(81c) Energy Management System for Ethylene Complex

Energy costs typically dwarf other operating expenses for an ethylene plant. In addition, fuel consumed in furnaces and boilers contributes to greenhouse gas (GHG) emissions. Shell, like many companies, has goals to reduce both operating costs and GHG emissions.

Tracking and reporting some aspects of plant performance (e.g., simple yield reporting) are relatively straightforward and calculations typically involve only a few meters or other process variables. Due to heat integration between process units and the complexity of energy flows into and out of units within an ethylene complex, it is difficult to get a clear picture of overall energy performance. Energy benchmarks and the approach to performance monitoring are often ad-hoc and customized. This can lead to problems maintaining the calculations and reporting tools. It can also make it difficult to understand relative performance between even similar units.

Shell's Norco Chemical Plant developed an Energy Management System (EMS) to provide real-time reporting of energy consumption and serve as a standard platform for managing energy performance. This paper will provide an overview of the EMS, Shell's approach to developing the system, the benefits of the EMS, and potential barriers to developing and maintaining an effective EMS.