Artc 2009

BayOpXTM Operational Excellence through optimized Energy and Raw Material Efficiency
Dr. Dieter Heinz, Dr. Hans-Joachim Leimkuehler ARTC 12th annual conference, Kuala Lumpur, 10-12 March 2009
Agenda Bayer Technology Services BayOpXTM

Introduction of BayOpXTM Energy Efficiency Examples
Conclusion
12th ARTC, Kuala Lumpur BayOpXTM - Dr. Dieter Heinz 2008-11-27 Page 1
Bayer Technology Services: Portfolio

Product & Process Innovation
Broad Customer Range

Engineering Procurement Construction
Process Optimization & Troubleshooting
External Customers Process Industries
Global Presence Business Requirements

Efficiency Innovation
Cost Leadership Globalization
BTS-Asia Current working locations

Caojing - China Pudong - China Jinshan - China Hangzhou - China Zhang Jia Gang - China Beijing China Nanjing - China Weifang - China Tongling - China Guangzhou China Map TaPhut - Thailand Singapore City - Singapore Jakarta Indonesia Surabaya - Indonesia Thane - India New Delhi - India
14 : Locations 700 +: employees +:

Conclusion
The challenge of Operational Excellence

Areas of Optimization Energy consumption OEE Asset Utilization Availability Reliability Raw Materials Utilization Personnel demand Working Capital Constraints Quality Safety Target Minimization of Operational Cost Maintenance Cost
Achieving Operational Excellence is a multidimensional optimization task It requires a stringent workflow, knowledgeable experts and efficient tools
BayOpX Operational Excellence @ BTS

ASSESSMENT
IMPLEMENTATION
SOLUTION
Areas Energy Efficiency Optimization &Targets

C I D M A
Energy Check Pinch Pont Analysis Climate Footprint Sustainable Implementation
Methodologies Tools & Solutions for a sustainable Implementation

Equipment Check Pinch Point Software Process Simulation Online Monitoring
BayOpX Approach provides Targets, Methodology and Sustainability BayOpX Approach provides Targets, Methodology and Sustainability

Conclusion
BayOpX Workflow on the example of Energy Efficiency

Analysis Analysis
Part I: Energy Efficiency Check

Identifies and prioritizes measures for energy & CO2 emission reduction
Idea Idea Generation Generation
Evaluation Evaluation
Implementation Implementation
Part II: Sustainable Implementation

ensures implementation of improvement measures increase awareness for energy-conscious behavior
Sustainability Sustainability
Analysis Phase determines main Levers for Energy Reduction

Analysis
Analysis Analysis Determine energy distribution Determine main energy consumers / producers Idea Idea Generation Generation Collect relevant data of main energy consumers / producers:
Operational data (power, temperature, flows etc.) Technical equipment data
Result: data base

Energy Distribution
reference case
Sankey Diagram
Idea Generation Phase determines Measures for Energy & CO2 Emission Reduction
Idea Generation
Analysis Analysis Goal: determine measures for energy & CO2 emission reduction Sources for improvement measures:
Checklists Brainstorming Discipline experts
Different Levels of Energy Optimization
Energy & Utility Systems Process Improvements
Process Control & Automation Equipment Check
Operational Improvements Heat Integration & Heat Recovery Facility Check / Buildings
Heat Integration & Heat Recovery

Heat Integration & Heat Recovery
Analysis Analysis Optimize heat integration by Pinch Analysis:
Application of commercial software by experts Consideration of process modification essential, e.g. pressure in distillation columns condenser temperature
Pinch Analysis
Pinch Point
TEMPERATURE
min Heating Demand
Heat Integration Possible
min Cooling Demand
ENTHALPY
Recover waste heat, e.g. by: Sustainability Sustainability

Absorption chiller Vapor recompression Generation of low pressure steam Pre-heating of feed streams
Assess Generation and Distribution of Energy & Utilities

