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Increase Energy Efficiency and Reduce Emissions

Honeywell offers solutions that can help industrial plants reduce energy consumption by up to 10% and help abate greenhouse gas emissions. These solutions include simulation tools, manufacturing execution systems, advanced process control applications and emissions monitoring. These solutions help customers to:

• Purchase energy economically
• Produce energy economically with improved efficiency
• Produce energy economically by reducing costs
• Prioritize energy usage and improve process efficiency
• Maintain environment and reduce emissions

Available Resources:

Podcast: Honeywell's Advanced Energy Solutions for Industrial Power Generators

White Paper: Energy Efficiency and Greenhouse Gas Abatement

Case Studies: Energy Efficiency

Compressors and some other plant equipment are heavy users of energy. It is not unusual for some of this energy to be wasted, for instance by operating compressors away from best operating point. Honeywell's Profit Controller can reduce energy consumption by over 5%, not only does this save money but reduces the plant's carbon footprint.

Available Resources:

White Paper: Profit Controller Saves BP Ula Field USD$1M in Reduced Carbon Taxes

Learn about Advanced Energy Solutions for Industrial Power Generators

Multivariable, predictive control and optimization applications such as Honeywell's Profit Controller have been commonly applied to refinery processes. The ability to take models derived from process data and configure them in a highly flexible manner allows the engineer to design controllers that can be suitable to maximize throughput, maximize yields and minimize energy just by changing cost factors in the objective function. This environment is very suitable for incorporating energy strategies into overall operating objectives. In fact, it is generally advisable to add energy efficiency objectives into existing strategies as it is important that minimizing energy is not done at the expense of maintaining yields of most valuable products.

Honeywell and UOP have developed a suite of energy optimization solutions that can provide refiners a 12 to 25 percent reduction in energy use, and associated costs and emissions. The solution combines process technology and engineering expertise from UOP with the process automation experience of HPS, and includes things like improving measurement and monitoring, using control and optimization applications, implementing advanced technologies, maximizing waste heat recovery, optimizing the H2 network, and exploring ways in which these results can be sustained and even improved over time.

Honeywell has recently released its Advanced Energy Solutions for industrial power producers. Built on the same foundation as Honeywell's Profit Suite solution, Advanced Energy Solutions is an integrated but modular advanced control solution that has been specifically designed for industrial steam and power plants.

Available Resources:

White Paper: Energy Optimization and CO2 Reduction in Refining

White Paper: H2 Management

Learn about Advanced Energy Solutions for Industrial Power Generators

There are a number of units within a MMM operation that are very large energy users. For example the comminution operations within a concentrator could consume 30 — 40 percent of the total energy. It is not unusual for some of this energy to be wasted, for instance by overgrinding. Honeywell's Profit Controller can reduce grinding circuit power consumption by over 5 percent, not only does this save money but reduces the plants carbon footprint. Similar energy savings have been proven when applying this technology to other processes such as alumina refining.

Getting Energy Cheaper

Many MMM operations have an on-site power generation facilities that may also be used for steam generation. Optimization of these facilities is complex but could result in significant energy savings and reductions in emissions. Honeywell's Advanced Energy Solutions is an integrated but modular advanced control solution that has been specifically design to meet the needs of industrial power producers.

Available Resources:

Case Study: Woresly Alumina improves productivity and saves energy

Learn about Advanced Energy Solutions for Industrial Power Generators

In the Pulp Mill

Honeywell's Profit Suite improves efficiencies in boiler, washing, TMP, lime kiln, and digester operations, drastically reducing energy usage. Honeywell's advanced control strategies for the pulp mill stabilize processes while reducing swings, and improving the efficiency of boilers and washers.

Honeywell's energy solution for utility and industrial power generators achieve maximum effectiveness in steam load allocation to boilers and turbines, to optimize boiler combustion processes, while stabilizing and maintaining steam header pressure.

