09 - Improve Energy Performance Using AspenONE Energy Management Solutions - Nattapol

Improve Energy Performance using
aspenONE Energy Management Solutions

India Engineering Solution Seminar
Date: February, 2016
Presented by: Nattapol A., APAC ENG Business Consultant
Agenda
Energy Challenges on Energy Management
AspenTech Solutions for Energy Management

Pinch Analysis Solution: Activated Energy Analysis
Utilities Optimization Solution: Aspen Utilities

Heat Exchanger Fouling Analysis Solution: Aspen Exchanger Design & Rating
2015 Aspen Technology, Inc. All rights reserved
Industry Challenges on Energy Managment

Most industrial processes consume energy
Many emit greenhouse gases
Inefficiencies in energy demand and supply

Often more energy supplied than needed
Energy supply costs plants millions of dollars annually

Greenhouse gases disposal, as well
Optimization corrects inefficiencies

Reducing energy inefficiencies saves companies money
AspenTech Energy Management Approach

Manufacturing Site
Public Utilities/Grid
Power
Fuel
Utilities
A Holistic Approach to
Energy Management
Address both Supply
& Demand sides.
Improve Design and
Optimize Processes & the
Utilities System.
Sustain the gains.
Enable continuous
improvement.
Production
Reduce Supply Costs
Reduce Energy Demand
Improve
Utilities Design
Improve
Process Design
Optimize
Utilities Operations
Optimize
Process Operations
Define An Optimal Strategy

to Achieve Corporate Energy Goals
AspenTechs Integrated Energy Management View
Utilities
Design
Operate
Design Utilities to
maximize
efficiency
Operate Utilities
to deliver at the
lowest cost
Supply
Utilities/Supply Provide at lowest cost
Process
Design the
process to use
less energy & be
more efficient
Sustain the
process at
lowest energy
cost
Process/Demand Use less energy

5
Demand
Pinch Analysis Solution:

Activated Energy Analysis
Challenges with Process Energy Analysis

1. Identify Saving
Potentials
2. Select Optimal
Utilities
3. Generate and
Evaluate Designs
4. Maximize
Energy and GHG
Savings
1st Challenge: Identify Saving Potentials

1. Identify Saving
Potentials
Utilize Activated Energy Analysis to view target

energy and GHG consumptions
2nd Challenge: Select Optimal Utilities

2. Select Optimal
Utilities
The target column shows the optimal

process usage scheme for both:
Process Utilities
Carbon Emissions
9
3rd Challenge: Generate and Evaluate Designs

Rapidly generate revamp scenarios and their energy
savings for process with the possible options to:
Modify existing
exchangers
Add exchangers
Relocate
exchangers
3. Generate and
Evaluate Designs
10
4th Challenge: Maximize Energy Savings

Visualize utility reduction for
revamp scenarios
Compare revamp scenarios
4. Maximize
Energy and GHG
Savings
11
Addressing Challenges with Process Energy Analysis

1. Identify Saving
Potentials
2. Select Optimal
Utilities
3. Generate and
Evaluate Designs
4. Maximize
Energy and GHG
Savings
12
Activated Energy Analysis

Combining the rigorous pinch technology of
Aspen Energy Analyzer within the simulation
Activated Energy Analysis,

introduced in Version 8 of
both Aspen Plus and
Aspen HYSYS, is formed
13
WINNER: Best Energy Management Technology

Asian Manufacturing Awards 2013
As the largest consumer of energy, the industrial sector is keenly focused on energy
efficiency and energy consumption. The Best Energy Management Technology Award went
to AspenTech in recognition of proven offerings to the process industries. Software
solutions such as Aspen Plus and Aspen Energy Analyzer allow owners of large, complex
facilities to realize significant savings that are a foundation for sustainable operations.
Bob Gill, Edititor-in-Chief, Control Engineering Asia
14
CASE STUDY: SCG Chemicals

Achieve Optimal Energy Savings with Activated Energy Analysis within
Aspen HYSYS
Business Challenge
Business&Challenge
Objective& Objective
Results & Benefits
SCG Chemicals looked to improve their existing work

by investigating a novel, or new process.
Further, SCG Chemicals looked for a way to design
and optimize this new process.
Solution Overview Solution Overview
To build this novel process, SCG Chemicals utilized

