Environment & Safety Gas Processing/LNG Maintenance & Reliability Petrochemicals Process Control Process Optimization Project Management Refining

KBC simulation software optimizes the hydrocarbon value chain

KBC (A Yokogawa Company) has launched its Petro-SIM® 7.5 process simulation software. This digital twin platform supports diverse needs across the hydrocarbon value chain, from upstream to downstream and petrochemicals and from design to operations.

Operators face challenges in maintaining the stability and efficiency of industrial operations due to feed property fluctuations, volatile prices and uncontrollable disturbances. This version introduces a real-time optimization (RTO) solution that optimizes production, energy use, emissions reduction, profitability, safety and reliability. It supports maximizing asset performance and sustainability building upon existing resources to optimize decarbonization efforts and return on investment (ROI).

According to Bradley Ford, global process optimization solution leader of technology at KBC, “Advanced process control systems are effective at managing fluctuations, but they fall short in delivering holistic optimization.” KBC’s analysis shows many RTO systems rely on complex and only partly integrated subsystems. This level of complexity, combined with a shortage of expert resources, often causes low service factor due to maintenance challenges. The Petro-SIM 7.5 simulator with RTO enabled can leverage non-technical skills for long-term maintainability to maximize the software’s benefits.

“With KBC's expertise, operational efficiency and environmental responsibility are prioritized and report a potential ROI of 300% and a payback period of up to six months,” said Ford.

The main benefits of the RTO tool in this new version include:

  • Leveraging existing investments—It builds upon current skills, rigorous simulation models, and model maintenance routines to provide an RTO that maximizes ROI.
  • Maximizing uptime—It dynamically tracks facility operations to maximize RTO performance for greater profitability, while handling occasional production disruptions.
  • Optimizing set points—It adjusts to changes in plant feed properties and product yields to ensure efficient operations that align with production schedule demands.

The RTO key features include:

  • Steady-state detection—Analyzes site data to determine if the unit operates at steady-state.
  • Gain generation—Automatically creates gain matrices at various operating points when the unit operation is in steady-state mode, which helps optimize setpoints for the underlying advanced process control system.

Additionally, Petro-SIM 7.5 software introduces an enhanced water electrolyzer model for more robust and accurate simulation of green hydrogen production processes to support sustainability initiatives.

By bridging virtual simulations with real-world scenarios, the platform not only bolsters operational resilience and production efficiency during uncertain times but also creates opportunities for growth and effective ESG management.

According to the company, these advancements in Petro-SIM 7.5 simulation software exemplify KBC’s capabilities to make plant operations more autonomous, economical, and efficient, as well as its commitment to Bringing Decarbonization to Life™. 



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