On the Paper Machine

The most important thing to control on a paper machine, when trying to reduce energy usage, is water removal. Drying accounts for 67 percent of the total energy consumed in the papermaking process, so by reducing the dryer load by only 3 percent, the cost per ton of paper produced can be reduced by $1.32/ton. Honeywell has several important strategies for efficient water removal in the drying section, and down the length of the paper machine.

Honeywell solutions include enhanced moisture measurements, CD actuators and advanced, multivariable control strategies designed to optimize and coordinate water removal, while maintaining quality parameters of the finished product.

Available Resources:

Case Study: Catalyst saves $1M per year in energy costs on their TMP Process

Video: Flambeau Paper saves energy by reducing dryer load on their paper machine

Learn about Advanced Energy Solutions for Industrial Power Generators

Optimize the Process with Advanced Process Control

Honeywell's Advanced Control and Optimization applications address all aspects of process optimization, from improving regulatory loop control to globally optimizing the entire process based on a unique layered approach. Profit Suite is unique in the industry with our layered optimization approach. This approach provides a scalable, benefits-driven approach for the deployment and long-term sustainability of the solution leveraging a common skill set from base Advanced Control technology to multi-unit and multi-plant optimization. Profit Suite technologies are designed to be flexible and applicable to a wide range of industrial processes, are easier to implement than competing products, and provide leading edge technologies for the maintenance and long-term sustainability of the solutions. As the foundation of Honeywell's layered optimization approach, Profit Controller provides the base for increasing economic benefits of your process in a user-friendly environment. Project payback periods of less than a year are typical with sustained benefits lasting indefinitely.

Honeywell's APC applications offer the following benefits:

• Increase profitability through increased production, reduced operating costs and improved product quality
• Improve plant safety with more flexible operations and early detection of abnormal events
• Increase employee productivity through improved operator effectiveness and lower engineering requirements
• Achieve the highest return on investment and continue to deliver sustainable results throughout the entire application lifecycle

Petrochemicals	Benefits (/yr)
Ethylene	2-4% increase in production
VCM	3-5% increased capacity / 1-4% yield improvement
Aromatics (50KBPD)	3.4M - 5.3M US$
Chemicals	Benefits (/yr)
Ammonia	2-4% increased capacity / 2-5% less energy/ton
Polyolefins	2-5% increase in production/Up to 30% faster grade transition
Oil & Gas	Benefits (/yr)
Upstream production	1-5% increase in production
Industrial Utilities	Benefits (/yr)
Cogeneration/Power Systems	2-5% decrease in operating costs
Pulping	Benefits (/yr)
Bleaching	10-20% reduction in chemical usage
TMP (Thermo Mechanical Pulping)	$1M-$2M

Refining	Benefits ($0.01/bbl)
Crude Distillation (150 KBPD)	5-13
Coking (40 KBPD)	15-33
Hydrocracking (70 KBPD)	13-30
Catalytic Cracking (50 KBPD)	13-30
Reforming (50 KBPD)	10-26
Alkylation (30 KBPD)	10-26
Isomerization (30 KBPD)	3-17
MMM	Benefits (/yr)
Alumina Refining	2-4% increase in production
Concentration	2-4% increase in production / 1-5% energy reduction / 1-4% recovery improvement
Smelting	2-4% loss reduction / Significant campaign life improvement

Available Resources:

Case Study: Gulf Petrochemical Increases Productivity and Energy Efficiency with Advanced Process Control

White Paper: Best Practices for Supporting and Maintaining Advanced Solutions

White Paper: Optimization Solution

Video: Chemical Plant Reduces Energy Costs with Profit Controller

Case Study: Codelco Improves Production with Profit Controller

Case Study: Saskferko Increases Energy Efficiency with APC

Product Information Note: Advanced Control and Optimization Integration with Experion

Case Study: BASF Increases Production and Achieves ROI in Six Months

The upstream and gas processing sectors are now recognizing the benefits of applying Advanced Process Control technology to their processes. Whilst there have been significant throughput improvements reported, this technology also stabilizes operations leading to reductions in tripouts and equipment wear, and hence reduced maintenance costs). Honeywell's Profit Controller is a state of art multivariable predictive controller that has been proven to work under the hard working conditions found in remote upstream operations. It has successfully been applied to many unit operations such as gas-lift optimization, slug mitigation, GOSP optimization, gas treatment, gas fractionation and LNG train optimization. Typical production improvements are from 1 to 5 percent additional volume, with payback measured in weeks.