Energy & Utilities
Analysis Analysis Assess generation and distribution What we mostly see (examples): Idea Idea Generation Generation
Overall boiler efficiency < 75 %, e.g. no pre-heating Inefficient degassing of boiler feed water Multiple let-down of steam (enthalpic losses) Low level of condensate return / reuse Low temperature difference in circulation systems No regular steam-trap maintenance Heat tracing not turned off in summer
Assess energy contracts:

e.g. peak demand reduction
All Improvement Ideas are evaluated

Evaluation
Analysis Analysis Evaluation of measures for energy reduction with regard to:
Feasibility (together with client) Savings potential Costs (rough estimate, if possible) Profitability (rough estimate, if possible)
Categories of feasibility and profitability:
A
Feasible and Profitable e.g. proven technology
B
Likely Feasible and Profitable needs further evaluation
C
Not Feasible or Profitable
Portfolio visualizes Profitability, Feasibility and Savings Potential of Improvement Measures

Portfolio
Analysis Analysis
Profitability profitable
C1

3 years ROI
not profitable
C3
difficult
Portfolio Categories A = feasible and profitable B = likely feasible and profitable, needs further evaluation C1 = technically (currently) not feasible but profitable C2 = technically feasible but not profitable C3 = technically (currently) not feasible & not profitable
C2
easy Technical Feasibility
Steam Electricity Coolants Gases
Bubble Size = Savings Potential
Sustainable implementation of energy efficiency comprises four elements

Elements for sustainable implementation
Analysis Analysis
Improvement Plan Improvement plan to ensure implementation of design measures (capex projects).
Monitoring
Monitoring (e.g. online) to enable sustainable implementation of operational measures.
Reporting
Improved reporting, target setting and responsibilities to support usage of tools
Cultural Change
Cultural Change to increase awareness for energy-conscious behavior and mindset.
More efficient operation often means motivating the operator to leave the comfort zone
More efficient operation often increases risks (quality and capacity). Requirements for more efficient operation are:
Ability to change let the operator know in which status the plant is
Visualization of energy influencing operating parameters (target vs. actual) Monitoring
Will to change motivate / force the operator to leave the comfort zone
Daily reminding, reporting and target setting Increase awareness and definition of responsibilities
Online Monitor
Spec. Steam Consumption
Red Brown Green
Reporting Cultural Change
Energy Protocol
2006 (Nov/Dec) 1. term 2007 2. term 2007
Load

Conclusion
Example 1: Distillation Column

CASE: Separation of Isomers INTENTION: Energy & OEE optimization increase of plant capacity increase of production yield high reproducibility of product quality reduction of laboratory costs STRATEGY: Process Analysis Performance Monitoring Data Analysis Online-Analytics Process Control Concepts
Controller
Controller
Example 1: Distillation Column

STEPS OF IMPLEMENTATION: Online Analytics Choice and design of measurement position Calibration procedures Reducing laboratory efforts Stabilizing product quality Controller Concept Choice and design of controller structure with respect to data Choice and parameterization of control algorithms
NIR NIR
Controller
NIR
Controller
NIR
10
Example 1: Distillation Column RESULTS & BENEFITS:

Capacity increase 8% Less off spec through constancy of product quality improved yield significant energy reduction significant reduction of laboratory analytics
previous mode of operation
new control concept
Concentration Feed rate
Example 2: optimization of process water

Objective Objective
Reduction of process water consumption Online monitoring of k-value (predictive maintenance)
Process water usage: ~ 60 MW
Plot-0 0 500 BW11WA11-k.real-VTPLN 2 BW11WA12-k.real-VTPLN 2 BW11WA21-k.real-VTPLN 10057 BW11WA22-k.real-VTPLN 2799 NE71WA01-k.real-VTPLN 1171 NE71WA02-k.real-VTPLN 1171 WA31WA01-k.real-VTPLN 1429 372.00 Tage 27.09.2007 12:27:35.505 WT11WA01-k.real-VTPLN 2896
Approach Approach
Visualization of performance of each heat exchanger Determination of process conditions for best praxis
1000
k-value monitoring predictive maintenance
1500 2000 2500 3000 3500 4000 20.09.2006 12:27:35.505 k-Wert k-Wert k-Wert k-Wert k-Wert k-Wert k-Wert k-Wert BW11WA11 BW11WA12 BW11WA21 BW11WA22 NE71WA01 NE71WA02 WA31WA01 WT11WA01
Result Result
~ 30 % process water usage reduction about one year Savings of ~ 400.000 /a
Process water management system: determination of best process parameters in dependence of load of each line
11

