Braskem Reduces Energy Usage by 20% with Aspen DMC3
公司规模
1,000+
地区
- America
国家
- Brazil
- United States
产品
- Aspen DMC3
技术栈
- Adaptive Process Control
- Aspen DMC3 Builder
实施规模
- Enterprise-wide Deployment
影响指标
- Energy Saving
- Productivity Improvements
技术
- 分析与建模 - 过程分析
- 应用基础设施与中间件 - 数据交换与集成
适用行业
- 化学品
适用功能
- 流程制造
用例
- 能源管理系统
- 过程控制与优化
服务
- 系统集成
- 培训
关于客户
Braskem is the largest petrochemical company in Latin America, the leading producer of polypropylene in the United States, and the eighth-largest resin producer worldwide. The company is positioned between extraction and plastic resin manufacturing, responsible for transformation from naphtha, natural gas, ethanol and salt into basic petrochemicals for polymer plants. The main final products Braskem produces are polyethylene (PE), polypropylene (PP) and PVC. Among basic petrochemicals, Braskem also produces solvents, aromatics and fuels. Since its founding in 2002, Braskem has been a major player in the international petrochemical market.
挑战
Braskem, a major player in the international petrochemical market, was facing challenges with variability in product quality, high energy usage, and excess reflux in their operations. The company had around 210 AspenTech advanced process control (APC) controllers installed among four Brazilian cracker sites. However, up until 2015, advanced process control was only installed on furnaces. The lack of an optimization algorithm on distillation columns resulted in lost potential benefits and unnecessary excess spending. There were frequent composition peaks and an excess of reflux, meaning excess utility spent on refrigeration compressors that use high pressure steam. Braskem decided to implement an optimization strategy using Aspen DMC3 to improve product quality and reduce project costs.
解决方案
Braskem implemented Aspen DMC3 on cold end units of ethylene site to reduce variations in quality and energy usage. The Adaptive Process Control technology in Aspen DMC3 allows simultaneous optimization and data collection with no interruptions to the process. Plant test data is used to build and update models which predict process response to manipulated variable moves and measured disturbances. That information is used to calculate the best moves to apply to the manipulated variables to stabilize production and push the process to the optimal point. Models are continuously adapted to represent unavoidable changing plant conditions. Braskem was able to implement Aspen DMC3 on their own with existing internal resources. In total, there were three engineers working on this project, all with less than five years’ experience.
运营影响
数量效益
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