Energy Savingand
Plant Performance ImprovementSymposium on Japan - Czech future comprehensive cooperation of Energy and Environment Sector 4thMay ,2009,at Hilton Prague
Reliability NO.1 Your partner for success
1Chiyoda Corporation, may 2009
Contents
1. Introduction of Chiyoda Group2. Challenge of Japanese Industrial Sectors ;
Refinery/Chemical Plants and Chiyoda's Assistance2-1. Overview2-2. Energy Optimization by Pinch Technology
2Chiyoda Corporation, may 2009
1. Name of Company Chiyoda Corporation
2. Date of Establishment January 20, 1948
3. Description of Company Integrated Engineering &Construction Service Provider
4. Name of President Takashi Kubota
5. Number of Employees Approx. 6,600 (Global Basis)
6. Capital ¥43.4 Billion
7. Revenues ¥603.6Billion (FY2007)
8. Head Office 2-12-1 Tsurumi-chuo Tsurumi-ku
Yokohama, Japan
Corporate InformationChiyoda Group (1/6)
3Chiyoda Corporation, may 2009
Business FieldChiyoda Group (2/6)
Gas Value Chain
Gas upstreamLNG(liquefaction, receiving
terminals)Synthesis gasGTL
Petrochemicals & Chemicals
OlefinsAromaticsMethanolFertilizer
Pharmaceuticals
Metals &Mining
General Industry
Environmental Protection
Refineries
Upstream
Electronic materialsFood processing
Flue gas desulfurizationAcid gas/CO2 capture and storageEnergy conservation
4Chiyoda Corporation, may 2009
Business Model
Operation and Maintenance service
By CLIENT
• Operator Assignment
• Start Operation
• MasterPlanningApproval
• BudgetApproval
• SpecificationApproval
• Drawing,CalculationApproval
• Attending ProgressMeeting
• Inspection • Attending ProgressMeeting
• Inspection
• Procedure Approval
• Basic Concept• Market Research• etc.
OPTION(If Required by Client)
FINANCE ARRANGEMENT• Investor Research• Official Development Assistance• Export Credit Agency• Other Funds
Research & Developmentfor Applied Mechanics, PollutionControl Technology, etc.
By CHIYODA
• Basic Operation,Logistics Concept
• Market Research
• Future Program
• Feasibility Study
• etc.
• Site, CapacityDetermination
• Basic Data• Master
Schedule• Manning
Schedule • Budget
Estimation• Other Client’s
Requirement• etc.
• Basic Design• Review of
Equip.• Review of
Material, Heat & Other Balance
• Construction CostEstimation
• Budget Allocation
• etc.
• Basic DesignSchedule
• Specification for subcontracting
• Quotation• Evaluation of
Sub-Contractor• Detail Design• etc.
• Procurement Detail Schedule
• VendorSelection
• Purchase Order
• Machine/Equip. Fabrication
• Inspection• etc.
• Construction Detail Schedule
• Temporary Work• Notification to
Authorities• Selection of
Subcontractor• Subcontracting• Construction under
Quality, Safety, Cost,Schedule Control
• Inspection• Preparation for
Commissioning• etc.
• Power -In• Machine
& Equip.Start-Up
• PipeFlushing
•etc.
• Training ofOwner’s Operator
Project Concept Master
Planning Basic Design Engineering
(Detail Design)Procurement
ConstructionCommissioning
TrainingOperation
Maintenance
EPC/EPCm EPC/EPCm O&MO&M
Plant Lifecycle EngineeringPlant Lifecycle Engineering
FEED*FEED*Project PlanningProject Planning
Decommissioning
DecommissioningDecommissioning
*Front-End Engineering Design
Chiyoda Group (3/6)
5Chiyoda Corporation, may 2009
Asset Integrity Management ServiceChiyoda Group (4/6)
Maintenance Maintenance ManagementManagement
InspectionInspectionManagementManagement
RiskRiskManagementManagement
EconomicEconomicManagementManagement
HSEHSEManagementManagement
InformationInformationManagementManagement
Safe & Stable Operation Safe & Stable Operation Safe & Stable Operation
Asset Management Strategy
Asset Management Strategy
High Performance Operation
EquipmentReliability
EquipmentReliability
DiagnosticsDiagnosticsAdvanced Eng.Advanced Eng.
