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ChemicalPlantPerformance:
ImprovementthroughQuantitative
Benchmarking
2010AIChE Regional
ProcessTechnologyConference,Galveston,TX
CurrentIssuesandOpportunitiesinRefining
LanyonCarr DavidGeddes
ProcessFrontier,Inc. PrepConsulting,Inc.
SanDiego,CA Denver,CO
Overview
Approach Features
New&uniqueapproachto Applicabletomultiinputmulti
performanceanalysis& outputsystemswithmultiple
improvement operatingparameters
Performanceanalysisand Shortimplementationperiod6to8
improvementofcomplexsystems weeks
Consistentapproachto Nomodelrequired onlyoperating
performanceimprovement data
Ranksperformanceofeach Sustainable nospecialist
operatingperiod maintenancerequired
QBMfindsGoldenBatch Basedonrealdata alwayscredible
operatingdays/periods=Best withOperations
Practice Rigorousmathematicalbasis
UseBestPracticeoperating Formulatedthewayplantis
informationtoimprovecurrent operated,i.e.qualities,production
operation targets,environmentaltargets,etc.
Approx.80%ofAPCbenefits
QBMistheabilitytomatchbestobservedoperations
2
BenchmarkingBasics
Aisacomparisonwiththebestpossible PerformancemeasuredefinedasOperational
operation(s)notaverage Efficiency(E)
Profitalonedoesnotcontainenough E=Outputs(production)/Inputs(resources)
informationtomakecomparisons I.e.returnoninputcosts,similartoROIorROA
Requiresthatentitiesoroperationsare Formulatedmathematicallyto:
reasonablysimilar Identifybestpracticeoperations
Currentapproachescomparessingleaspectsof Calculatesauniqueefficiencyforeach
operation,e.g.energy(Btu/bbl) operation
Degreeofsimilarityisnotclearoraddressedin Efficiencyaccountsforoperationalaspects:
conventionalbenchmarking
Plantratios
Comparisonsrequiresaratioofsorts,i.e.
normalization Constraints
Feedstockqualities
Physicaloperations,e.g.manualbypasses
Sumofoutputs(products,qualities,energy)
E=
Sumofinputs(energy,feedstocks,catalyst)
Effectivenessofhowresourcesareconvertedinto
products,i.e.minimumresourcestoachievegoals
Unitoperatinginstructionsaproxyforeconomic
performance derivativeproductofplanning E<70%
95>E=100%
70>E<80%
Profitisnotthefullstory,e.g.doesnotlocateareas
ofpoororoutstandingperformance 90>E<95%
80>E<90%
Otherperformanceratios ReturnonInvestment,
ReturnonAssets
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PerformanceMeasure Expanded
Theperformancemeasureisoperationalefficiencywhichis
definedastheweightedsumoftheoutputsdividedbythe
weightedsumoftheinputs:
Outputs products,
qualities,energy
(woi *Oi)
E=[EAlkylation =(wO1nC4+wO2RVP+wO3Octane)/wR1Energy]
(wIk *Ik) Inputsorresources
energy,catalysts,
feedstocks
Note:Thetargetsforunitoutputsandinputscomefromoperatinginstructions,whichareaproxyforthe
economicperformanceoftheunit operatinginstructionsareaderivativeproductfromplanning(LP)and
scheduling
Effectivenessofhowresourcesareconvertedinto
products,i.e.minimumresourcestoachievegoals
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QuantitativeBenchmarking
Features
Determinesoveralleffectivenessofallresources
Benchmarksarebasedonpastoperationoftheexactsameunit
AbilitytodealwithmultipleInputsandOutputssimultaneously
Inputs=resources,e.g.energy,feedstocks,catalysts,chemicals&additives,tec.
