Maximize Your Energy Savings

Using Energy Analysis within

Aspen Plus and Aspen HYSYS
aspenONE Engineering V8.6

Jack Zhang,
Product
Management
Presenter
Name,
Presenter
Title Katherine Hird, Product Marketing

August 26, 2014

2014 Aspen Technology, Inc. All rights reserved

August 26, 2014

Before we begin

2014 Aspen Technology, Inc. All rights reserved

Ongoing Series of Technical Webinars

Engineering webinars for education and best practices

UPCOMING WEBINARS OF INTEREST:

Create World-Class Designs with aspenONE Engineering Desktop for Small & Medium
Businesses September 4th

RECENT (On-Demand) WEBINARS:

V8.6 Launch

Ensure Safe Operations with Relief Sizing in Aspen Plus and Aspen HYSYS June 2014

See Whats New in Safety Analysis, Economics, Dynamics, Solids Modeling, and MoreJune 2014

Analyze and Troubleshoot Compressor Systems Easily with Activated Dynamics in

Aspen HYSYS V8.6 (Technical) June 2014

Energy Analysis

Reduce Energy Expenditures using Activated Energy Analysis in Aspen HYSYS and
Aspen Plus January 2014

2014 Aspen Technology, Inc. All rights reserved

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary & Supporting Materials
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

Introduction

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Energy Costs are Significant

Typical Refinery
Operating Costs

Typical Olefins Plant

Operating Costs

Energy Costs
40 45%

Energy Costs
50 60%

Refinery energy costs: $75 -140M p.a.

Chemicals energy costs: $75 -125M p.a.

Global spend on energy: $60 110B p.a.

Global spend on energy: $20B p.a.

Note: Feedstock costs are excluded

2014 Aspen Technology, Inc. All rights reserved

Energy Management Life Cycle Activities

Invest
Capital

Aspen Plus/Aspen HYSYS

Design

Activated Energy Analysis

Aspen Energy Analyzer

Aspen PIMS/Platinum

Revamps,
Aspenre-designs
Petroleum Scheduler
&
Aspenmodels
Utilities Planner
to
continuously
Aspen
Plus/Aspen
HYSYS
increase
energy
Aspen
InfoPlus 21
efficiency

Planning &
Scheduling

Run Existing
Plant as
Efficiently as
Possible

Energy
Performance
Management

Aspen Role Based Visualization

Aspen Utilities Online Optimizer

Advanced Process
Control

2014 Aspen Technology, Inc. All rights reserved

Aspen APC
Aspen Utilities Online Optimizer

Address Challenges Faced in the Energy Analysis Process

Economical and

Maximum scope

practical solutions

to reduce energy

to save energy

Activated analysis is the

solution
Verify the solutions

Solve the

inexpensively

problems quickly
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Activated Energy Analysis in Simulators

Energy usage has
Identify energy saving potentials
reduced significantly

Add two new

Identify potential
changes to the
exchangers
flowsheet to save energy

2014 Aspen Technology, Inc. All rights reserved

Activated Energy Analysis in aspenONE

Combining both

Aspen
Simulators

Aspen Energy
Analyzer

Activated Energy Analysis

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10

Activated Energy Analysis in aspenONE

Activated Energy Analysis available in both

Aspen Plus

Aspen HYSYS
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11

Activated Energy Analysis in aspenONE

Activated Energy Analysis Integration Benefits

User does
not have to
leave
modeling
environment

Optimization
solutions
are
generated
fast

2014 Aspen Technology, Inc. All rights reserved

Integration
simplifies
workflow

12

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary & Supporting Materials
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

13

Activated Energy Analysis Workflow

Inside Aspen Plus and Aspen HYSYS

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14

Overview of Energy Analysis Workflow

1

Prepare
process
flowsheet

Estimate
energy
saving
potentials

Evaluate
process
changes

Design
the
network
Verify the

energy
savings

Develop material and heat balance in Aspen Plus and HYSYS

Define and assign utilities to the processes

Define heat recovery temperature approach

Select the process scopes to analyze
Calculate energy target
Evaluate actual energy consumption vs. target consumption

Examine the key operating parameters in the process

Optimize operating parameters to maximize energy saving potentials
Verify the changes with simulation/fields

Generate ideas of changes with constraints (e.g. Column heat

integration, feed preheating, etc.)
Screen the most promising options

Modify the process based on the suggested improvements

Size the heat exchangers (with Activated Exchanger Design and
Rating)
Estimate the capital cost of new equipment (with Activated Economics)
Select the projects based on economics paybacks

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15

Step 1: Prepare a Flowsheet for Energy

Analysis
Model the process in Aspen Plus and Aspen HYSYS
DO NOT model utilities as material streams if the utilities
consumption is meant to be optimized
Example 1: Minimize cooling water usage?