Aspen HYSYS V8.4 to simulate the first pass of this
process.
SCG Chemicals then utilized Activated Energy Analysis

within Aspen HYSYS V8.4 to optimize their process, and
then further investigate this analysis with Aspen Energy
Analyzer.
15
Results & Benefits
The package of Activated Energy Analysis in Aspen HYSYS V8.4 is a

powerful tool to:
Guide solutions for energy savings
Evaluate payback period
Process optimization and heat integration optimization led steam optimization
Steam usage reduction of 24%
Saving consumption of steam (24.1 USD/T-feed)
Debit production of steam (17.2 USD/T-feed)
CASE STUDY: Korea Energy Management Corporation

Achieve Energy Efficiency Using aspenONE
Business Challenge
Business&Challenge
Results & Benefits
Korea has a long term target for energy efficiency, and has
implemented different energy efficiency policies to help
achieve these goals, including Energy Audit Programs.
Korea Energy Management Corporation (KEMCO) performs
energy audits on companies and must have an effective way
to reduce energy costs and GHG emissions.
For this case of optimization for Naptha Hydro Treating in BTX process,
KEMCO made process changes and was able to reduce
Energy Consumption by 1.9 Mcal/hr
Energy Cost by 1.3 M$/yr
With a 2 year payback period for the investment required for the
process changes
For their optimization workflow, KEMCO utilizes the

aspenONE engineering suite, including Aspen HYSYS, Aspen
Energy Analyzer, Aspen EDR, and ACCE
In this case, KEMCO specifically looked at the optimization

for Naptha Hydro Treating (NHT) in a BTX process to
optimize process energy
16
Results & Benefits
CASE STUDY: Cheil Industries Inc.

Save Energy in a Refinery Utilizing aspenONE
Business Challenge
Business&Challenge
Results & Benefits
Cheil Industries Inc. (CII) is a subset of Samsung

Group. In their Construction & Engineering department
they are concerned with energy management and
consulting services.
For this case study they looked to optimize a CFU

process of A Refinery in R.O.Korea for: energy
efficiency and CO2 reductions, lowest cost, and
highest productivity
Utilized a variety of products in the aspenONE

Engineering suite to reconstruct a HEN network
Aspen HYSYS
Aspen Energy Analyzer
Aspen EDR (i.e. Aspen Shell and tube Exchanger
17
Results & Benefits
Utilizing multiple products: Aspen HYSYS, Aspen Energy Analyzer,

and Aspen EDR, all within the aspenONE suite, enabled
improvements to the HEN reconstruction. Using these three solutions
together, the project was able to:
Provide possible energy
savings of 6 Gcal/hr
Reduce CO2 emissions
Reduce operating cost
Increase productivity
Utilities Optimization Solution:

Aspen Utilities
18
Incorporating Energy Management into site planning and

scheduling
Operations planning (monthly/weekly) and scheduling
(daily) have a big impact on overall energy use
Energy rarely modelled accurately in the planning and
scheduling tools
Big energy savings are possible by better planning and
scheduling.
Needs to consider both Process production and Utilities
operations
19
Utilities Production Planning and Scheduling

Target to reduce the $/kJ
Import / Export
Contracts
Utilities System
Operation
Optimize make vs. buy

of electricity
Optimise Switching
Drives in Process Units
Use best mix of fuels
Negotiate better
contracts
20
Choose most efficient operation

Energy/utilities consumption planning
Eliminate flaring
Optimise loads on power plant
Reliable nomination
Exploit contract limits
Reduce steam venting
Investment Analysis
Utility System Operation Challenges

Which boilers should I use and at what load
should I run these boilers?
What fuels should I use and how much should I purchase what contract?
How much electricity should I purchase, how much could I sell and at what price?
At what load should I run the GTG?
PROCESS
UNIT B
PROCESS
UNIT A
How much steam do I need to provide

today, tomorrow, next week? How does
Actual compare to Plan?
How is my equipment performing? When should I shut

down for maintenance?
What drives should I use for the

BFW pump?
Is it economic to run my steam

turbine generator?
PROCESS
UNIT E
PROCESS
UNIT C
PROCESS
UNIT F
What is the lowest

operating cost to reliably provide the
Utilities to the Processes
UTILITIES SUPPLY
21
PROCESS
UNIT D
PROCESS
UNIT G
UTILITIES DEMAND
Planning of Energy and Utilities (Off-line)

Using Aspen Utility Planner
Demand Forecasting
(integrated with Planning
tools, LP)
Utilities Production Planning

(Boiler Load Allocation,
Choice of Fuels, Choice of
Drives, etc.)
Import/Export Nominations
Utilities
Planner
Editors
Business Processes: Daily, Weekly,