WorkManagement
WorkManagement
EAM/CMMSEAM/CMMS Business Process
Consultation
Business Process
Consultation・Material Engineering
& Diagnosis・Lifecycle Engineering
& Risk Consulting
・SystemImplementation
・Data Preparation & Migration
・Business ProcessManagement
System Optimization
System Optimization
Process Performance
Process Performance
・Energy Saving・Process
Optimization
6Chiyoda Corporation, may 2009
Diagnosis of Existing Facility :Fired Heater
Plant Reliability Improvement by Advanced Eng’g (5/6)
TMT[℃]
Tube Skin Temperature
Upper Tube
Side TubeGas Temperature Flow Pattern
Flue Gas Flow
0.00.10.20.30.40.50.60.70.80.91.01.11.2
0 100 200 300 400 500
輻射部入口からの距離(m)
コーキング速度(-)
Time=720hr
Steam Rate:300kg/hrSteam Rate:600kg/hr
Distance from Radiant Inlet (m)
Cok
ing
Rat
e (-)
0.00.10.20.30.40.50.60.70.80.91.01.11.2
0 100 200 300 400 500
輻射部入口からの距離(m)
コーキング速度(-)
Time=720hr
Steam Rate:300kg/hrSteam Rate:600kg/hrSteam Rate:300kg/hrSteam Rate:600kg/hr
Distance from Radiant Inlet (m)
Cok
ing
Rat
e (-)
Coking Prediction
Coke Volume Distribution (Inside Tube)
Coking Rate
To examine....
- Flue gas flow pattern and temperature
distributions
- Tube heat flux distributions
- Tube skin temperature distributions
- Coking rate inside cracking tube
Coking Simulation
FilmFilm
CBS
CS C*
1)
2)3)ks
X=αC*
4)
Oil Oil PhasePhase
Tube MetalTube Metal
FilmFilm
CBS
CS C*
1)
2)3)ks
X=αC*
4)
Oil Oil PhasePhase
Tube MetalTube Metal
C*BS(
≒0)
7Chiyoda Corporation, may 2009
Chiyoda Group Companies JAPANChiyoda Corporation
* Yokohama Head Office* Koyasu Research & Development Center
Chiyoda Advanced Solutions Chiyoda KoshoChiyoda Keiso
THE NETHERLAND* The Hague Representative Office
CHINA- Chiyoda Corporation (Shanghai)* Beijing Office
THAILAND- Chiyoda (Thailand) Limited* Bangkok Head Office
NIGERIA- Chiyoda Nigeria Limited
* Lagos Office
SAUDI ARABIA- Chiyoda Petrostar Ltd.
* Al-Khobar Office* Jeddah Head Office
UAE* Abu Dhabi Office
QATAR- Chiyoda Almana Engineering L.L.C.*Middle East Headquarters Doha Office
INDONESIA- P.T. Chiyoda International, Indonesia* Jakarta Office
SINGAPORE- Chiyoda Singapore (Pte) Ltd.* Singapore Human Resources Office
MALAYSIA- Chiyoda Malaysia Sdn. Bhd
MYANMAR- Chiyoda & Public Works
Co., Ltd.
U.S.A- Chiyoda International
Corporation
INDIA- L&T Chiyoda Ltd.
PHILIPPINES- Chiyoda Philippines Corporation
ITALY* Milan Representative Office
RUSSIA- Moscow Office
KOREA* Korea Representative Office
AUSTRALIA- Chiyoda Oceania Pty Ltd.
