Transcript Powerpoint - Energy Efficiency Opportunities

Page 1
Introduction
Energy Management
• Generally static
• Based on historical data
Control Systems
• Real time control of processes
• Processes track to a collection of set points
• Run the process within certain limits
Systems Optimisation
• Use real time data
• Adjust system wide set points to optimise profits
• Take into account external factors
• Whole of system focus – optimise across whole
system not just individual process
Increasing complexity
Increasing control
Greater efficiency
Page 2
What is System Optimisation?
Optimiser uses historical data and
predictive algorithms to optimise
performance
Information sent back to process via
control system
Controller provides process information
to optimiser
Optimised instructions sent back to
process
Information from process sent to control
system
Optimised instructions sent back to
process
Page 3
What is System Optimisation?
Offline open loop
systems optimisation
Online open loop
systems optimisation
Closed loop real time
systems optimisation
Simplot Australia (energy
metering and energy
performance indicators)
AngloGold Ashanti (singlevariable control)
Worsley Alumina (multivariable control)
Increasing automation
Simplot Australia (variable
head pressure control of
refrigeration plant)
Page 4
Costs and Benefits
BENEFITS
 Increased throughput
(3% to 5%)
 Increased energy efficiency
(3% to 5%)
 Decreased energy costs
 Increased product quality
(10 to 20%)
 Decreased operator input
 Payback periods of 6 months to 4 years
POSSIBLE COSTS
 Engineering
 New instrumentation
 New controls equipment
 Training
Page 5
Australian Case Study - Simplot
Background
 Food company in Devonport, Tasmania
 Produce frozen vegetables
 Time critical process
 No energy sub-metering
Motivation
 Improved energy management – cost increases
 Reduce energy intensity by 25%
Benefits
 Reduced energy intensity by 20%
 Reduced energy costs
 Reduced partial loading of compressors
 Greater process resilience
Page 6
Australian Case Study – AngloGold Ashanti
Background
 Sunrise Dam Gold Mine
 Operating since 1995
 Typical Carbon-in-leach process
Motivation
 Optimise throughput
 Eliminate causes of downtime
How Systems Optimisation was implemented
 Took stock of existing control systems
 Prioritised causes of downtime
 Identified control improvements
 Trained operators
 Monitored results
Page 7
Australian Case Study – AngloGold Ashanti
Benefits
 Fewer maintenance events
 Increased throughput
 Improved energy efficiency
 Reduced Unit Costs
Next Steps
 Processing plant optimised
 Look at upstream processes next
Page 8
Australian Case Study – Worsley Alumina
Background
 Refinery opened in 1984
 Upgrades started in 2004
Motivation
 Improve profitability
 Automate operator knowledge
Page 9
Australian Case Study – Worsley Alumina
How Systems Optimisation was implemented
 Mandate from Senior Management
 Front end study
 Implementation of Multi-variable control
 Continuous measurement of results
Page 10
Australian Case Study – Worsley Alumina
Benefits
 More accurate control, less operator intervention
 Optimised set-points = improved profitability
 Reduced maintenance costs
 Improved reliability
Page 11
Australian lessons learned
 Make the most of what you have before you invest
 Prepare a persuasive business case – whole of business costs
and benefits
 Undertake a staged implementation process
 Ensure you have access to the required skills
 Manage the learning process
 Maintain operator proficiency
Page 12
Key Industries
Overseas industries that have benefited:
 Large commercial buildings
 Power generation
 Cement manufacture
 Petrochemical
 Steel making
Australian industries that could benefit:
Food processing
Minerals processing
Transport
Commercial buildings
Page 13
Legal Disclaimer
Important Notice
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Email: [email protected]
Page 14
Spent Liquor Temperature Variation Before & After MVC.
30.0%
25.0%
20.0%
15.0%
10.0%
5.0%
0.0%
70
72
74
76
78
80
82
84
86
88
Temperature (degC)
BaseCase
PerfRun
Page 15
Operator moves for 3 different processes before and after MVC.
140
122.4
120
Moves/day
100
80
60
40
32.7
31.1
20
30.1
28.4
13.9
3.9
3.6
3.8
2.7
0
All MV's
Tr1A
Tr1B
MVC Off
Tr2A
Tr2B
MVC On
Page 16
Levels of Process Control
SO
Systems Optimisation
(multiple process units)
Advanced Process
Control (multivariable
process unit)
Advanced Regulatory Control
(single variable feed forward/back
loop control)
Basic Regulatory Control (single variable, single
loop control)
Instruments & Actuators
Processing Plant
Page 17
Page 18
Discussion – Systems Optimisation
• Do you think your corporation currently optimises its existing
energy management tools?
• Do you think there are aspects of systems optimisation that
could be explored by your corporation?
ENHANCING AUSTRALIA’S ECONOMIC PROSPERITY