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