- Major Overseas Subsidiaries & Affiliated Companies* Overseas Offices
Chiyoda Group (6/6)
8Chiyoda Corporation, may 2009
Overview (1/5)Challenges: in case of Refineries in Japan: in case of Refineries in Japan
■■ Energy SavingsEnergy Savings** IndustryIndustry’’s formulated Action Plan to reduce energy use s formulated Action Plan to reduce energy use
by 1by 133% by 2010 was adopted% by 2010 was adopted** Until 2007, unit energy consumption by 15% was alreadyUntil 2007, unit energy consumption by 15% was already
improvedimproved■■ Production Continuity with an Aged PlantProduction Continuity with an Aged Plant** Most of Japanese refineries were constructed Most of Japanese refineries were constructed before 880's0's** Reliable Production Continuity Plan is strongly required Reliable Production Continuity Plan is strongly required
even for aged planteven for aged plant
9Chiyoda Corporation, may 2009
Methodology for Solution
Overview (2/5)
Advanced Engineering
Plant Performance Improvement
FactFactFindingFinding
10Chiyoda Corporation, may 2009
Achievements : Energy Savings inJapanese Refineries
Overview (3/5)
0.50
0.60
0.70
0.80
0.90
1.00
1990 2007 2010
Year
1.0
Actual
0.85
Target
0.87
11Chiyoda Corporation, may 2009
Achievements : Plant Performance Improvement in Japanese Refineries
Overview (4/5)
Source: Agency for Natural Resources and Energy, Current Status of Japanese Refining Industry (2006 )
Country No. of Shutdowns No. of Shutdownsper Crude Throughput
Japan 15 Base (=100)
USA 254 480
UK 10 180
12Chiyoda Corporation, may 2009
Chiyoda’s Recent Experience in Energy Saving
Overview (5/5)
Refinery 11Petrochemicals 72Power plant 9Steel 8Pharmaceuticals 1Others 10
Total 111
As of Oct.2007 in the past 6 years
13Chiyoda Corporation, may 2009
Pinch Technology Energy Optimization by Pinch Technology (1/10)
*Analytical Method to find the best way to utilize heat efficiently*Expansion of Pinch Application
400
300
200
100
0-400-500 -300 -200 -100 0 100 200 300 400 500
Enthalpy [10^6kcal/h]
Solid: Target Dotted: Actual
Tem
pera
ture
(ºC
)
Optimization of steam level consumed
Optimization of steam level generated
Recovery of Hot Water and its utilization
Recovery of very low pressure steam and its utilization
Heating Media
Cooling Media
HeatingHeatingdemanddemand
CoolingCoolingdemanddemand
Actual
coldcold
hot
hot
RegionalOptimization
Multi-UnitsOptimization
Ene
rgy
Savi
ng
Zer
o E
mis
sion
Present Future
IndividualOptimization
Past
Evolution of Pinch TechnologyAnalysis of Heat-utilization by Pinch Technology
14Chiyoda Corporation, may 2009
Energy Optimization by Pinch Technology (2/10)
CHIYODA’sExperience of FS for energy sharing
MIZUSHIMA
MIZUSHIMA
10 major industrial areas in Japan
CHIBACHIBA
KAWASAKI
YOKKAICHIOSAKASYUNAN
KASHIMAKASHIMA
UBEUBE
OHITAOHITA
①①
②②
KITA-KYUSYU
Industrial areas in Japan studied with Pinch Technology
15Chiyoda Corporation, may 2009
How to apply Pinch TechnologyEnergy Optimization by Pinch Technology (3/10)
Pinch Analysis (Ind. area)
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00 2.50工場熱電比率 (R)
工場
コージェネ効
率
-1000
100200300400500600700
Tem
pera
ture
[C]
-1000 -800 -600 -400 -200 0 200 400
SourceSinkHot UtilityCold Utility
加熱用役のターゲット
クラスター排熱100
200
300
400
500
600
Tem
pera
ture
[C]
-50 -25 0 25 50 75 100125150Enthalpy [MW]近隣への熱輸送
Ind. AreasAnalysis
Pinch Analysis (Each Site)
Site E
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00 2.50工場熱電比率 (R)
工場
コージェネ効
率
0
50
100
150
200
250
Tem
pera
ture
[C]
-100 -50 0 50 100Enthalpy [MW]
コージェネ効率解析
Site D
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00 2.50工場熱電比率 (R)
工場
コージェネ効
率
0
50
100
150
200
250
Tem
pera
ture
[C]
-100 -50 0 50 100Enthalpy [MW]
コージェネ効率解析
Site C
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00 2.50工場熱電比率 (R)
