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Audited benefits of $1.038M per year from the application of AMS Optimizer on plant 1 |
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Additional benefits of over $0.6M identified by YNCC from plant 2 |
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Challenge
Yeochun NCC (YNCC), an equal joint venture between Daelim Industrial Corporation and
Hanwha Chemicals Corporation, operate 3 naphtha cracking plants at the Yeosu complex.
Each plant has a utility center supplying steam and electricity to the connected site,
downstream product units and to external customers. There are 9 boilers, 4 steam
turbine generators and 2 gas turbines distributed across the 3 utility plants.
The boilers fire both gas and a mixture of oils. All fuel required
within YNCC is generated internally.
Each utility center supplies steam at 4 pressure levels and there are
inter-connections between plants 1 and 3 at two steam levels. Plant 2
has no steam connections with the other plants. Plants 1 and 3 can
import electricity to balance requirements, whilst plant 2 has the capability to
import or export power. There are no electrical connections between the utility plants.
YNCC identified the requirement to obtain the most cost effective method
of improving operations, meeting steam and power needs and reducing
operating costs across the utilities plants. Applying a real-time
optimization system was seen as the major contributory factor to achieve
this goal. Solution
YNCC selected Emerson's AMS Optimizer to provide a
real-time optimization system to recommend the optimum operation of
their utilities complex. AMS Optimizer is Emerson's flag ship application
for utilities optimization which forms part of AMS Suite, an
integrated family of applications for predictive maintenance, performance
monitoring and economic optimization.
The AMS Optimizer system comprises:
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An open-loop optimizer to determine the optimal economic
operation of the available equipment on each of the 3 plants. |
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An equipment selection tool to identify additional
benefits available from swapping auxiliary loads between steam and electric drives. |
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An offline optimization tool to allow ad-hoc runs of the
plant economic optimizer to be performed. |
The optimization system uses a detailed model of the utilities complex and
equipment as the basis to make recommendations on the
optimum loading for the steam generation and power generation equipment.
The online optimizer obtains current plant data from the site historians
and generates optimized setpoints based on current conditions and plant
demands. These setpoints are presented in a user interface to the plant
operators for implementation.
The AMS Optimizer delivers benefits through fuel and power import
savings. Required steam generation is redistributed across the
available boilers according to their operating efficiencies providing
fuel savings. Steam usage is redistributed across the headers to
minimize let downs and condensing flows, reducing steam generation
requirements, and to optimally balance the power generation units with
power import.
The AMS Optimizer equipment selection tool considers changes to the
auxiliary load drives. A number of the auxiliary loads are powered from
either electric motor or steam turbine drives. This tool provides
recommended changes to the current number of electric/steam drives to
assess additional benefit from line-up changes. It runs alongside the
plant optimizer and results are returned to the user interface.
An offline version of AMS Optimizer is also being used allowing
'what-if' case studies to be performed. This offline tool comprises the
same plant model and optimizer as the online version.
This project was executed by a joint Emerson and YNCC project team. YNCC
were responsible for system configuration and testing. Emerson provided
system design, technical support and training. AID Corporation of Seoul
acted as the local project coordinator.
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