Monthly, Annual:
Equipment
Availability
(Multi Period)
Contract Models
Time-dependant
Cost Information
Define Utilities Planning Scenario
Utilities Planner
(rigorous Model)
Model-based optimization of the

utilities system
(multi-period & multi-site)
Utilities Demand
(Multi Period)
Optimize
Budgets
Investment Planning
Tariff Evaluation
22
Excel-based GUI
(with Add-In)
Emissions Prediction
Show results for the specific Scenario
Forward Planning of Energy/Utilities with Aspen Utilities

Aspen Utilities Planner
Data Input
Data Entry
through
standard
Aspen Utilities
Editors
(or Excel)
Outputs
Utilities
Contract
Data
Linearized
Optimization
Model
Equipment
Availability &
Constraints
Demand
Forecasting
Investment
Evaluation
Rigorous
Simulation
Model
off-line
23
Budgets/
Forecasts
Utility
Consumption
Planning
View Results
Configured
Excel
Interface File
Using Aspen Utility Planner within Excel
Excel Addin
24
View Optimised Utility Production Plans
25
What-If Analysis
GT-1 needs to be shutdown for maintenance, what is the optimum configuration of the
utility system ?
Electricity price is high does it pay to increase condensing in STG 1?

GT-1
STG-1
26
Real time operations of Energy/Utilities with

Aspen Utility Online Optimizer
Data Input
Data Entry
through
standard
Aspen Utilities
Editors
(or Excel)
Outputs
Budgets/
Forecasts
Utilities
Linearized
Optimization
Model
Contract
Data
Equipment
Availability &
Constraints
Investment
Evaluation
Rigorous
Simulation
Model
Demand
Forecasting
Utility
Consumption
Planning
View Results
Configured
Excel
Interface File
off-line
Demand
forecasting not
required for
online model
DCS
on-line
Raw Data
Reconciled, Target &

Optimized Data
Real Time Database

InfoPlus. 21, PI
Aspen Online GUI

for Interactive use
On Line Link
Operations Optimization
Performance Monitoring
(process units, demand side)
Cost Allocation
27
InfoPlus.21
Web.21
Utilities Operations Online User Interface
28
Benefits across organization with consistent model

Operators; Shift Manager/Engineer;
Monitoring (hourly, weekly, monthly)
Purchasing; Environmental; Accounting
Plan vs. Target vs. Actual (Monitor if Process Energy Use is on Target)
Cost Accounting (based on real cost) & Emissions accounting
Operational Decisions (hourly)
Equipment Loads/ Choice of Fuels
Operators; Shift Manager/Engineer
Switching equipment on/off (Motors versus turbines)

Steam balance - venting
Fuel gas balance - flaring
Tactical Decisions (1-30 days)

Demand Forecasting / Production Planning
Shift Manager/Engineer;
Purchasing; Trading; Accounting
Maintenance scheduling
Emissions Forecasting and Trading
Strategic Decisions (1 month to 5 years)

Evaluation of future investment
Budgeting
Contract Negotiations (more and more complex)
29
Plant Management;
Purchasing; Accounting
Mitsui Chemicals
Operating cost reduction with closed loop utilities optimizer
Challenge
Solution
Results
Significant business changes in the Ichihara

works plant due to
Changes in operational units
Partial shut downs
Fuels strategy and cost
Changes offer opportunities to operate
differently
Lower boiler and turbine loads increased
flexibility of the plant
What was the new optimum operating
balance?
Ref: Development of an Operational Optimization System for a
Utility Plant, Kazuhisa Tsuchiya, Mitsui Chemicals,
AspenTech Global Conference: OPTIMIZE 2011,
Washington, D.C., May 2011
30
Mitsui Chemicals
Challenge
Solution
Results
Developed a complex-wide utilities model

in Aspen Utilities Planner
Deployed an automated process to run
utilities optimizer using:
Real-time historian data
Aspen Utilities model
Aspen DMCplus (APC) to
automatically implement optimal
solution
Excel interface provided for operators to

conveniently enter the non-historian data
31
Mitsui Chemicals
Challenge
Solution
Results
With increased flexibility, Mitsui Chemicals

could choose
Optimal fuel type depending on price
Balance turbines used
This new technology enabled business
process helps operators to make informed
choices
Review the optimized results for a
reality check
Transfer new settings to APC

