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One Central Park, Northampton Road, Manchester, M40 5BP, UK +44 161 9186789 www.processint.

com
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A Case Study for Refinery Utility
A Case Study for Refinery Utility
System
System
Optimisation
Optimisation
Guangzhou Refinery, Sinopec
Guangzhou Refinery, Sinopec
Contact: Dr. Steve Hall
Tel: 0161 918 6789
Mob: 07534 721862
steve.hall@processint.com
www.processint.com
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System Information
Complex steam network
Has gone through many modifications
Many pieces of equipment
4 coal fired boilers + 1 CFB boiler
Turbo-generators, 3 Back Pressure turbines and 4
Condensing turbines
Many waste heat boilers
Many refining processes
With many local steam generators and turbines
Many potential constraints on operation
optimization and revamping
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Project Steps
Project Steps
Equipment model building
Network model building
Model validation
Multi-case optimization
Optimization validation
Implementation of operation optimization
Revamping study
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Equipment Model: Backpressure Turbine
Equipment Model: Backpressure Turbine
Relative Error:
3.64%
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100 120
Steam Flow
t/h

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Actual Predicted by PIL


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Equipment Model: Multi
Equipment Model: Multi
-
-
stage Condensing Turbine
stage Condensing Turbine
Standard Error:
3.83%
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10000
15000
20000
25000
30000
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Steam Flow, t/h
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Steam Network Model - Simplified
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Steam Network Model Full Detailed Version
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The utility system was optimised to include
practical restrictions and economics.
Note: PIL optimised the operation of
existing equipment i.e. only what was
already there
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Effects of Optimal Operation Changes
Effects of Optimal Operation Changes
-15.9 Export Power MW
0 Export Power /y
0 Import Power MW
0 Power import cost /y
-5.7 Power generation MW
0 Fuel gas consumption t/h
20.8 Total coke consumption t/h
- 41.4 Total coal consumption t/h
-11.8 million Total fuel cost /y
-10 million Total operating cost /y
Largest Changes
The energy cost is reduced by 7.6% without capital
investment
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Sensitivity Analysis
Sensitivity Analysis
Due to measurement errors, some estimated
parameters may not be consistent with
measurements
PIL and the Operators agreed the results together
Sensitivity analysis was used to help operators make
judgements about the direction of operational
adjustments e.g. increasing flow through a particular
steam turbine
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Example: Sensitivity Analysis of a Boiler
Example: Sensitivity Analysis of a Boiler
-0.11 - +0.2 Cost Change (million/y)
127.2 127.3 127.5 Total Operating Cost (million/y)
221 t/h 220 t/h 219 t/h Maximum Steam Generation
Up
Current
Set Point
Down
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-130 Down to 23t/h
-77 Down to 24t/h
-29 Down to 25t/h
+31 Up to 26t/h
- Current value 25.5t/h
Cost Changes ( thousand/y)
Passout
Flow
-144 Down to 72t/h
-96 Down to 73t/h
-49 Down to 74t/h
+46 Up to 76t/h
- Current value 75t/h
Cost Changes ( thousand/y)
Min
Cond.
Flow
Example: Sensitivity Analysis of a Condensing Turbine
Example: Sensitivity Analysis of a Condensing Turbine
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Steam Network Model Optimised, showing S
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ITE
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Interface
Interface
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SITE
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Data Input
Data Input

Steam Turbine
Steam Turbine
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SITE
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Report Window
Report Window

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