31 st International Oil and Gas Conference and Exhibition, Siófok 6 th October 2017

Transcription

1 A rolling stone gathers no moss Adaption of advanced process control system and optimization of technology process for energy efficiency improvement in Algyő Gasplant Bodócs Attila Kormányos Attila st International Oil and Gas Conference and Exhibition, Siófok 6 th October 2017

2 THE PROCESS Development of Control System DeltaV DCS, APC Launching of New Products Production of 80/20 Pentane Blend High Quaility ( 99 %) Propane Energy optimization Gas engine heat recovery Demag compressor heat recovery Interconnection of hot oil systems, 2 furnaces have been stopped Technology modification PB column has been stopped

3 WHAT SHOULD WE DO? What should we do in order to achieve the goal? Analizing of process Control system survey The examination of all stages of operation and process Identifying of key points Where and how can we make rational changes? Apply such control system that is appropriate for the tasks Create the conditions (new measurements, controls) Modify the technology (stop equipments, if their operation is not reasonable, create new systems connecting to the old systems) Examine the customer s requirement, and more efficient operation support the necessary quality (gift-quality terminate, producing HC-poducts that are comfortable for the requirements)

4 THE ALGYŐ GASPLANT Main processes of technology: Gas preparation: preparation of inlet gases to the National Pipeline (sale of product gas) Gas processing: producing liquid HC-products (C3, PB, ic4, nc4, ic5, nc5) from liquefied condensates discharged during the gas preparation on the gas fractionation distillation columns

5 THE FIRST STEP: APC To initiate APC RS3 - DeltaV migration was needed in the fractionator Loop 2010 Performance Audit preceded the implementation, which made the control circuits okay APC has unexpected results: 50% energy savings at the fractionation plant distillation tower Hot oil Fuel gas CO2 Pressure Reflux ratio Product quality

6 THE RESULTS OF APC 2010 Pressure Pressure Pressure Reflux 6,5 bar 12 bar Reflux 1 bar 2,7 bar Reflux 1 bar 2,5 bar Hot oil 3.5 t/h 12 t/h Hot oil 6 t/h 13,5 t/h Hot oil 15 t/h 35 t/h 25 t/h 98 t/h 28 t/h 44 t/h 35 t/h 75 t/h Fuel gas usage m³/year 51,83 % 49,62 % 34,23 % 28,1 % Pressure Pressure Reflux 9,5 bar 15,3 bar Reflux 4,7 bar 7,1 bar 5,5 bar 7,5 bar Hot oil 8,5 t/h 13,8 t/h Hot oil 7,5 t/h 9,5 t/h 15 t/h 35 t/h 22 t/h 33,5 t/h 15,3 t/h 20,5 t/h 15 t/h 45 t/h

7 THE RESULTS OF APC 2010 Improve site energy efficiency Provide fuel savings of at least 734,000 /year 40% reduction in hot oil consumption Fractionation plant has reached the minimal specific energy consumption with applied equipments 1.2 million /year Benefit is audited by MOL Maximize valuable product yield Increase operational stability Improve on-spec production even as product specs change Throughput maximized PredictPro optimizer maximize benefits in each column based on relative product prices Reliability Variability is reduced resulting in stable plant operation Stable product quality Reduced operator action required for changes in feed composition and product specs

8 STOPPING THE PB MIX COLUMN 2011 The required PB quantity is mixed in the Storage Unit from the C3 and C4 products m3 fuel gas saving per day

9 COMPRESSORS GAS ENGINE HEAT RECOVERY SYSTEM The heat utilization of the fuel gas of the gas engines of the 9 engines (GANZ-MÁVAG PA4-V-185 GE-C) located in the NF ETC plant with 2 HOVAL heat exchanger units The heat transfer medium is Thermol 32 oil The max. available temperature is 160 C Instead of steam heating, hot glycolic water supplies the heaters with 3 heat exchangers Instead of steam-fueled glycol regenerators, new thermo oil-fueled glycol regenerators were installed Providing the heating of EE II-K-4 pentane column 2 Of the 4 steam-heated deethanizer columns were shut down and 2 were changed to themo- and hot oil heating 2 boilers of 20 tons have been shut down 6,5 7 million m3 fuel gas saving per year

