Decarbonization is part of every company’s long-term strategy. However, a key challenge is to reduce emissions now, without major capital expenditure. Siemens’ gPROMS Utilities digital application helps large-scale process sites minimize day-to-day hydrocarbon fuel requirements — and hence GHG emissions — using digital twin-based optimization technology. This can reduce emissions by 3–8%.
The digital twin of the site energy systems captures all relevant interactions. The optimizer navigates hundreds of operational decisions of the energy landscape and provides operators with the most efficient operational settings.
Recommendations can be implemented automatically, in closed loop mode or at the discretion of operators, who can make decisions using the best available data.
The optimizer provides a range of suitable changes, ranging from “minimal disruption” (e.g. change some setpoints) and “some savings” to “substantial changes and benefits” (e.g. shut down Boiler A and start up Boiler B).
Use gPROMS Process to create a simulation model (digital process twin) of the entire site-wide energy system, including boilers, gas and steam turbines, steam headers and so on.
The model is implemented on the plant within the gPROMS Digital Applications Publisher (gDAP), connected to real plant data.
The Optimizer executes every 15 minutes to determine the optimal settings, such as those that minimize energy consumption for the next period.
The new settings are provided to operators on visualization screens within the plant automation system or custom dashboards.
The site-wide utilities optimizer was implemented in the control room for operations decision support on a major refinery site. Operators can see the current profits gap and a list of potential actions to reduce the gap. The system
provides hour-by-hour decision support and instant optimal recovery to upsets and disturbances.