Available Resources:

Case Study: BP Marlin Platform Increases Production with Honeywell's Profit Controller

Case Study: Woodside in Australia improves process performance with Honeywell's Advanced Process Control

Oil refiners have, for a long time, recognized the value in advanced control to stabilize the process and increase profits. The minerals processing sectors are now recognizing the benefits of applying this technology to their processes. While there have been significant throughput improvements reported this technology also stabilizes operations leading to wear reductions, and hence reduced maintenance costs. Honeywell's Profit Controller is a state of art multivariable predictive controller that has been proven to work under the hard working conditions found in mineral processing operations. It has successfully been applied to many unit operations such as milling, flotation, thickening, drying and digestion processes.

Available Resource:

Case Study: Codelco Copper Increases Production with Honeywell's Advanced Process Solutions

Improve Quality and Reduce Waste for Papermakers

Increasing costs for energy and raw materials combined with a downward pressure on paper prices from global over capacity is resulting in pressure on paper manufactures to further improve operational efficiencies. A Honeywell QCS system with CD actuators is a way to capture some incremental profitability by increasing product quality, minimizing production costs, and maximizing paper machine efficiency.

Honeywell's Quality Control Systems for papermaking processes provide a comprehensive suite of online sensors, combined with fast scanning and data processing speeds, to deliver precise, high-resolution measurements. Honeywell's CD actuators close the control loop by optimizing the quality parameters to reduce product waste, improve machine efficiencies and decrease raw material and energy costs.

• Increase product quality
  • Reduce Moisture, Weight and Caliper variability by 50~90%
  • Stabilize MD trends
  • Ensure minimum product compliance
  • Enable higher value added grades to be produced
• Minimize production costs
  • Reduce high cost materials (fiber)
  • Reduced energy usage
  • Reduce waste and broke
• Maximize paper machine efficiency
  • Faster break recoveries to saleable quality
  • Improved machine productivity by up to 10%
  • Quicker grade changes
  • More effective production scheduling

Available Resources:

Video: Learn What Honeywell Customers Say About Our Quality Control Systems

White Paper: How Mills Are Using QCS Systems to Improve Quality and Productivity

Multivariable, predictive control and optimization applications such as Honeywell's Profit Controller have been commonly applied to refinery processes. The ability to take models derived from process data and configure them in a highly flexible manner allows the engineer to design controllers that can be suitable for many purposes. The same controller can be used to maximize throughput, maximize yields and minimize energy just by changing cost factors in the objective function.

Improved Blending and Movement Operations in Refining

By delivering complete planning, execution and performance monitoring of blending and movement operations, Honeywell's blending and movement products improve operations and optimize in-line blending to increase plant profitability and minimize incidents. These products provide and execute formulations that meet inventory constraints, delivery schedules and product specifications while also facilitating data analysis and determining key performance indicators.

Honeywell's blending and movement solutions offer improved blending operations, reduced re-blends and more efficient movements. Additional benefits may be achieved through inventory savings, reduction in the number of costly incidents and more efficient use of staff. Payback can be realized in as little as six months.

Typical benefits include:

• $.05 /bbl savings from monitoring, measuring and acting on key blending and shipping KPIs
• Up to $200,000 savings per year due to reduced inventory from improving blending for a 100k bpd refinery
• Reduction in custody transfer errors worth $100,000+ per year in savings from more accurate, reliable blending and movements
• Reduced demurrage fees which can result in $millions of savings per year due to improved movement reliability and flexibility

Available Resource:

Case Study: Navajo Refinery Improves Process Performance with Advanced Process Control

Case Study: MOL Optimized Blending Processes

White Paper: Optimization Solutions

Case Study: Honeywell helps Grupa Lotos Improve Efficiency and Quality

Case Study: Hellenic Optimizes Process Performance