工場
コージェネ効
率0
50
100
150
200
250
Tem
pera
ture
[C]
-100 -50 0 50 100Enthalpy [MW]
コージェネ効率解析
Site B
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00 2.50工場熱電比率 (R)
工場
コージェネ効
率
0
50
100
150
200
250
Tem
pera
ture
[C]
-100 -50 0 50 100Enthalpy [MW]
コージェネ効率解析
Site A
30%40%50%60%70%80%90%
100%
0.00 0.50 1.00 1.50 2.00
2.50工場熱電比率 (R)
統合
エネル
ギー効
率
0
50
100
150
200
250
Tem
pera
ture
[C]
-100 -50 0 50 100Enthalpy [MW]
Co-Gen Analysis
Plant Profile
Establishment of Data Base
Site E
排熱データ蒸気ユーザー
用役バランス用役リスト
Site D
排熱データ蒸気ユーザー
用役バランス用役リスト
Site C
排熱データ蒸気ユーザー
用役バランス用役リスト
Site B
排熱データ蒸気ユーザー
用役バランス用役リスト
Site A
Waste Heat DataSteam User
Utility BalanceUtility List
Multiple sites are condensed into one virtual site that is pinch-analysed
Individual site analysis Area analysis
16Chiyoda Corporation, may 2009
Potential energy savings :Chiba and Mizushima AreasEnergy Optimization by Pinch Technology (4/10)
① Chiba ②Mizushima Mizushim/Chiba
1) No. of Sites 23 35 1.52) Integrated fuel
Consumption (Fuel + power)2.88 mil.kL 3.50 mil.kL 1.2
3) Theoretical energy saving potential by R-Curve
analysis
0.51mil.kL 0.95 mil.kL 1.9
4) Theoretical energy saving potential by SSSP analysis
0.13 mil.kL 0.30 mil.kL 2.3
Total 0.64 mil. kL 1.25 mil. kL
Domestic crude oil consumption Equiv. to 1day
Equiv. to 2days
Summaryunit:Annual crude oil rate equivalentmil.kL:million kL
Domestic crude oil consumption in Japan: 0.60 million kL/day (approx.)
17Chiyoda Corporation, may 2009
History of Realization of Energy Saving Energy Optimization by Pinch Technology (5/10)
2002 2003 2004 200520012000
FeasibilityStudy
BasicDesign Engineering
Project Development
Execution①① Chiba areaChiba area
FeasibilityStudy
BasicDesign Engineering Execution
②② MizuhsimaMizuhsima areaareaFuji oil & Sumitomo chemical
FSBasic DesignEngineering
ExecutionKashima areaKashima area
FSBasic DesignEngineering
OhitaOhita areaareaUbe areaUbe area
18Chiyoda Corporation, may 2009
Map of Chiba Area Energy Optimization by Pinch Technology (6/10)
AnegasakiAnegasaki GoiGoi
Refinery: 1Petrochemical: 3Others: 1
Refinery: 2Petrochemical: 4
Refinery: 1Petrochemical: 11
RoadRoad
2km
15km
N
19Chiyoda Corporation, may 2009
Energy Saving Project in Chiba AreaEnergy Optimization by Pinch Technology (7/10)
Utility
Fuji OilFuji Oil
Sumitomo Sumitomo ChemicalChemical
Process ProcessPower
generationHeat sharing
Road
2.0km2.0km××2.5km2.5km
Sumitomo Sumitomo ChemicalChemical
Sumitomo Sumitomo ChemicalChemical
The 27th Energy Conserving Machinery Awards, Jan. 2007
Energy Saving:10,500 kL/YrCO2 reduction;28,000 ton/yr
Integrated energy monitoring system
20Chiyoda Corporation, may 2009
Achievements in Chiba Area : Energy SavingEnergy Optimization by Pinch Technology (8/10)
Temp.℃
Fuji Oil Sumitomo
1200
150100
Utilizing
Area U
tilizing Area
Wasted
Area
LH
Power
Generation
Energy Conservation
4,900kl/y
Energy Conservation
5,600kl/y
CO2 Reduction28,000t-CO2/y
Recent Achievement
21Chiyoda Corporation, may 2009
Achievements in Chiba Area :Integrated Energy Monitoring System
Energy Optimization by Pinch Technology (9/10)
Data Data
Level 2Area Optimization
Level 1Single Site
Optimization
FujiOil
SumitomoChemical
Boiler water
Shared Energy
Network
The 27th Energy Conserving Machinery Awards, Jan. 2007
Features;Features;1) Secrecy1) Secrecy2) Robustness2) Robustness3) Expandability3) Expandability
22Chiyoda Corporation, may 2009
Achievements in Chiba Area :Low Heat Power Generation System
Energy Optimization by Pinch Technology (10/10)
VaporizerVaporizer
CondenserCondenser TurbineGeneratorTurbineGenerator
Circulation pump
Circulation pump
The 27th Energy Conserving Machinery Awards, Jan. 2007
23Chiyoda Corporation, may 2009
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