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Thai Oil Refinery-wide Optimization Vision & Utilities Optimization Case Study. Session ID #: PBSS214 Presented by: Chanchana Payungwong, Thai Oil Group 11/9/11. Agenda Today. Introduction to TOP group Introduction to Real Time Optimization Best Practices for Refinery Optimization

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thai oil refinery wide optimization vision utilities optimization case study

Thai Oil Refinery-wide Optimization Vision & Utilities Optimization Case Study

Session ID #: PBSS214

Presented by:

Chanchana Payungwong, Thai Oil Group

11/9/11

agenda today
Agenda Today
  • Introduction to TOP group
  • Introduction to Real Time Optimization
  • Best Practices for Refinery Optimization
  • Overview Thai Oil Refinery-Wide Optimization System
  • Thai Oil Utility Optimization Case Study
      • Objective
      • Project team execution
      • Work Scope
      • Optimized and Constraint Variables
      • System Configuration
      • Implementation Result & Current Performance
      • Conclusion and Next Step
introduction to top who are we
Introduction to TOP – Who are we?

Oil Refinery

Petrochemical &

Lube Base

Power Generation

Transportation & Others

J-Power 19%

PTT 26%

100%

100%

100%

55%

100%

Thaioil Ethanol (TET)

Thai Oil(TOP)

Thai Paraxylene(TPX)

Thai Lube Base(TLB)

Thaioil Power(TP)

Thaioil Marine(TM)

Aromatics

Capacity:

PX 489 KTA

MX 90 KTA

BZ 177 KTA

TL 144 KTA

TOTAL 900 KTA

Lube Base Oil

Capacity:Base Oil 270 KTA

Bitumen 400 KTA

Oil & Chemical TankersCapacity: 152,500 DWT

Sells Electricity & steam to Group

Capacity: 275 KBD

Mitr Phol

Group 35%

Padaeng

35%

30%

Others 60%

Small Power Producer

(SPP) Program3-on-1 Combined Cycle

Electricity 118 MW

Steam 168 ton/hour

9%

PTT 31%

Maesod Clean Energy (MCE)

56%

Thappline(THAP)

Sugarcane Based EthanolCapacity: 200,000 lit/day

PTT 20%

100%

TOP 24%

Multi-product pipelineTotal Capacity:26,000 million lit/year

50%

Saptip

(SAP)

Independent Power (Thailand )(IPT)

Thaioil Solvent via TOP Solvent (TS)

100%

Cassava Based EthanolCapacity: 200,000 lit/day

Solvent distribution

In Thailand

1st IPP Program2-on-1 Gas-Fired,Combined Cycle

Electricity 700 MW

20%

80.52%

100%

TOP Solvent Vietnam

SakChaisidhi (SAKC)

PTT Group 80%

100%

PTT ICT Solutions(PTT ICT)

Capacity:

100,000 lit/year

Solvent distribution

In Vietnam

Thaioil Energy Service (TES)

Core Business

Value Enhancement

Earning Stability

Marketing / IT Support

introduction to real time optimization
Introduction to Real Time Optimization
  • RTO
  • Real-Time Optimization
  • ROMeo
  • Rigorous Online Modeling and Equation-Based Optimization
time and scope of comparison
Time and Scope of Comparison

Feedstock Selection

Product Demand/Supply

Operating Targets

Scope

Planning/

Scheduling

Operations

Optimization

Site

Pricing

Online

Optimization

Targets

Plant/

Unit

Plant Operation

Plant Interaction

Advanced

Control

Set Points

Control

Loops

Equipment Operation

Equipment Interaction

Days

Minutes

Hours

Time

best practices for refinery optimization
Best Practices for Refinery Optimization

APC

Optimum point

Max yield

Min energy

Quality

Temperature

Quality

APC

Pressure

RTO

!!

