Systems Optimisation Background and Benefits

1. Systems Optimisation Background and Benefits

2. Introduction Increasing complexity Increasing control Greater efficiency • Energy Management • Generally static • Based on historical data • Control Systems • Real time control of processes • Processes track to a collection of set points • Run the process within certain limits • Systems Optimisation • Use real time data • Adjust system wide set points to optimise profits • Take into account external factors • Whole of system focus – optimise across whole system not just individual process

3. What is System Optimisation? • Optimiser uses historical data and predictive algorithms to optimise performance • Information sent back to process via control system • Controller provides process information to optimiser • Optimised instructions sent back to process • Information from process sent to control system • Optimised instructions sent back to process

4. Offline open loop systems optimisation Closed loop real time systems optimisation Online open loop systems optimisation Worsley Alumina (multi-variable control) AngloGold Ashanti (single-variable control) Simplot Australia (energy metering and energy performance indicators) Simplot Australia (variable head pressure control of refrigeration plant) Increasing automation What is System Optimisation?

5. Costs and Benefits POSSIBLE COSTS • Engineering • New instrumentation • New controls equipment • Training • BENEFITS • Increased throughput (3% to 5%) • Increased energy efficiency (3% to 5%) • Decreased energy costs • Increased product quality (10 to 20%) • Decreased operator input • Payback periods of 6 months to 4 years

6. Australian Case Study - Simplot • Background • Food company in Devonport, Tasmania • Produce frozen vegetables • Time critical process • No energy sub-metering • Motivation • Improved energy management – cost increases • Reduce energy intensity by 25% • Benefits • Reduced energy intensity by 20% • Reduced energy costs • Reduced partial loading of compressors • Greater process resilience

7. Australian Case Study – AngloGold Ashanti • Background • Sunrise Dam Gold Mine • Operating since 1995 • Typical Carbon-in-leach process • Motivation • Optimise throughput • Eliminate causes of downtime • How Systems Optimisation was implemented • Took stock of existing control systems • Prioritised causes of downtime • Identified control improvements • Trained operators • Monitored results

8. Australian Case Study – AngloGold Ashanti • Benefits • Fewer maintenance events • Increased throughput • Improved energy efficiency • Reduced Unit Costs • Next Steps • Processing plant optimised • Look at upstream processes next

9. Australian Case Study – Worsley Alumina • Background • Refinery opened in 1984 • Upgrades started in 2004 • Motivation • Improve profitability • Automate operator knowledge

10. Australian Case Study – Worsley Alumina • How Systems Optimisation was implemented • Mandate from Senior Management • Front end study • Implementation of Multi-variable control • Continuous measurement of results

11. Australian Case Study – Worsley Alumina • Benefits • More accurate control, less operator intervention • Optimised set-points = improved profitability • Reduced maintenance costs • Improved reliability

12. Australian lessons learned • Make the most of what you have before you invest • Prepare a persuasive business case – whole of business costs and benefits • Undertake a staged implementation process • Ensure you have access to the required skills • Manage the learning process • Maintain operator proficiency

13. Key Industries • Overseas industries that have benefited: • Large commercial buildings • Power generation • Cement manufacture • Petrochemical • Steel making • Australian industries that could benefit: • Food processing • Minerals processing • Transport • Commercial buildings

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15. SpentLiquor Temperature Variation Before & After MVC.

16. Operator moves for 3 different processes before and after MVC.

17. Levels of Process Control Systems Optimisation (multiple process units)

19. Discussion – Systems Optimisation • Do you think your corporation currently optimises its existing energy management tools? • Do you think there are aspects of systems optimisation that could be explored by your corporation?