry like mixing, solids handling, separation, drying, and packaging. It concludes by stating that integrating CFD methods can improve processes and shorten product development cycles in pharmaceutical industry.
Each individual business with their own unique assets and supply chain optimizing their decisions according to their incentives, abilities and working culture. The latest developments in Planning (Petro) and AI use cases.
Petro-SIM is a purpose-built oil and gas process simulation software that combines process simulation capabilities with reservoir modeling and production system modeling to enable modeling of full field development and production over the life of a facility. It integrates leading thermodynamic models and provides unique capabilities for modeling changing conditions over time. Petro-SIM also allows for detailed hydrate and flow assurance modeling and prediction using its integrated Multiflash compositional modeling.
1. Modern pulp mills often rely on manual and time-consuming scheduling methods that lack optimization capabilities, resulting in unrealized economic potential.
2. Greycon has introduced PulpPlan, a new optimization-based scheduling system that uses mathematical modeling, nonlinear optimization, and scenario analysis to determine optimized production schedules for pulp mills in just a few seconds.
3. By coordinating all production areas, PulpPlan aims to maximize production according to demand while minimizing costs and rate changes, ensuring target stock levels and an even distribution of stock during shortages.
Episode 47 : CONCEPTUAL DESIGN OF CHEMICAL PROCESSES
Chemical process design is the application of chemical engineering knowledge (chemical, physical and/or biological transformations of raw materials) into products and economics in the conceiving a chemical process plant to profitably manufacture chemicals in a reliable and safe manner without unduly affecting adversely the environment and society
Chemical process plants are by nature large capital investment projects that
are expensive to build and operate
have very long life times and
manufacture specific chemicals
Chemical process plants must be designed well to avoid large financial losses over long periods of times due to inefficient processes/poor operations
SAJJAD KHUDHUR ABBAS
Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Revolutionizing The Downstream Supply ChainDavid Evans
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through the use of technology and innovative business models. It proposes a system with four components: 1) outsourcing distribution operations to eliminate large in-house logistics teams, 2) implementing a shared fleet model to improve vehicle utilization, 3) introducing dynamic scheduling and routing powered by advanced analytics to optimize operations, and 4) enabling dynamic slot booking and pricing to maximize profits. Adopting this holistic approach through an integrated technology solution can streamline operations, lower costs, and create value for oil companies and their partners.
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through the use of technology. It proposes a four component system: 1) outsourcing distribution operations, 2) using a shared fleet model, 3) implementing dynamic scheduling and routing, and 4) employing dynamic slot booking and pricing. This system aims to streamline operations, increase efficiency, optimize costs and provide benefits to oil companies, haulers, and customers through real-time data, automated processes and increased visibility and control of operations. Quantitative benefits observed by clients include up to 18% reduction in trips, 15% reduction in inventory, and 25% increase in deliveries handled by the same number of dispatchers.
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through technology-based solutions. It proposes a four component system: 1) outsourcing distribution operations, 2) using a shared fleet model, 3) implementing dynamic scheduling and routing, and 4) enabling dynamic slot booking and pricing. This system aims to streamline operations, increase fleet utilization, optimize scheduling and pricing, and improve customer service and cost savings for oil companies, haulers, and customers. The system has the potential to reduce delivery costs by 15-18% and inventory levels by up to 15% while handling 25% more deliveries with the same staff.
A comparison of a novel robust decentralized control strategy and MPC for ind...ISA Interchange
This document summarizes a research article that compares a novel decentralized control strategy based on override control to a model predictive controller (MPC) for controlling an industrial high purity methanol distillation column. Both controllers were able to maintain tight product purity and high recovery specifications under disturbances. The MPC provided tighter control of product purity but used more energy, while the proposed override control provided tighter recovery control and had lower costs. An economic analysis showed the optimal choice depends on factors like energy costs.