CDU

HVU

Control temp, pressure, flow

Without APC

With APC

With APC&RTO

SPEC./ Energy

SPEC./ Energy

SPEC./ Energy

Time

Time

Time

overview thai oil refinery wide optimization system
Overview Thai Oil Refinery-Wide Optimization System

Scheduler and LP Planner

RTO Status

Done

Refinery-Wide Offline Model (RWOM)

On-going

RTO Optimization

Naphtha Splitter, CCR1,2, MXU, Isomerazation

Plan

SPIRAL Assay Data base

Crude

RTO Optimization TPX

RTO Optimization CDU3/HVU3

CDU2/HVU2

CDU1/HVU1

RTO Optimization TLB (VDU)

RTO Optimization Utility

RTO Optimization FCCU

RTO Optimization H2 Balance

RTO Optimization HCU1

RTO Optimization HCU2

thai oil utility optimization case study
Thai Oil Utility Optimization Case Study

Project award in end of Y2009

Kick-off meeting in mid of Jan 2010

Project Time frame:

  • Kick-off until FAT = 5 months
  • Open loop commission = 2 months
  • SAT = peak and off-peak period

Optimization period = 0.5 hour

% Convergence Y2011 = 86.4%

utility optimization objective
Utility Optimization Objective

Online optimization

  • Maximize utility plant profit by optimizing fuel cost (Fuel gas, Fuel oil, Natural gas) for power consumption/export and satisfy steam requirements respecting all plant operation and contact constraints
  • Utility plant profit = Power export value – Fuel cost - Contract penalty

Offline optimization

  • Utility Optimization Model for off-line study on start-up/shutdown GTG, STG, pump/motor turbine switch, utility operation changes
utility optimization solution of change
Utility Optimization – Solution of change

Real-time optimization opportunity for utility plant includes:

  • Boiler and generators start up/shutdown frequently
  • Motor/turbine pumps and compressors switch
  • Electricity export change during peak and off-peak period and difference in weekdays, weekends and special period
  • Penalty if not satisfied electricity export contact
  • Fuel price difference
  • Disturbance from weather, process demand e.g. steam sootblow
project team execution
Project Team Execution

Project Manager

Project Manager

Project Coordinator

Lead Engineer

Lead Engineer

Application Engineer

Operator

Process Technologist

PI/RTO System APC/Base Layer

utility optimization work scope
Steam System

HHP Steam Header and Distribution

2 HHP Boilers & 4 HHP WHR Boilers

HP Steam Header and Distribution

3 HP Boilers

MP Steam Header and Distribution

LP Steam Header and Distribution

Motor/Steam Turbine changeable pumps and compressors

Steam letdown

Condensate recovery system

Power System

Electricity distribution

4 Gas turbines

8 Steam turbines

2 Diesel engine generators

Fuel System

Natural gas

Fuel gas

Fuel oil

Boiler Feed Water System

Utility Optimization Work Scope
optimized and constraint variables
Optimized and Constraint Variables
  • Utility Optimization Variables
  • Gas turbine generator power production
  • Steam turbine generator power production
  • Fuel oil, Fuel gas consumption
  • Utility Optimization Constraints
  • Electricity export
  • Boiler steam production
  • GTG and STG steam production
  • Steam letdown each step
  • Operation constraints
utility optimizer execution sequence
Utility Optimizer Execution Sequence

Optimized Set Points

implemented by Operators

  • Operator
  • Plant
utility optimizer system configuration

Database

Steady = 1

Utility Optimizer System Configuration

Operator Graphic User Interface

PI Historian

Read statusflags

Read key rawMeasurements

Read hourly avg.Measurements

WriteResults

Steady StateDetect (1 min)

MSAC

(4 min)

ModelSequence

Run

Write

Read

implementation result
Implementation Result
  • Optimization benefits are results of the followings
      • Minimize boiler fuel oil and increase fuel gas to generate steam due to higher fuel oil price
      • Optimize steam boiler production in order to minimize overall fuel cost
      • Increase GTG power production and WHR steam generation because of lowest natural gas price and reduce STG power production to maintain steam and power balance
      • Optimize GTG power production in order to minimize overall cost
current performance
Current Performance
  • Y2011, utility optimization system runs average 39.6 times per day
  • % Convergence of utility optimization is average 86.4 % in Y2011
conclusion and next step
Conclusion and Next Step
  • Conclusion
  • Utility advisory optimization system successfully helps maximize utility production profit at real-time
  • Utility optimization model is used for rigorous off-line study before making decision on operation change
  • Next Step
  • Study to implement closed loop real time optimization to fully capture on-line optimization benefits
thai oil refinery wide optimization vision utilities optimization case study1

Thai Oil Refinery-wide Optimization Vision & Utilities Optimization Case Study

THANK YOU

By: Chanchana Payungwong

Contact: chanchana@thaioilgroup.com