Sustainability Impact to my Enterprise

Short Company Description

Modeling-based Energy Optimization & Development of More Efficient & Resilient Operating Philosophy in UGDC NGL Plant. The modelling has been developing based on comprehensive data analysis and continuous improvement actions to raise overall .efficiency.

Location

Egypt

I am a

Large Corporation End User

Segment Type:

Energies and Chemicals

Company Size

50M - 250M euro

Is there someone in your organization who is most responsible for these results? If so, please share their name and email address.

Ahmed Mohamed Mohsen aabdallah@ugdco.com aabdallah8981@gmail.com

I have been supported by a Schneider Electric contact. If “Yes”, please indicate the name of your Schneider Electric contact.

1. Do you Strategize?

No

A. Do you have a decarbonization plan with milestones? If so, please share your roadmap/plan.

B. Have you completed Sustainability School?

2. Do you Digitize?

Yes

A. Have you deployed centralized utility data management and monitoring software for energy and carbon analysis and reporting?

Large Excel workbook and then the data migrated to online DCS dashboard for real-time analysis and operators guidance.

B. Are you using metering of major energy loads to uncover opportunities to reduce energy and emissions?

Fuel gas consumption in significant energy users (gas turbines and fired heater) are measured (metered) by flow transmitters. All dependent and independent parameters and variables are compiled for comprehensive scrutinized data analysis and consumption rationalization to comprehend the system, and then to model the system's performance, then to reveal the opportunities and bottlenecks, then to optimize effectively.

C. Do you monitor energy efficiency and equipment performance and provide actionable insights?

Too many efficiency figures and customized energy indicators are used to indicate equipment efficiency and most importantly, the overall plant energy efficiency indicators. For example, fired heaters are monitored by thermal/heating efficiency (Observe differences, act, load the higher efficiency, always optimize, anomalies activate inspection & maintenance activities). Turbines are monitored by their overall power system efficiency factor (a dimensionless term for the required power ratio to actual energy flow), and plant combined heat and power energy indicator indexed to the most impactful parameters as found from data analysis. Moreover, a developed actual to defined optimum ratio is developed.

D. Are you using power management and monitoring to monitor power quality and increase business resiliency and continuity?

Modelling-based approach is adopted to define the optimization targets. Turbines are monitored by their overall power system efficiency factor (a dimensionless term for the required power ratio to actual energy flow), and plant combined heat and power energy indicator indexed to the most impactful parameters as found from data analysis. Moreover, a developed actual-to-defined optimum ratio is developed.

E. Have you deployed innovations to maximize efficiency and digitalization of your operations?

An array of analysis was established by big data compilation, daily compression power data analysis (based on adiabatic compression), daily plant heat analysis, then combined heat and power analysis (collective overview concept of analysis), then ending up with real-time analysis as a step to probable energy management digitalization. Along the mentioned array of daily comprehensive analysis, high-quality new information about opportunities and bottlenecks have been revealed for further processing and handling to effectively optimize energy consumption. A large Excel workbook was diligently utilized and then the data migrated to an online DCS dashboard for real-time analysis and operators guidance.

F. Have you implemented asset upgrades and modernization programs to optimize and increase the longevity of your plant equipment and so, avoid emissions?

No.

G. Have you embraced the digital integration of power and process as a way to minimize energy consumption while optimizing your process?

An array of analysis was established by big data compilation, daily compression power data analysis (based on adiabatic compression), daily plant heat analysis, then combined heat and power analysis (collective overview concept of analysis), then ending up with real-time analysis as a step to probable energy management digitalization. Along the mentioned array of daily comprehensive analysis, high-quality new information about opportunities and bottlenecks have been revealed for further processing and handling to effectively optimize energy consumption. For example, significant heat consumers were addressed and optimized and other process limitations were solved. A large Excel workbook was diligently utilized and then the data migrated to an online DCS dashboard for real-time analysis and operators guidance.

