Process Unit Energy Optimization

Emerson’s SmartProcess suite of applications optimize major unit operations (Fired heaters, distillation columns, fractionizers, dryers, compressors, etc..) using Model Predictive Control (MPC). MPC uses dynamic models of the process, and a record of its past behavior, to predict how the process will behave in the future. These predictions are then used to determine an optimum sequence of control actions that ensure all process control objectives are achieved simultaneously.

Emerson’s embedded APC tools have increased the ease of use of the technology making it available to control engineers as opposed to only specialist engineers.

• APC techniques often show significant improvement over regulatory PID functions, with potentially large returns
• No requirement for very specialized skill-sets and experienced resources to implement and maintain
• Use not limited to larger refineries or petrochemical
• MPC application will continue to provide value so long as it updated when process changes or regulatory changes are made to the unit being controlled

Process units where achieving stable, optimal performance is more challenging, for example due to longer dead time, process interactions or multiple process constraints. Examples of these types of units include reactors, distillation columns, fractionators, heaters and dryers.

Mol Algyo reduced energy consumption at its gas plant using Emerson’s smart process distillation optimiser.

Results include:

• 35% reduced energy cost (Eur 1.2 million per year)
• Return on investment less than 2 months
• Reduced operator workload
• Improved process stability and automatic disturbance rejection.

• Reduced energy used by the process unit

• Increased safety and reliability

• Mol Algyo Gas Plant: SmartProcess Distillation Optimizer
• Huntsman Corporation: SmartProcess Distillation
• Rompetrol: SmartProcess Fractionator and Heater Solutions

Please contact Emerson Process Management for more information.