Achieved an operational cost reduction
1.5%
32
LyondellBasell
Improve efficiency with on-Line energy management
Challenge
Solution
Result
Corporate energy goals:

Reduce total energy by over 2%
per year
Continually improve energy

intensity
Challenge:
Complex energy supply contracts
Site has lots of energy intensive

equipment
Ref: Brian Finnegan, et. al., LyondellBasell,

AspenTech User Conference, Houston, May 2009
33
LyondellBasell
Challenge
Result
Solution
Focus on operators and provide

actionable information
Aspen Plus, Aspen Plus Optimizer,
Aspen Utilities On-Line Optimizer,
and aspenONE Production
Management & Execution (PM&E)
suite
Experience of AspenTechs
Professional Services acknowledged
and appreciated by the Client

34
LyondellBasell
Challenge
Result
Solution
Better management of complex

utility systems
Improved make or buy decisions
Improved startups & shutdowns
Energy
Management
Accurate what-if analyses

Value
Gained
Models used for engineer and

operator training
Current Practices
Shorter Delay
Better cogeneration steam

scheduling
Projects will meet their expected
benefits target

35
CASE STUDY: ENI

ENI Energy Optimization System with Aspen Utilities
Business Challenge
Business&Challenge
ENI wanted an energy management system to

optimize the overall performance of the Sannazzaro
Refinery Utilities System.
Part of ENIs mission to improve energy efficiency at

the refinery included optimizing the process and
utility operations, by minimizing supply costs.
This project was a collaboration between ENI and

AspenTech services and developed in three phases.
The core of the Energy Management System was the
Aspen Utilities Model, broken into two applications:
Aspen Utilities Online Optimizer
Aspen Utilities Planner

36
Results & Benefits
Results & Benefits

Project Execution Benefits:
Lower external software services costs by up to 66%

Self sufficient to maintain in the future
Aspen Utilities Online Optimizer

Aspen Utilities Planner Benefits
Benefits
Evaluation of:
Actionable recommendations to
plant operators how to reduce
Impact on utility costs when production
cost
rates change
Reduction in:
Operating cost
Steam venting
Fuel flaring
Cost impacts of changes in utility prices

New contracts
Optimal equipment usage during

abnormal operation
Future Projects
Implement same project execution methodology for Taranto Refinery
Heat Exchanger Fouling Analysis Solution:

Aspen Exchanger Design & Rating
37
Heat Exchanger Fouling Fundamental

Fouling results from the accumulation of scale, organic matter, corrosion
products, coke, particulates or other deposits on the heat transfer surface
of heat exchangers and costs millions of dollars a year
EFFECTS OF FOULING
Thermal
Hydraulic
38
The fouling layer creates an

additional resistance for heat
transfer, hence reduces the
performance of the
equipment
Flow area available is reduced

as the deposits grow,
increasing pressure drop
Heat Exchanger Fouling: CDU Preheat Trains

Fouling formation in preheat exchangers of a
crude distillation unit (CDU) is identified as a main
energy consuming unit in petroleum refineries.
Almost half of the overall operational cost of the

refineries is due to the energy loses resulted from
fouling formation in the preheat exchangers1
39
S. Asomaning, C.B. Panchal, C.F. Liao Heat Transfer Engineering, 17 (2000), p. 21

Parametric Studies with Aspen Simulation Workbook

Aspen Simulation Workbook provides easy and robust integration between Aspen Techs
Engineering tool (Aspen Plus, Aspen HYSYS, Aspen Exchanger Design and Rating, etc.)
& Microsoft Excel
Among its features are:
Copy and paste functionality to bring input and output variables to Excel
Run Scenarios & Parametric Studies. With this feature you can easily and quickly run hundreds of
scenarios to analyze process sensitivity, check design cases,etc.
Rapidly develop user interfaces
Workflow automation: Automate repetitive tasks through VBA code
40
Parametric Studies with Aspen Simulation Workbook
Aspen Simulation Workbook
Aspen Shell & Tube or

Aspen HYSYS
Parametric Study
41
Heat Exchanger Fouling Monitoring

FI
TI
Can specify
any number
of buy or
sell
contracts
Tags
HX
Model
Vars
Heat Transfer Coefficient

50
TI
40
TI
30
20
10
Tag history pulled into MS Excel by IP.21

Linked to HX model using Aspen Simulation
Workbook
HX model predicts U or fouling factor
Enables operating decisions
42
ASW
Overall U
FI
TI
Historian
(e.g., IP.21)
Clean
0
9/20
11/9
12/29
Date
2/17
4/8
Specify rigorous Heat Exchanger Models from the simulator