3. Do you Decarbonize?

Yes

A. Do you use automation and energy management systems to control equipment and systems efficiently?

A modeling-based deeper energy management system is adopted to signify the energy system's performance abilities and limitations and act accordingly. An array of analysis was established by big data compilation, daily compression power data analysis (based on adiabatic compression), daily plant heat analysis, then combined heat and power analysis (collective overview concept of analysis), then ending up with real-time analysis as a step to probable energy management digitalization. A large Excel workbook was diligently utilized and then the data migrated to an online DCS dashboard for real-time analysis and operators guidance. Regarding the automation, one fired-heater control loop was always in manual mode and well-configured, tuned, and turned to automatic successfully. The HMI of gas turbines got closer to the operators in the control room to get closer accessibility to turbines control rather than being 1 KM away from the control room.

B. Have you implemented practices that have increased your energy efficiency?

Direct Measurable Impact (Average Results): 10% reduction in fuel gas consumption and GHG emissions in 2023 1.14 MMSCFD fuel gas reduction 23 KTA reduction in Carbon Dioxide emissions with their potential economic impact from probable carbon credit, trade, or taxation systems Saving fuel cost/OPEX 2.33 MM$ in 2023 (6400 $/day) Projected cumulative savings are 22.7 mm$ & 225 KTA CO2 till 2030 Turbines overall power system efficiency term was raised from 0.30 to 0.34 - 0.36 and now depends on the pressure ratio. Sales gas compressors' minimum discharge pressure was limited to 57 bar and delimited now and reached 50 bar. Plant combined heat and power energy indicator (developed analytical term) enhanced from 0.17-0.18 to 0.15-0.16 (MMBTU fuel gas / feed gas MMSCFD x Grid pressure bar)

C. Do you use renewables (PPAs, EACs, or onsite generation) for at least a portion of your energy needs?

No

D. Do you source energy through renewable energy power purchase agreements (offsite) or Energy Attribute Certificates to minimize your scope 2 emissions?

No

E. Do you use electricity from onsite renewable energy generation for reduced scope 2 emissions?

No

F. Have you implemented energy storage for improved resiliency, and to minimize peak demand and the associated carbon emissions? 

No

G. Have you aggregated distributed generation assets to maximize economic value and grid impact?

No

H. Have you seen carbon reduction through improved operations focused on energy efficiency and decarbonization?

23 KTA CO2 saved in 2023 by saving an average of 1.14 MMSCFD fuel gas consumption (10% reduction).

I. Have you seen carbon reduction through modernization projects focused on energy efficiency and decarbonization?

J. Have you implemented practices to increase your energy efficiency?

Based on modeling and data analysis results and the extracted information, performed optimization for operating conditions, optimizing and standardizing human performance for consistency, establishing new energy management system, deciphered relationships, exploited the revealed opportunities, and debottlenecking and delimitation, and solving problems for units operations. For example, Debottlenecking Major Heat Consumers and Delimitation of Compressors Discharge Pressure and others.

K. Do you have a commitment program with your suppliers to reduce Scope 3 emissions?

No

L. Do you have a commitment program with your upstream suppliers and downstream distribution to track and reduce Scope 3 emissions?

No

M. Do you utilize digital modeling to capture embodied carbon data from materials and equipment?

No

N. Have you incorporated electric vehicle charging infrastructure into your operations for fleets, employees, and/or customers?  

No

O. Have you converted some of your fleet vehicles or available parking to electric vehicles or EV-ready?  

No

P. Have you electrified some of your operations to reduce your scope 1 emissions and enable use of renewables to shrink your carbon footprint?

No

Q. Are you purchasing low embodied carbon materials and equipment?

No

R. Are you using condition-based maintenance to extend your equipment life, delaying the purchase of new equipment and reducing the associated embodied carbon?

S. Do you purchase carbon offsets to balance any residual scope 1 and 3 emissions?

T. Do you reduce water usage through improved operations focused on efficiency? 

Green areas irrigation is sourced from treated sewage/waste water treatment unit.

U. Do you monitor and adjust water usage based on water availability risks forecasts? 

No

V. Do you have optimization programs for clean-in-place operations, water and wastewater treatment and recovery focused on efficiency? 

No

W. Are circular materials procured and waste minimized in your operations?

No

X. Do you have a plan to move your fossil energy-based processes to electrification?

No

Y(i). Have you deployed innovations or circularity business models? Please select all that apply:

Deployed innovations to reduce energy consumption and carbon emissions of your operations

Y(ii). What are the results of these innovations?

Participating and sharing the project's idea with too many companies and institutions.

Additional documents (if any)

Translation (when applicable)