Outputs=products,productqualities,energyexports,environmentalproducts
Problemisformulatedinthewaytheplantisbeingoperated,i.e.operatorshaveto
controltheunittomeetcertainqualitytargets,productiontargetsforproducts,
environmentalconsiderations
Outputfromsystem
Calculatesauniquesinglenumberforoveralloperationthatcan becomparedto
otherpreviousoperations
ProvidetargetsforInputsandOutputstoimproveoverallperformance
ProvideeffectiveKPItargets
Directlyprovidetargetsforoperatingparameterstoimproveoverallperformance
Targetsareupdatedatleastoncepershift
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HFAlkyFlowDiagram
iC4Spec
RVPSpec setnC4inAlkylate
Octane setIsotoOlefinsMolarratio
IsotoOlefinsVolumeratio 8
AlkyProblemStatement
Parametersvariedduringsimulation SensitivityAnalysis
DeC3toIsostripperfeedratio Constantratios
Feedcompositions
Isostripperfeedheatexchanger
Isostrippermaximumcapacity
duty variedfeedrate
Isobutanerecycle Isostripperfeedheatexchanger
Isostrippersidereboilerduty duty
Isobutaneinnbutaneproduct
DeC3reboilerduty
nButaneinalkylateproduct
HFStripperfeedtoOverheadratio Isobutanetoolefinsmolarratio
Isobutanetoolefinsvolumeratio DeC3toIsostripperfeedratio
Cis2buteneinolefinsfeed
OperatingParameters
CausesofEfficiencychanges
IsobutanetoOlefinsratio(volume)
Operatingratios
nButanedrawrate Constraints
AlkylateRVP OperationalEffects
nC4%inalkylate TransportPhenomenologicaleffects
(HeatTransfer,Momentum
DeC3toIsostripperfeedratio Transfer,MassTransfer) not
Isostripperfeedheatexchanger simulated
duty
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QBMUsesProcessData
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ConstantRatios=ConstantEfficiency
ReducedFeedRate ReducedFeedRate corrected
CaseNumber BaseCase(40) (15) ratios(42.1) RatioedValues
OlefinsFeedrate 370.792 280.000 280.000
IsobutaneFeedrate 132.050 99.912 99.647 99.716
IsostripperHeatExchangerDuty MMBtu/hr 11.576 4.394 8.721 8.742
IsostripperReboiler MMBtu/hr 28.722 31.985 20.901 21.690
IsostripperSideReboiler MMBtu/hr 20.000 20.000 15.000 15.103
DeC3Reboiler MMBtu/hr 20.000 15.000 15.700 15.103
HFStripperReboiler MMBtu/hr 1.750 1.750 1.310 1.322
Propane Bbl/hr 78.706 59.774 58.880 59.434
nButane Bbl/hr 34.150 25.077 25.826 25.788
Alkylate Bbl/hr 318.563 241.109 240.577 240.560
AlkylateAPI DegAPI 72.600 72.617 72.600
D8650%Temp DefF 201.657 201.610 201.658
AlkylateRVP Psi 5.870 5.880 5.870
AlkylateOctane MON 88.585 89.378 88.585
IsoRecRatio Vol 4.471 5.711 4.355
IsoRecRatio Molar 5.970 8.073 5.974
OlefinsMolarRate lbmol/hr 693.329 523.561 523.561 523.561
IsobutaneMolarRate lbmol/hr 4139.451 4226.813 3127.889 3125.866
IsobutaneRecycle Bbl/hr 1525.851 1499.150 1119.822 1152.851
Iso/DeC3FeedRatio mol/mol 2.362 3.178 2.341
DeC3OH/Reflux mol/mol 1.220 1.219 1.206
IsoFeed/DeC3Bot mol/mol 2.910 3.917 2.894
HFFeed/OH mol/mol 2.523 2.069 2.522
Steam/Feed (MMBtu/hr)/Bbl 13.667 17.632 13.592
iC4innButane 5.000 5.000 4.780
nC4inAlkylate 5.000 5.000 4.220
OperationalEfficiency 0.979 0.811 0.990
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FeedCompositionChanges
Figure 1 Figure 2
Figure 3
Figure1
C3=aredetrimentaltoalkylateoctaneandalkylate
rate(producesmorepropane).QBMcorrectlypredicts
decreaseinefficiencywithanincreaseinpropene
Figure2
1butenesarebetter(notasgoodas2butenes)for
octaneandalkylaterate.QBMcorrectlypredictsan
increaseinefficiencywithanincreasein1butenes
Figure3
2butenesarethebestfeedstockforoctaneand
alkylaterate.QBMcorrectlypredictsanincreasein
efficiencywithanincreasein1butenes
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IsostripperMaxConstraint
Efficiencygoesthrougha
maximumasenergycostis
E
reducedandalkylateproduct
rateisincreasedbutoctane
additiondecreases
OlefinsFeedRatebbl/hr
OlefinsFeedRatebbl/hr
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EfficiencySensitivities
0.7% innC4
