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Utility Plant Optimization at Samsung Fine Chemicals |
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Samsung Fine Chemicals in Ulsan, Korea has a powerhouse that is very typical for chemical plants. There are three oil-fired boilers, three back-pressure turbines, a condensing turbine, three levels of process steam, and an electric tie-line to the Korean grid.
The company wanted to optimize this operation in order to improve their energy efficiency and reduce emissions. Like any power house, large or small, this requires a number of applications for performance measurement, advanced control, and optimization. For Samsung, Honeywell deployed applications from its Advanced Energy Solutions portfolio, including:
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 | PPM - Plant Performance Measurement for boilers and turbines |
| ACC - Advanced Combustion Control for boilers |
| MPC - Master Pressure Control for steam systems and headers |
| ELA-B - Economic Load Allocation for Boilers |
| ELA-T - Economic Load Allocation for Turbines |
| PPO - Plant Performance Optimization |
While the configuration of each utility plant is different, all utility plants produce the same products (electricity and steam). What are the potential savings from these advanced applications? Samsung Fine Chemicals measured their utility cost savings at just over $1M per year. Most of the savings came from improved efficiency in steam generation, and about 15% came from larger in-house generation of electricity due to optimization. No credit was given for the more stable operation of the entire utilities operation that comes from a more integrated approach to controlling the boilers and the various steam headers. Like process plants, utility plants can generate substantial savings when advanced control and optimization are effectively applied to typical operations. |
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