APPLICATION OF LEAN PRACTICES FOR IDENTIFICATION OF SOLUTIONS IN REDUCING FUR...IRJET Journal
This document discusses applying lean practices to reduce furnace oil usage per cylinder at Kairali Structural Fabrications Private Limited (KSFPL). KSFPL manufactures LPG cylinders and uses furnace oil for stress relieving operations. The project aims to reduce oil consumption by ensuring consistent batch production of 1000 cylinders per day in the furnace. Currently, preheating the furnace for each operation uses a large amount of oil. Value stream mapping identified delays causing production of less than 1000 cylinders per day. 5Why analysis revealed delays were due to lack of cylinders and power cuts. Implementing lean tools like consistent production and value stream mapping can help achieve the target of 1000 cylinders per day and reduce furnace oil usage per cylinder
Get with the system - Rogerio Martins, Schneider Electric disucsses the advantages of modern distributed control systems in coal handling preparation plants.
Generalized capital investment planning of oil-refineries using CPLEX-MILP an...Alkis Vazacopoulos
Performing capital investment planning (CIP) is traditionally done using linear (LP) or nonlinear (NLP) models whereby a gamut of scenarios are generated and manually searched to make expand and/or install decisions. Though mixed-integer nonlinear (MINLP) solvers have made significant advancements, they are often slow for industrial expenditure optimizations. We propose a more tractable approach using mixed-integer linear (MILP) model and input-output (Leontief) models whereby the nonlinearities are approximated to linearized operations, activities, or modes in large-scaled flowsheet problems. To model the different types of CIP's known as revamping, retrofitting, and repairing, we unify the modeling by combining planning balances with the scheduling concepts of sequence-dependent changeovers to represent the construction, commission, and correction stages explicitly. Similar applications can be applied to process design synthesis, asset allocation and utilization, and turnaround and inspection scheduling. Two motivating examples illustrate the modeling, and a retrofit example and an oil-refinery investment planning are highlighted.
This document discusses strategies to improve employee productivity (also known as "wrench time") in oil refinery maintenance environments through automated workforce management. It proposes a three-phased approach: 1) Optimized rostering (shift planning) to better respond to fluctuating demand. 2) Schedule optimization to ensure the right workers with the right skills and tools are assigned the right tasks. 3) Mobility to provide workers with up-to-date information in the field. These phases aim to increase wrench time from a typical 20% rate to 30% by addressing factors that reduce productivity like overstaffing, delays waiting for parts or permits, and unplanned changes that disrupt schedules. Higher wrench time can improve system performance,
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Refineries use planning models to guide operational decisions, but changing conditions require frequent model updates to ensure profitability. Aspen HYSYS simulation software helps planning models stay accurate by transferring calibrated process data. Its integration with Aspen PIMS planning software streamlines model updating through shared tools and easy data transfer, helping refineries optimize profits.
The Evolving Landscape of Semiconductor Manufacturing to Mitigate Yield Losse...yieldWerx Semiconductor
Semiconductor manufacturing, often described as a labyrinth of complex and multi-layered processes, is central to the production of integrated circuits. These circuits, already intricate, are becoming progressively more complex with each technological leap. This evolution intensifies the requirement for robust performance metrics, such as defect rate, semiconductor yield improvement, and cycle time. Through rigorous monitoring and analysis of these parameters, manufacturers can make significant enhancements to their performance, yielding a substantial impact on operational efficiency and profitability. This detailed exposition presents a comprehensive examination of yield modeling, dynamic capacity re-allocation mechanisms, yield competitiveness, and yield prediction models, offering invaluable insights for the semiconductor manufacturing industry.
Efficient and Effective CFD Design Flow for Internal Combustion EnginesReaction Design
1) Traditional IC engine CFD simulations use simplified chemistry models that are insufficient for designing new high-efficiency engine concepts where kinetics effects dominate.
2) Detailed chemical kinetics models have been developed through the Model Fuels Consortium but cannot be directly incorporated into CFD due to high computational cost.
3) Reaction Design's CFD software uses novel parallel chemistry solvers that dramatically reduce simulation times, allowing the use of detailed chemical kinetics models for predictive 3D engine simulations.
