SMART MANUFACTURING FOR CHEMICAL PROCESSING: ENERGY EFFICIENT OPERATION OF AIR SEPARATION UNIT

Project Lead: Texas A&M Engineering Experiment Station (TEES)

Partners: Praxair, Process Systems Enterprise, AspenTech, OSISoft, Rensselaer Polytechnic Institute, University of Texas Austin

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Problem Statement:  An Air Separation Unit (ASU) is a complex and energy intensive process for chemical industries. Sub-optimal performance of these processes result in a loss of energy efficiency. For Praxair in the US, each 1% in operating efficiency is worth about $10 M/yr.

Project Goal: The goal of this project is to develop a number of SM Platform™ ready tools and deploy them on Praxair’s commercial Air Separation Unit for improving energy efficiency.

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Technical Approach:

  • Create data acquisition tools, asset templates and predictive tools for the air separation units and demonstrate their application in an integrated environment.

Key Tasks/Milestones:

  • Develop data model templates for the air separation unit for data acquisition and modeling & control environments (M6)

  • Implement a coupled on-premise & cloud historian system to collect plant data for analysis in the cloud (M6)

  • Develop steady state, dynamic, control oriented, planning and scheduling models for ASU (M9)

  • Develop data models for individual assets for integration into a Remote Asset Management workflow (M12)

  • Develop analysis tools for the efficient monitoring and operation of the Air Separation Unit (M15)

  • Validate analysis tools through field testing on an air separation unit at Praxair (M24)

Potential Impact:

  •  Increase in operating efficiencies of Air Separation Units estimated at $10M/yr. for one large manufacturer, with potentially similar impact to other manufacturers with similar ASUs Contributes to CESMII’s energy reduction and energy productivity goals

Benefit to CESMII:

  • Data templates, models, analytics tools available to other members with similar processes through the SM Platform™

    Contribution to the SM Platform™ core technologies (data acquisition, contextualization and apps)

 

Project Cost Share and Duration:

Project Duration: 24 months, CESMII Cost Share: 58%, Member Cost Share: 42%

 
 
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