Example 2: Quenching water not optimized

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16

Step 2: Estimate Energy Saving Potentials

Evaluate potential utilities to reduce cost
In Aspen Plus

In Aspen HYSYS

Define a new utility but do not

assign it to any process
Current usage is zero but suggest to use
it with 9.11 MMBtu/hr target duty

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17

Steps 3: Optimize Key Process Parameters

to Maximize Energy Saving Opportunities
Set up sensitivity analysis in process simulation
Implement the changes in process simulation

Create multiple energy analysis projects in Energy Analysis

environment
Compare energy saving potentials between multiple projects
Select the project with maximum energy saving potentials to
design the network

Extensive interaction between simulation and energy analysis tools

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18

Steps 4: Generate Ideas for Network Design

Three design options
Modify Exchangers: Add surface areas to existing heat
exchangers
Add Exchanger: Add new heat exchangers sequentially
Relocate Exchanger: Relocate existing heat exchangers
sequentially

User may apply the above changes in combination

As an example:
Add a HX

Add 2nd HX

Relocate a HX

DO NOT need to modify the process flowsheet

Tune the designs to respect the process constraints

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19

Step 5: Verify the Energy Savings

Implement most promising changes in process simulations
Design the modified/new heat exchangers with rigorous
heat exchanger model
Activated Exchanger Design & Rating in simulation

Estimate the extra capital cost required for the changes

Activated Economics in process simulation

Estimate the impact of changes on operability and

controllability of the plant
Activated Dynamics in process simulation

Select the most economical and practical projects

2014 Aspen Technology, Inc. All rights reserved

20

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary & Supporting Materials
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

21

Demonstration
with Aspen HYSYS V8.6

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22

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

23

S-Oil Corporation

Improve Energy Efficiency Without Cutting Production

Business Challenge & Objective
Achieve maximum energy efficiency through reduction
in the Solomon Energy Intensity Index, while
maintaining production increases.
Solution Overview
S-Oil was able to use Aspen HYSYS and Aspen
Energy Analyzer in order to model its refining
process and identify and implement process
revamp ideas to its refinery.

Results & Benefits

S-Oil was able to save $39 million in its refinery
with a payback period less than 1 year, reduce
energy consumption by 102 MW, and increase
energy efficiency while lowering its Solomon
Energy Intensity Index

2014 Aspen Technology, Inc. All rights reserved

24

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary & Supporting Materials
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

25

Summary
Activated energy analysis combines the power of process
modeling with Aspen Energy Analyzer
Scope energy saving opportunities
Screen potential process changes to maximize energy
efficiency
Reduce energy consumption in the most economical ways
Significantly improve engineering productivity

Activated energy analysis facilitates the best practice of

energy analysis work process
Work side-by-side with other AspenTechs technologies

Activated energy analysis is able to help user to

Reduce energy consumption by 10-30%
Increase throughput by 10% when energy is the bottleneck
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26

Supporting Materials
Jump Start Guides
Activated Energy Analysis in Aspen Plus and Aspen HYSYS

Demo cases in Aspen Plus and Aspen HYSYS

Ethylene
Crude Preheat Train
Natural Gas Plant Model

Viewlets for advanced topics

Model reactor in Aspen Plus for energy analysis
Prepare a flowsheet with pseudostreams to avoid duplication
Best practice to model crude preheat train in HYSYS for energy
analysis
Etc.
2014 Aspen Technology, Inc. All rights reserved

27

Agenda
Introduction
Activated Energy Analysis
Workflow

Demonstration
Measuring Success
Summary & Supporting Materials
Questions and Answers

2014 Aspen Technology, Inc. All rights reserved

28

Q&A

Jack Zhang
Jack.Zhang@AspenTech.com
Katherine Hird
Katherine.Hird@AspenTech.com

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