Apply model predictive control to reduce batch cycle time and increase consis...ARC Advisory Group
Model predictive control (MPC) can reduce batch cycle times and improve consistency for batch manufacturing processes. When applied to batch distillation at a pharmaceutical plant, Baxter was able to reduce the batch cycle time by 20% by using MPC instead of PID control. Other companies like BASF and Kaneka have also successfully applied MPC to batch reactors and seen benefits like reduced variability and increased capacity. While MPC requires more initial investment, the improvements in cycle time, quality, and consistency can significantly outweigh the additional costs for suitable applications.
Petro-SIM is an industry-leading process simulation software for hydrocarbon industries. It contains rigorous simulation models and an intuitive interface. The open platform architecture allows for integration with other technologies and team collaboration. Petro-SIM supports improved process modeling, optimization, and business transformation through its superior simulation capabilities and integration features.
This article presents the discrete event simulation developed with Northwestern University to optimize an injector production line. This article was presented at the recent Winter simulation Conference (held in December 2008)
Generalized capital investment planning of oil-refineries using MILP and sequ...optimizatiodirectdirect
Abstract
Performing capital investment planning (CIP) is traditionally done using linear (LP) or nonlinear (NLP) models whereby a gamut of scenarios are generated and manually searched to make expand and/or install decisions. Though mixed-integer nonlinear (MINLP) solvers have made significant advancements, they are often slow for industrial expenditure optimizations. We propose a more tractable approach using mixed-integer linear (MILP) model and input-output (Leontief) models whereby the nonlinearities are approximated to linearized operations, activities, or modes in large-scaled flowsheet problems. To model the different types of CIP's known as revamping, retrofitting, and repairing, we unify the modeling by combining planning balances with the scheduling concepts of sequence-dependent changeovers to represent the construction, commission, and correction stages explicitly. Similar applications can be applied to process design synthesis, asset allocation and utilization, and turnaround and inspection scheduling. Two motivating examples illustrate the modeling, and a retrofit example and an oil-refinery investment planning are highlighted.
ARTIFICIAL INTELLIGENCE AND COMPUTATIONAL FLUID DYNAMICS AbhishekPatil387
This document discusses the applications of artificial intelligence and computational fluid dynamics in the pharmaceutical industry. It begins with introducing AI and how it is being used for drug discovery through deep learning techniques. It then discusses various applications of AI in healthcare such as disease identification, personalized treatment, drug discovery/manufacturing, and clinical trial research. The document next discusses computational fluid dynamics and how it can be used to analyze and optimize unit operations in pharmaceutical industry like mixing, solids handling, separation, drying, and packaging. It concludes by stating that integrating CFD methods can improve processes and shorten product development cycles in pharmaceutical industry.
Each individual business with their own unique assets and supply chain optimizing their decisions according to their incentives, abilities and working culture. The latest developments in Planning (Petro) and AI use cases.
Petro-SIM is a purpose-built oil and gas process simulation software that combines process simulation capabilities with reservoir modeling and production system modeling to enable modeling of full field development and production over the life of a facility. It integrates leading thermodynamic models and provides unique capabilities for modeling changing conditions over time. Petro-SIM also allows for detailed hydrate and flow assurance modeling and prediction using its integrated Multiflash compositional modeling.
1. Modern pulp mills often rely on manual and time-consuming scheduling methods that lack optimization capabilities, resulting in unrealized economic potential.
2. Greycon has introduced PulpPlan, a new optimization-based scheduling system that uses mathematical modeling, nonlinear optimization, and scenario analysis to determine optimized production schedules for pulp mills in just a few seconds.
3. By coordinating all production areas, PulpPlan aims to maximize production according to demand while minimizing costs and rate changes, ensuring target stock levels and an even distribution of stock during shortages.