Introduction of BayOpXTM Energy Efficiency Raw Material and Equipment Efficiency
Conclusion
BayOpXTM offers a systematic approach

Systematic approach for efficiency enhancement Applicable e.g. for Energy efficiency programs
More than 40 successfully executed projects
Analysis Analysis Idea Idea Generation Generation Evaluation Evaluation
Equipment efficiency programs

Capacity Reliability Availability
Increased raw material efficiency Elaboration of measures by BTS experts and clients process experts Evaluation of measures Technical feasibility (experiments if necessary) Economic evaluation Strong focus on sustainable implementation in the plants
12
BayOpX: Potentials & typical Savings & Earnings

BayOpX Areas
Operational Excellence (Ref.: Bayer Projects)

Start of project: 100% End of project: Savings & Earnings
100%
BayOpX: Operational Excellence by BTS

BayOpX Areas
How will YOUR

Start of project: 100% End of project: Savings & Earnings look like ?
100%
13

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BayOpXTM Operational Excellence through optimized Energy and Raw Material Efficiency

Agenda Bayer Technology Services BayOpXTM

Bayer Technology Services: Portfolio

Broad Customer Range

Process Optimization & Troubleshooting

External Customers Process Industries

Global Presence Business Requirements

Cost Leadership Globalization

BTS-Asia Current working locations

14 : Locations 700 +: employees +:

Agenda Bayer Technology Services BayOpXTM

The challenge of Operational Excellence

BayOpX Operational Excellence @ BTS

Areas Energy Efficiency Optimization &Targets

Methodologies Tools & Solutions for a sustainable Implementation

Agenda Bayer Technology Services BayOpXTM

BayOpX Workflow on the example of Energy Efficiency

Part I: Energy Efficiency Check

Idea Idea Generation Generation

Part II: Sustainable Implementation

Analysis Phase determines main Levers for Energy Reduction

Result: data base

Idea Idea Generation Generation

Different Levels of Energy Optimization

Energy & Utility Systems Process Improvements

Process Control & Automation Equipment Check

Heat Integration & Heat Recovery

Idea Idea Generation Generation

min Heating Demand

Heat Integration Possible

min Cooling Demand

Recover waste heat, e.g. by: Sustainability Sustainability

Assess Generation and Distribution of Energy & Utilities

Assess energy contracts:

All Improvement Ideas are evaluated

Idea Idea Generation Generation

Categories of feasibility and profitability:

Portfolio visualizes Profitability, Feasibility and Savings Potential of Improvement Measures

Idea Idea Generation Generation

Sustainable implementation of energy efficiency comprises four elements

Idea Idea Generation Generation

Monitoring (e.g. online) to enable sustainable implementation of operational measures.

Improved reporting, target setting and responsibilities to support usage of tools

Cultural Change to increase awareness for energy-conscious behavior and mindset.

Reporting Cultural Change

2006 (Nov/Dec) 1. term 2007 2. term 2007

Agenda Bayer Technology Services BayOpXTM

Example 1: Distillation Column

Example 1: Distillation Column

Example 1: Distillation Column RESULTS & BENEFITS:

previous mode of operation

new control concept

Concentration Feed rate

Example 2: optimization of process water

k-value monitoring predictive maintenance

Agenda Bayer Technology Services BayOpXTM

BayOpXTM offers a systematic approach

Analysis Analysis Idea Idea Generation Generation Evaluation Evaluation

Equipment efficiency programs

BayOpX: Potentials & typical Savings & Earnings

Operational Excellence (Ref.: Bayer Projects)

BayOpX: Operational Excellence by BTS

How will YOUR