This reduces the flame temperature and may encourage the operator to increase the flow of fuel, worsening the carbonisation. Hence, the measurement at the arch determines whether complete or incomplete combustion takes place at the burner level. Business process understanding The oxygen level inside the furnace is measured at three different places: the stack, arch and SCR. If excess oxygen is present in the arch O 2 sensor, an excess amount of oxygen is being used in the furnace. Typical ranges of oxygen at various locations in the furnace are:
Sensor information and manufacturing information
Actual blast furnace
Virtual blast furn
Raw materials
Database
Disturbance
Data scien (big data ana
Sensors
AI
Utility
Mathematical-physica Chemical-thermodynam Statistical mod
Operations Video
Equipment level
% oxygen present
Arch SCR Stack
2-3
3-3.5
Estimation of real- conditions Model prediction co
3-4
Manufacturing conditions
It is important to measure the oxygen level in the arch because combustion of the fuel gases takes place prior to the arch. By measuring the oxygen level here, we can determine whether the reaction inside the furnace is complete or incomplete combustion. CarbonSense solution CarbonSense achieves a reduction in energy consumption and GHG emissions and an increase in furnace run length by optimising the furnace
Solution Overview with Process Digital Twins
operating parameters of petrochemical and chemical plants. In a typical ethylene production furnace, coke formation is a major problem that reduces heat exchange and leads to more fuel being burnt, and thus more emissions being released into
Sl. No.
KPI
Key levers
Improvement
Compliance with Business benefits
1
Percentage reduction
• Continuous monitoring of excess O 2 % for controlling CO, CO 2 • Temperature of SH zones
Estimated reduction in GHG effects by 6%
in emissions
regulatory
requirements
to predict NOx emissions
NOx SOx CO 2
~ 5% ~2.4%
~3%
2
Increase in furnace
• Continuous monitoring of CPR • Predicted CPR and real-time
Around 11 days of ~ 12% increase in number
run length
increased run length
of cycles of furnace
recommendation to reduce coke formation
runs annually
3
Increase in yield
• Optimisation of COT by controlling fuel combustion • Stabilising the flow rate of ethane feed and fuel flow rates
Around 10-12% increase
Estimated around 10% increase in
and revenue
in yield and OEE
revenue from operations
Table 1
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