Episode 47 : CONCEPTUAL DESIGN OF CHEMICAL PROCESSES
Chemical process design is the application of chemical engineering knowledge (chemical, physical and/or biological transformations of raw materials) into products and economics in the conceiving a chemical process plant to profitably manufacture chemicals in a reliable and safe manner without unduly affecting adversely the environment and society
Chemical process plants are by nature large capital investment projects that
are expensive to build and operate
have very long life times and
manufacture specific chemicals
Chemical process plants must be designed well to avoid large financial losses over long periods of times due to inefficient processes/poor operations
SAJJAD KHUDHUR ABBAS
Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Revolutionizing The Downstream Supply ChainDavid Evans
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through the use of technology and innovative business models. It proposes a system with four components: 1) outsourcing distribution operations to eliminate large in-house logistics teams, 2) implementing a shared fleet model to improve vehicle utilization, 3) introducing dynamic scheduling and routing powered by advanced analytics to optimize operations, and 4) enabling dynamic slot booking and pricing to maximize profits. Adopting this holistic approach through an integrated technology solution can streamline operations, lower costs, and create value for oil companies and their partners.
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through the use of technology. It proposes a four component system: 1) outsourcing distribution operations, 2) using a shared fleet model, 3) implementing dynamic scheduling and routing, and 4) employing dynamic slot booking and pricing. This system aims to streamline operations, increase efficiency, optimize costs and provide benefits to oil companies, haulers, and customers through real-time data, automated processes and increased visibility and control of operations. Quantitative benefits observed by clients include up to 18% reduction in trips, 15% reduction in inventory, and 25% increase in deliveries handled by the same number of dispatchers.
This document discusses revolutionizing the downstream supply chain in the oil and gas industry through technology-based solutions. It proposes a four component system: 1) outsourcing distribution operations, 2) using a shared fleet model, 3) implementing dynamic scheduling and routing, and 4) enabling dynamic slot booking and pricing. This system aims to streamline operations, increase fleet utilization, optimize scheduling and pricing, and improve customer service and cost savings for oil companies, haulers, and customers. The system has the potential to reduce delivery costs by 15-18% and inventory levels by up to 15% while handling 25% more deliveries with the same staff.
A comparison of a novel robust decentralized control strategy and MPC for ind...ISA Interchange
This document summarizes a research article that compares a novel decentralized control strategy based on override control to a model predictive controller (MPC) for controlling an industrial high purity methanol distillation column. Both controllers were able to maintain tight product purity and high recovery specifications under disturbances. The MPC provided tighter control of product purity but used more energy, while the proposed override control provided tighter recovery control and had lower costs. An economic analysis showed the optimal choice depends on factors like energy costs.
APPLICATION OF LEAN PRACTICES FOR IDENTIFICATION OF SOLUTIONS IN REDUCING FUR...IRJET Journal
This document discusses applying lean practices to reduce furnace oil usage per cylinder at Kairali Structural Fabrications Private Limited (KSFPL). KSFPL manufactures LPG cylinders and uses furnace oil for stress relieving operations. The project aims to reduce oil consumption by ensuring consistent batch production of 1000 cylinders per day in the furnace. Currently, preheating the furnace for each operation uses a large amount of oil. Value stream mapping identified delays causing production of less than 1000 cylinders per day. 5Why analysis revealed delays were due to lack of cylinders and power cuts. Implementing lean tools like consistent production and value stream mapping can help achieve the target of 1000 cylinders per day and reduce furnace oil usage per cylinder
Get with the system - Rogerio Martins, Schneider Electric disucsses the advantages of modern distributed control systems in coal handling preparation plants.
Generalized capital investment planning of oil-refineries using CPLEX-MILP an...Alkis Vazacopoulos
Performing capital investment planning (CIP) is traditionally done using linear (LP) or nonlinear (NLP) models whereby a gamut of scenarios are generated and manually searched to make expand and/or install decisions. Though mixed-integer nonlinear (MINLP) solvers have made significant advancements, they are often slow for industrial expenditure optimizations. We propose a more tractable approach using mixed-integer linear (MILP) model and input-output (Leontief) models whereby the nonlinearities are approximated to linearized operations, activities, or modes in large-scaled flowsheet problems. To model the different types of CIP's known as revamping, retrofitting, and repairing, we unify the modeling by combining planning balances with the scheduling concepts of sequence-dependent changeovers to represent the construction, commission, and correction stages explicitly. Similar applications can be applied to process design synthesis, asset allocation and utilization, and turnaround and inspection scheduling. Two motivating examples illustrate the modeling, and a retrofit example and an oil-refinery investment planning are highlighted.