Activated EDR
Improve fidelity of process simulation by specifying rigorous heat exchanger models within
Aspen Plus or Aspen HYSYS
43
INEOS: HX Performance Monitoring

Business Challenge & Objective
Heat exchanger fouling was impacting energy
consumption & unit capacity
Needed a way to easily monitor performance & guide
maintenance decisions to reduce down-time
Solution Overview
Aspen HYSYS with rigorous Aspen EDR models
Results & Benefits

Built an automated performance modeling tool that
monitors & reports heat exchanger fouling &
performance on a daily basis
Optimized cleaning schedules and reduced plant

down time a $3-4MM/year savings
44
Ref: Robert Pes & Pierre Sr Peyrigain, INEOS Lavera, Aspen

HTFS Annual User Group Meeting, Cologne, Dec. 2006
Saudi Aramco & InProcess: Hx Performance Monitoring

Business Challenge & Objective
Monitor crude pre-heat exchanger fouling and its
impact on refinery performance
Solution Overview
Built a model of the pre-heat train in Aspen HYSYS
using rigorous Aspen EDR models
Used Aspen EDR to calculate fouling resistances and
assess impact of these on the process performance
Results & Benefits
Developed a tool for regular use by operators to
avoid overscheduling cleaning
Increased process uptime increasing refinery

profitability and avoiding extra costs
45
Ref: Stephan Wagner, Saudi Aramco

Manel Serra & Maria Jesus Guerra, Inprocess
AspenTech OPTIMIZE, Boston, MA, May 2013
Thank you
Q&A
46

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Improve Energy Performance using

aspenONE Energy Management Solutions

Presented by: Nattapol A., APAC ENG Business Consultant

AspenTech Solutions for Energy Management

Utilities Optimization Solution: Aspen Utilities

2015 Aspen Technology, Inc. All rights reserved

Industry Challenges on Energy Managment

Inefficiencies in energy demand and supply

Energy supply costs plants millions of dollars annually

Optimization corrects inefficiencies

2015 Aspen Technology, Inc. All rights reserved

AspenTech Energy Management Approach

Reduce Supply Costs

Reduce Energy Demand

Define An Optimal Strategy

2015 Aspen Technology, Inc. All rights reserved

AspenTechs Integrated Energy Management View

Utilities/Supply Provide at lowest cost

Process/Demand Use less energy

2015 Aspen Technology, Inc. All rights reserved

Pinch Analysis Solution:

2014 Aspen Technology, Inc. All rights reserved

Challenges with Process Energy Analysis

2015 Aspen Technology, Inc. All rights reserved

1st Challenge: Identify Saving Potentials

Utilize Activated Energy Analysis to view target

2015 Aspen Technology, Inc. All rights reserved

2nd Challenge: Select Optimal Utilities

The target column shows the optimal

2015 Aspen Technology, Inc. All rights reserved

3rd Challenge: Generate and Evaluate Designs

2015 Aspen Technology, Inc. All rights reserved

4th Challenge: Maximize Energy Savings

Compare revamp scenarios

2015 Aspen Technology, Inc. All rights reserved

Addressing Challenges with Process Energy Analysis

2015 Aspen Technology, Inc. All rights reserved

Activated Energy Analysis

Activated Energy Analysis,

2015 Aspen Technology, Inc. All rights reserved

WINNER: Best Energy Management Technology

Bob Gill, Edititor-in-Chief, Control Engineering Asia

2015 Aspen Technology, Inc. All rights reserved

CASE STUDY: SCG Chemicals

Results & Benefits

SCG Chemicals looked to improve their existing work

Solution Overview Solution Overview

To build this novel process, SCG Chemicals utilized

SCG Chemicals then utilized Activated Energy Analysis

Results & Benefits

The package of Activated Energy Analysis in Aspen HYSYS V8.4 is a

Guide solutions for energy savings

Evaluate payback period

Process optimization and heat integration optimization led steam optimization

Steam usage reduction of 24%

Saving consumption of steam (24.1 USD/T-feed)

Debit production of steam (17.2 USD/T-feed)

2015 Aspen Technology, Inc. All rights reserved

CASE STUDY: Korea Energy Management Corporation

Results & Benefits

Energy Consumption by 1.9 Mcal/hr

Energy Cost by 1.3 M$/yr

Solution Overview Solution Overview