PTQ Q4 2022 Issue

Scenario analysis Off-design cases, such as start-ups, ramp-up, feed and operating mode change, are often not evaluated as part of a complex design and may result in unforeseen challenges and delays during operation. Such delays can result in severe economic penalties. The complex-wide flowsheet can be used to analyse such scenarios to identify critical constraints and plan mitigation strategies in a timely manner. Case study KBC served as an OTA for an Asian company planning to build a grassroots refinery-petrochemical complex. KBC’s SMEs were integrated with the owner’s team after the detailed feasibility study for the complex was completed. As an OTA, KBC evaluated licensor evaluation and selec - tion, reviewed licensor basic engineering and design pack - ages, and participated in various critical meetings with licensors, PMCs, and vendors. Using information from technology licensors in the Petro- SIM simulator, a rigorous digital twin for the whole complex was developed. A process digital twin was then used to evaluate several opportunities for margin improvement and energy conservation. As a result of these opportunities, refinery margins exceeded 10%. Compared to the base case, the complex overall energy consumption was reduced by roughly 6%. Key improvements included: • Feedstock optimisation • Improved feed definition • Refinery-petrochemical value chain maximisation • Gasoline blend feasibility • Steam and power system optimisation • Complex turnaround optimisation

Integrated complex optimisation The potential from incremental improvement with increased conversion capabilities of a fuel refinery with added petrochemical integration is USD 1.5 to 2 per bbl of processed crude. The value gained from effective molecu- lar management is significant. Figure 4 shows the typical feed preference and selection criteria for key refineries and petrochemical processes. A rigorous complex-wide process digital twin enables effective molecular management at the design stage by providing detailed carbon number breakdowns from crude assays through blending and petrochemical units for the whole integrated complex. These enhanced capabilities allow site-wide optimisation opportunities to be identi- fied across the integrated complex. Such opportunities can be easily implemented at the design stage and lead to improved project economics. Steam and power system optimisation Refineries and petrochemical facilities face increasing pressure from regulators to decarbonise their current and future facilities. KBC includes the complex-wide steam and power system optimisation with net zero vision (see Figure 5 ). Using this model with KBC’s proprietary Best Technology methodology for energy optimisation, a holis - tic analysis is performed to optimise the entire system and identify energy-saving opportunities for each process unit. Thus, the complex saves energy and enjoys higher cash margins. Additionally, improving energy efficiency is the most cost-effective way to mitigate CO₂. Reducing CO₂ emissions also reduces the capital investment required for carbon capture facilities.

UB-2

CFBC-1 CFBC-2

CFBC-4

UB-1

CFBC-3

VHPS Gen

VHP steam

VHPS Cons

STG-5

STG-3&4

KT-1

STG-2

HPS Gen

HP steam

HPS Cons

KT-2

HP-MP

MPS Gen

MP steam

MP BFW heater

MPS Cons

KT-3

MP-LP

Flash steam

LPS Gen

LP steam

LPS Cons

Renery deaerator

Petchem deaerator

Figure 5 Petro-SIM Model for complex-wide steam and power network

PTQ Q4 2022