This document discusses strategies to improve employee productivity (also known as "wrench time") in oil refinery maintenance environments through automated workforce management. It proposes a three-phased approach: 1) Optimized rostering (shift planning) to better respond to fluctuating demand. 2) Schedule optimization to ensure the right workers with the right skills and tools are assigned the right tasks. 3) Mobility to provide workers with up-to-date information in the field. These phases aim to increase wrench time from a typical 20% rate to 30% by addressing factors that reduce productivity like overstaffing, delays waiting for parts or permits, and unplanned changes that disrupt schedules. Higher wrench time can improve system performance,
Similar to Article [Hydrocarbon Processing]- Refinery-wide Model in Aspen HYSYS (20)
Business paper: Employee Productivity in Oil Refineries
Article [Hydrocarbon Processing]- Refinery-wide Model in Aspen HYSYS
1. 10 Wednesday, March 16, 2016 American Fuel Petrochemical Manufacturers | 114th Annual Meeting
Improving profit margins with a
refinery-wide process model
SANDEEP MOHAN, AspenTech
Refinery-wide models can be used
to identify specific process areas for
profit improvement, offer alternative
improvement plans, and predict and
compare the impact of each alterna-
tive on refinery profits. A refinery-
wide modeling capability can evaluate
the impact of refinery expansions or
improvements, and determine opera-
tional responses to unexpected events.
Refiners can improve profit margins
in a challenging, competitive environ-
ment by ensuring that their planning
models are up-to-date using rigorous
process simulation software.
Profit margin analysis is a crucial
exercise for refineries, which typical-
ly run on low margins—often around
5% or less—and are heavily depen-
dent on fluctuating market conditions.
Changing market dynamics add to
complexity. Demand is shifting toward
lighter products, and the quality of oil
is changing to more sour and heavy
crudes. Environmental restrictions im-
pose tighter fuel specifications in many
locations. Processing is now more
challenging, expensive and complex.
Selecting crude oil slates that reach
profitability goals and meet final
product specifications is operationally
complicated, especially when refinery
complexity ranges from a simple top-
ping operation to a deep conversion
facility integrated with a petrochemi-
cal plant (FIG. 1).
The probability of sustained low
oil prices is forcing owner-operators
to adopt cost-cutting and performance
improvement programs that focus on
asset utilization, downtime reduction,
improved product quality and greater
yield. The goals are simple, but re-
fineries are not. The complexities of
refinery operations and configurations
make the decision-making process ex-
tremely difficult, especially given the
uncertainty and differences in feed
specifications, product demand and
economic objectives.
A new model for a refinery-wide
model. Cutting through complexity
and driving higher margins can be
achieved with a refinery-wide process
model. Process simulation tools have
helped refineries make the right deci-
sions and respond to operational is-
sues. However, the standard approach
to simulating processes will not deliv-
er the step change in performance that
refineries need going forward. What is
required is a complete and robust en-
gineering system that can optimize the
full plant, offer decision-support tools
for fast responses and calculate costs
to align with economic objectives.
Existing refinery-wide models can
be cumbersome and complex. A man-
ageable and easy-to-use solution that
facilitates faster and better decision-
making will allow refineries to quickly
identify specific process areas in need
of improvement, generate alternative
improvement plans and predict the
impact of each alternative on overall
profitability (FIG. 2). Aspen HYSYS
is a comprehensive process model-
ing tool used by the world’s leading
oil and gas producers, refineries and
engineering companies for refinery-
wide process simulation and process
optimization in design and operations.
