valiprocessing
Data Validation & Reconciliation technology included in ValiStudio allows Belsim to provide the chemical manufacturing, such as ammonia and methanol industry, with a relevant solution to improve quality and reliability of process data and deliver cost savings and improved process control.
ACCURATE PROCESS DATA
INSPIRES INFORMED DECISIONS.
• VALIPROCESSING FEATURES:
  • Rigorous mass and energy flow modeling
  • Improved reliability of measurement data
  • Detection of faults and deviations in instruments & controllers
  • Evaluation and monitoring of equipment/catalyst performance
  • Calculation of KPIs with confidence interval ranges
  • Detection of underperformance
  • Optimization of unit operation (setpoints, maintenance schedule, ...)
  • Efficiency improvement by acting on time and on right parameter
  • Generation of customized reports using ValiReport Excel add-in
  • Evaluation of "What-If" scenarios
  • Design / revamping of units or plants
• APPLICABILITY
  • Steam reforming plants
  • Ammonia production plants
  • Methanol production plants
  • Fertilizer industry
  • Petrochemicals plants
• OUR CUSTOMERS
  • YARA
  • SAFCO
Model of Reforming Part in Ammonia Plant (Hydrogen Production).
01.
PROCESS MODELING FOR VALIPROCESSING
- STEAM REFORMING.
  • Modeling based on elementary physico-chemical principles
  • Use of proprietary built-in customizable thermodynamics package
  • Compatibility with third party packages for thermodynamics
  • Simultaneous consideration of all mass and energy balances and performance equations
  • Equipment represented with easy recognizable industry-standard symbols
  • Possibility to define own measurements, equations, and constraints through internal coding language
  • Color coding for quality of measurements after reconciliation
  • Instant access to complete property set of all streams and equipment
  • Drill down hierarchical structure based on interlinked process flow diagrams
KPI MONITORING - S/C Ratio & Furnace Performance
Measured & Reconciled Values for Steam to Carbon Ratio.
  • Monitor Steam to Carbon ratio versus time
  • Take better decisions based on reconciled values
  • In example : Reconciled S/C are higher than expected. Errors were detected in flow rate measurement (steam and process gas).
  • Result : Recalibration of flow rate meters delivered 500-600 kEuro/year in savings
  • Monitor furnace efficiency versus time
  • Point out underperformance by monitoring KPIs versus benchmark values
  • Act on purpose : air fuel ratio control, heat exchangers cleaning,...
  • Switch from Preventive Maintenance to Condition Based Maintenance
  • Quantify instantly impact of applied process changes and get clear process feedback
Furnace Performance Monitoring.
PERFORMANCE IMPROVEMENT STUDIES
Energy Consumption vs. Pressure at Constant NH3 Output
  • Quantify impact of changing specific parameters, such as natural gas inlet pressure, on specific energy consumption of plant
  • Tune process on optimum values and act directly online
  • Reduce energy consumption, diminish losses, and increase process yield
  • Identify parameters influencing global process performance
  • Understand how measurement errors propagate into process KPIs

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