10 COMPRESSORS GAS ENGINE HEAT RECOVERY SYSTEM 2012 Gasfracionation Unit Furnaces Heat recovery of gas powered compressors 1,5 2 MW HEAT ENERGY WHRU

11 INTER-CONNECTION OF THE TWO HOT OIL SYSTEMS STOPPED THE EE FURNACES 2013 Heat recovery of gas powered compressors Gasfracionation Unit Furnaces To provide heat to the entire Gasplant we do not need 4 furnaces The two hot oil systems have been interconnected The EE furnaces have been stopped The hot oil system is connected to the waste heat recovery system of the Solar gas turbine m3 fuel gas saving per day WHRU

12 PRODUCT TYPE EXTENSION PENTANE-BLEND AND HIGH PURITY PRODUCTS /80 normal-pentane production (Pentane Blend) (2014) Pentane column reflux can be reduced to less than 12 t/h! Production of liquid propane products with purity over 99%(2016)

13 DEMAG HEAT RECOVERY LTEX (Low Temperature Extraction): Gas preparation technology Using all the cold energy from decreasing pressure (Turboexpander, Cold Box). Compression of 110 to 130 thousand m 3 gas per hour from 20 to 51 bar with Demag turbocompressor (driven by: Taurus 70 gas-turbine) After compression, C gas was cooled below 60 C with air coolers The temperature of the hot oil heated by the furnaces is C (heat demand of triethylene glycol regenerator) After the implementation of APC, distillation columns pressures and temperatures were reduced Pressure (bar) Base temp.( C) E II-K-1 9,5 88 E II-K-2 4,5 107 E II-K EE II-K-1 6,5 120 EE II-K EE II-K Demand of heat energy (MW) 1,4 2,2 Using a suitable heat exchanger, 3MW of heat energy can be harvested from the thousand m 3 /h gas with the heat of C The high temperature hot oil exchanger was installed before the reboiler of the propane column to provide extra heat The reboiler of iso-butane column is double, one connected to Demag System The hot oil is the same as the one used in the high temperature circuit

14 DEMAG HEAT RECOVERY 2015

15 DEMAG HEAT RECOVERY 2015 Gasfracionation Unit Furnaces Heat recovery of gas powered compressors WHRU m3 fuel gas saving per day Demag Heat recovery 2,5 3 MW HEAT ENERGY

16 DEMAG HEAT RECOVERY Results: effect on Solar gas turbine efficiency 2015 The efficiency of Solar Taurus 70 gas turbine after the start of DEMAG heat recovery unit: %

17 OVERVIEW NF gas engine heat recovery: Max. 160 C thermo oil heating system 1,2 2 MW Demag heat recovery: Low temperature hot oil heating system ( C) 2,5 3 MW Heat consumers: LTEX technology Glycol regenerators Heating loops Deethanizers of gas preparation units E and EE processing units Gas turbine waste heat recovery unit: High temperature hot oil system ( C) 7,2 7,8 MW E plant furnaces: High temperature hot oil system ( C) 1,5 2 MW Sum. heat energy required: MW

18 The amount of heating furnace-fuelgas required for the processing of 1 tonne fraction feed (m3/ton) APC implementation Stopping PB column Gas engines heat recovery Interconnection of hot oil systems Pentane Blend DEMAG heat recovery

19 Energy Advisor 2017

20 Heat Balance Energetic APC 2017 Estabilishing Energetic APC in order to maximize the efficiency of the heat recovery units: Gas engine heat recovery DEMAG heat recovery

21 THE PROCESS Energy Advisor Development of Control System DeltaV DCS, APC Energy optimization Gas engine heat recovery Demag compressor heat recovery Interconnection of hot oil systems, 2 furnaces have been stopped Technology modification PB column has been stopped Heat Balance APC Launching of New Products Production of 80/20 Pentane Blend High Quaility ( 99 %) Propane

22 You can't always get what you want But if you try sometime you find You get what you need THANK YOU FOR YOUR ATTENTION