Such refinery-wide models are
a mixture of short-cut and rigorous
sub-models, and they can eliminate
third-party maintenance expenses
and enable quick, accurate profit mar-
gin analysis.
Integrating planning and process sim-
ulation tools with a single flow sheet.
Simulating the entire refinery-wide
process in a single flow sheet enables
the evaluation of strategic options for
both current and reconfigured opera-
tions. Using the process simulation
model, planners and process engi-
neers can simplify updates of plan-
ning models, evaluate the economic
impact of operational improvements
and unexpected events, and suggest
remedial actions.
Varying refinery operating condi-
tions cause planning models to be-
come quickly outdated, making them
ineffective for optimal refinery opera-
tions. A rigorous and predictive pro-
cess simulation tool, can help keep the
planning model up-to-date, thereby
enabling refineries to make the most
profitable product slate out of the
most economical feedstock.
The first step in developing a refin-
ery-wide process model is to reproduce
the refinery-wide planning model. This
is enabled by a “short-cut petroleum
shift reactor model” within the process
simulator that is an exact replica of the
reactor representation used in the plan-
ning model. With an expanded com-
plete suite of rigorous reactor models
available in the process simulation en-
vironment—including fluid catalytic
cracking (FCC), hydrocracking and
delayed coking—the process engineer
can selectively upgrade sub-models to
rigorous models within a single pro-
cess simulation environment. This al-
lows refinery process engineers to eas-
ily manage and maintain the model,
while ensuring the rigor required for
accurate refinery margin analysis.
The calibration facility in process
simulation tools ensures that the re-
finery model simulated is an actual
reflection of current operating condi-
tions. Key parameters from the mod-
els can be transferred into the planning
tool. By sharing the same crude oil as-
say information, planning and process
simulation models are consistent and
contribute to better operational perfor-
mance. Crude distillation unit (CDU)
models in advanced process simulation
software can be calibrated to provide
configuration parameters for planning
model sloppy cuts to better match plant
performance. The integration of CDU
modeling in the planning and process
simulation tools significantly simpli-
fies the workflow used to update the
CDU portion of the planning model.
An integrated process simulation en-
vironment. A refinery-wide model
uses a hybrid approach of linear mod-
els for high-level performance analy-
sis, and fully rigorous crude distilla-
tion and reactor models for planning
update and engineering studies. The
refinery-wide model can be further
extended to include other rigorous
models, as necessary, to support vari-
ous business scenarios.
Integration is key. A “clone” of the
refinery model can be created, so a
simple refinery-wide process model
has the same level of sophistication
and accuracy as a planning model.
The rigor of the process model can
then be enhanced by selectively in-
serting rigorous models of sub-units
using graphical engineering flow-
sheet technology.
The refinery-wide process simula-
tion model, enabled by an integrated
process simulation environment, can
be used to predict the impact of capi-
tal projects, such as reconfigurations
planned to tailor the refinery to dif-
ferent crude and product mixes. It can
also be used to evaluate the economic
feasibility of operational improve-
ments, such as a change in the catalyst
for the FCC unit, or to determine the
right response to unexpected events,
such as breakdown of a key pump.
Mostimportantly,thiscapabilityini-
tiates a culture of true partnership be-
tween planners and process engineers,
building a system where planners
use refinery-wide planning models to
conduct rapid economic evaluations,
while process engineers use refinery-
wide process model to provide a more
accurate profit margin assessment on a
case-by-case basis. This collaborative
use enables a holistic view of plant op-
erations and supports flexible and agile
refining operation. •
FIG. 1. Reaching profitability goals, meeting final product specifications and complying
with tighter environmental restrictions are making processing more challenging,
expensive and complex.
FIG. 2. Refiners can improve profit
margins in a challenging, competitive
environment by ensuring that their
planning models are up-to-date using
rigorous process simulation software
like Aspen HYSYS.
Conference Daily Published by HYDROCARBON PROCESSING®
DAY THREE Wednesday | March 16, 2016
114th American Fuel
Petrochemical Manufacturers
ANNUAL MEETING