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Advanced Chemical Engineering

Advanced Chemical Engineering. Overview and Capabilities. Presentation Outline. Portfolio Overview Areas of Applications Applications Benefits Why KBR? Overview Dynamic Simulation OTS APC Summary. Technology Operations Advanced Chemical Engineering. Portfolio Overview.

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Advanced Chemical Engineering

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  1. Advanced Chemical Engineering Overview and Capabilities

  2. Presentation Outline • Portfolio Overview • Areas of Applications • Applications Benefits • Why KBR? • Overview • Dynamic Simulation • OTS • APC • Summary

  3. Technology Operations Advanced Chemical Engineering Portfolio Overview Advanced Services Dynamic Simulation Computation Fluid Dynamics Logistics Simulation Liquid Transient Analysis Technical Data Support Advanced Solutions Operator Training Simulator Advanced Process Control Real-Time Optimization Alarm Rationalization Manufacturing Execution Systems

  4. Areas of Applications Troubleshooting Front End Design EPC Commissioning & Startup Operation & Maintenance Dynamic Simulation Liquid Transient Analysis CFD Pinch Analysis Operator Training Simulators Advanced Process Control Alarm Rationalization Real Time Optimization

  5. Applications Benefits • Resolution of complex design & field problems • Provides hands-on training for smooth startup, shutdown and normal operation • Faster plant commissioning • Ensures safe operations • Increased plant reliability & availability • Optimizes operations – production, energy use, emissions • Minimize CAPEX & OPEX 1 day to 1 week production gain per year ($0.5MM - $10MM)

  6. Why KBR? • Intimate knowledge of process and operations • Specialized and experienced execution team • Depth of talent pool within the organization • plant services, start-up/commissioning teams, machinery, etc • Attention to detail and quality • Open and transparent communication channel • One stop solution provider

  7. Advanced Chemical Engineering Dynamic Simulation

  8. Steady State Simulation (Picture) Dynamic Simulation (Movie) What is Dynamic Simulation? Dynamic Simulation tracks the real behaviour of a process or whole plant over time.

  9. Why Dynamic Simulation? • Robust Design for the Full Range of Operation • Startup, shutdown, restart, load variation and other non-steady state operations • Minimize design margins • Verify control systems • Driven by Industry Demand • Larger and complex systems • Reliability, availability, operability and performance optimization • Optimal design of flare and relief systems • Improve on past experience

  10. Ammonia Utilities – Flare and Steam Control System Ethylene Furnace Control Utilities – Flare, Steam and Fuel Gas Compressors Petro-Chemicals Reactor Depressuring Refining Facilities Utilities – Flare, Steam and Fuel Gas LNG and Offshore Compressor Studies Control System Verification Utilities – Flare, Steam, Fuel Gas Equipment Specific Heat Exchangers Vessels Dynamic Simulation Applications in KBR

  11. Dynamic Simulation – Model Validation • Refrigeration Compressors • Surge control • Overall Process Responses • Plant Turndown

  12. What Does a Dynamic Model Look Like?

  13. Dynamic Simulation of Ethylene Furnace Pass-by-Pass Variation Steam Decoke Different Feedstock Yield Model from Team Ethylene Pre-cracking in Cross-Over Two-Phase Heat Transfer & Pressure Drop Flue Gas - Control of Firing, Excess Oxygen, ID Fan

  14. Refinery Expansion Dynamic Simulation - Relief & Flare Systems • Adequacy of relief & flare system design • Relieving sequence • HIIPS Validation

  15. Advanced Chemical Engineering Operator Training Simulator

  16. Dynamic Model of the Plant What is OTS? Plant DCS Consoles

  17. Advanced Automation Examples Advanced Process Control

  18. What is Advanced Process Control? • STABILIZE unit operation - minimize variability of key process variables • PUSH to constraints - reach closer to the product quality and equipment limitations • OPTIMIZE - minimize energy consumption or maximize plant throughput Original Setpoint New Setpoint $$$ Product Specification Optimized Setpoint Poor Control(without APC) Better Control(with APC)

  19. Advanced Process Control - Ammonia In general, the benefits of implementing a APC system in an ammonia plant are: an increase in the ammonia throughput by 1 to 4%, decrease in the energy consumption by 1 to 3%

  20. Advanced Process Control - Ethylene BEFORE AFTER observation ( Ethane - ppm) range

  21. Advanced Process Control - Benefits • FCC Unit (Mexico) • Improvement in converter operation from • Better conversion • Closer operation to constraints • Benefits of over $1,000,000 / year from increase in production of higher value products

  22. Summary KBR Technology Advanced Services & Solutions Proprietary Technologies Client Support Services

  23. Thank you very much… Questions?

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