fora1% inE
4.5% iniC4
fora1% inE
0.5MMBtu/hr in
0.4 inIsoMolar Dutyfora1% inE
Ratiofora1% inE
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RankEfficiencies
findsEfficient
benchmark
operatingpoints
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IdentifyBenchmarks
thatdetermine
thebestoperation
frontier
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SelectBenchmarks
whichisusedtocalculate
operationimprovement
moves
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Improvecase10Operation
maxefficiency
casesnoted
lookatimproving
case10operation
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Newvaluesfor10.5inputvariables
calculatedusingbenchmarkvalues(ingrey)andweights
therestofthe10.5valuescomefromtheprocess
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Improvecase10.5Operation
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Movefrom10.5to10.7
Newvaluesfor10.7inputvariables
calculatedusingbenchmarkvalues(ingrey)andweights
therestofthe10.7valuescomefromtheprocess
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PerformanceImprovement
Benchmark
Frontier
Improvement
inoperation
Benchmarks
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DashboardDisplay
Current
operation
Components
forEfficiency
Setpointsfor
controllers
Operating
Parameters
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Sequence
Quantitativerankingofhistoricaloperationsand
identificationofBestPracticeoperations
Indentifythebenchmarkedoperations(Operational
Efficiency=1)
DeterminehowwellamIoperatingcomparedtowhere
Ishouldbeoperating
AssociateeachinefficientoperationwithasetofBest
Practice operationsthataremostsimilartocurrent
operation shortestpathtoefficientoperation
UseofBestPracticeoperationstocalculatethe
operatingtargetstomakethecurrentoperation
Efficient
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PerformanceImprovementTechniques
APC Optimization Benchmarking QBM
Planttesttodevelop Significanttimeand KPIsarestatic DynamicKPIsor
model costtodevelop Nomethodologyto Targets
Modelmaintenance solution improveKPIs Targetsforoperating
Nodirectinformation Modelmaintenance Difficulttomake parameters
wrtKPIs Requiresexperienced senseofmultiple ConsidersallKPIs
Requiresexperienced optimizationengineer KPIs simultaneously
controlengineer Closedloop IndividualKPIs Targetsupdatedat
Closedloop Identifiesnew cannotdetermineif leastoncepershift
Identifiesnew significantoperating operationisefficient Structuredintheway
operatingregions regions Notspecifictothe theplantisbeing
unitbeingoperated operated
BenchmarksandKPI Solutionoperating
targetsareupdated regionfamiliarto
infrequently operators
ProcessEngineeruses
andmaintainsthe
system
Benefitslimitedto
thebestpast
operation
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ProfitImprovement
P3
P3 > P2 > P1
P2
P1
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Benefits
Areas Mechanisms
Reduceenergyconsumptionandcosts Energytargetistheminimumeffectiveenergyuse,
Increaseproductrevenues minimizestheresourcetomakethespecified
Adherencetoqualitiesspecifications outputs.Switchdrivesfromsteamtoelectricity.
Reducefeedstockcosts Maximizeproductratesconsistentforagivensetof
inputs
Reduceenvironmentalimpactorcosts
Qualitiesareanoutputfromtheprocess,deviations
Reducecatalystuse fromthequalities(positiveornegative)detract
Reducechemicals&additives fromtheoutputs.
Aswithenergy,QBMminimizestheamountof
resourcestoproducetheoutputs
Environmentalproductsareconsideredproducts
withanegativevalueandthusreducesthetotal
output.Assuchthecontributionfromthe
environmentalproduct(s)areminimized
Catalysts,chemicalsandadditivesareallconsidered
resourcesorinputstotheprocess.AssuchQBM
minimizestheamountofresourcestoproducethe
outputs
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ThankYou
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