The only one & The largest Integrated Olefin Petrochemical Company in Indonesia In Cilegon Banten Province - Indonesia

Transkripsi

1 Kesiapan Industri Kimia Dalam Implementasi Industri 4.0 (Case study PT. Chandra Asri Petrochemical Tbk) Indonesia Industrial Summit 2018 April 4-5, 2018, Jakarta Convention Center Prepared by Helmilus Moesa (Advisor PT. Chandra Asri Petrochemical Tbk ) The only one & The largest Integrated Olefin Petrochemical Company in Indonesia In Cilegon Banten Province - Indonesia

2 1. Company Introduction PT. Chandra Asri Petrochemical Tbk. a. Site Location (Where We are & What We are doing) b. Business Process, supply & demand and multiplier efek. 2. Road map peningkatan Kapasitas Produksi ( ). 3. Peningkatan Effektivitas, Produktivitas, Efisiensi, Quality & Safety melalui process control dan digitalisasi. 4. Pemakaian Teknologi Process Control & Digital. a. PI Coreseight. b. Optience. c. Advanced Process Control (APC) & Real Time Optimizer (RTO) d. OCS e. Machine learning. 5. Summary Agenda

3 1a. Site Location PT. Chandra Asri Petrochemical Sites Locations In Cilegon (120 KM from Jakarta) Consists of 3 Locations, 9 s with total area=156 Hectares Location-3 20 Hectares (Bojanegara) 2 s Head Office (Jakarta) LOCATION-1 (120Hectares-Anyer) 4 s CAP 3

4 1b. Overall Block Diagram Business Process PT. Chandra Asri Petrochemical Tbk. external Customer

5 REFINERY 1c. Multiplier Effect Of PT. Chandra Asri Petrochemical Tbk LPG & Lighter Blue Sky Balongan & Cilacap Acetic Acid EDC VAM Ethyl Acete VCM BBM PVA PVC Application Of Petrochemical Products Packaging Bottle Cling rap film Crude Oil Naphtha Gasoline Kerosine Diesel Residu Ethylene Cracker Olefin Ethylene PT. Chandra Asri Petrochemical Tbk Propylene EO/EG Ethyl Ben Crude C5 Aromatic SM Piperylene PET/PES Polystyrene Polyethylene DCPD Polypropylene Dash board/ Automotive parts Battery case Glass aqua Refrigerator CPU Comp Remote Control Natural Gas LNG PLANT Condensate LNG Export Crude C4 Pygas Butadiene Benzene Acrylic Acid ) SBR Alkyl-Benz MTBE Al-Benz Sulfo- Super Absorbent BUTENE-1 Formulation Insulation cable Pipes Tyre Infus Textiles Pempers Polyester

6 1d. Indonesian Polypropylene & Polyethylene supply and Demand

7 Total Production (KTA) 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1, Peningkatan kapasitas PT. Chandra Asri Petrochemical Tbk ( ) KTA 3,301 3,458 Note: KTA : Kilo Ton per Anum 1 KTA : 1,000 Tons/Year KTA 3,938 4,171 6,500 8, New SSBR = 120 KTA Expansion BD= 37 KTA New PE = 400 KTA Expansion PP = 80 KTA KTA KTA Debottle necking - Ethylene = 40 KTA - Propylene = 20 KTA New MTBE =130 KTA New Butene-1 = 43 KTA KTA Second Complex CAP - Ethylene = 1000 KTA - Propylene = 550 KTA - C4 = 262 KTA - BD = 175 KTA - Benzene = 363 KTA KTA New Coal to Pet-Chem = 450 KTA NG to Pet-Chem = 850 KTA PX, PET, PES = 200 KTA

8 3. Peningkatan Produktivitas dan Effisiensi (Through Optimization of Process Control & Digitalisation) ADVANCED PROCESS CONTROL (APC) CONSTRAINTS REAL TIME OPTIMIZER ADVANCED PROCESS CONTROL APC : REAL TIME OPTIMIZER MAXIMIZE CAPACITY, PUSH CAPACITY UNTIL REACHES CONSTRAINT, STABILIZE QUALITY RTO : MAXIMIZE PROFIT, DRIVEN BY ECONOMIC DISTRIBUTED CONTROL SYSTEM (DCS) SET POINTS PID CONTROLLER SEQUENCE CONTROL MOTOR START/STOP INTERLOCK LOGIC CONTROL REGULATORY CONTROL DISTRIBUTED CONTROL SYSTEM (DCS), COMPRESSOR SURGE CONTROL (CCC) TURBINE SPEED CONTROL (TRISEN TS410), EMERGENCY SHUTDOWN SYSTEM (TRICONEX), FIRE & GAS DETECTION SYSTEM PLANT & EQUIPMENT TRANSMITTERS, CONTROL VALVES, FRACTIONATION COLUMNS, COMPRESSORS, TURBINES, PUMPS REACTORS, CRACKING FURNACES CONTROL VALVES TRANSMITTERS

9 Product Yield CONFIDENTIAL 3 a. Peningkatan Yield Yield Optimization % TAM WORLD CLASS Product Yield % 68.0 % % 68.1 % 2025 Q1 (Quartile-1) Q2 (Quartile-2) % 65.5 % APC Implementation % Year 9

10 Energy Consumption CONFIDENTIAL 3 b. Pengurangan pemakaian energy APC Implementation GJ/T-HVC GJ/T-HVC GJ/T-HVC Furnace Revamping Utility Optimization 2025 WORLD CLASS Energy Consumption Q1 Year 10

11 3 c. Optimalisasi Profit margin CAP complex simulation by optience It optimizes Operating Rate & Max Profit Feedstock Ranking SP Qty Rank Naphtha A KT 1 Naphtha B (20) - 5 Naphtha C (5) - 3 Naphtha D - 7 KT 4 Naphtha E 9 35 KT 2 Naphtha D (14) - 6 LPG LPG LPG Maximum Profit Margin Main Product Yield

12 Total Defect Area (mm 2 ) 3d. Peningkatan kualitas produk (dengan teknologi OCS) Pelletizer machine (Field) BATCH READING 12 pc film ~ 30 gr ~0.2% sample is inspected BATCH SAMPLING 1 sample of 15 Kg every 4 Hr 3.75 Kg/Hr CONTINUOUS READING 100% sample is inspected CONTINUOUS SAMPLING Trickle 100 g/10 sec ~36 Kg/Hr Bad Good Limit

13 3 e. Continuous Emission Monitoring System (CEMS) Gas Turbine Exhaust CCR Field DCS DCS-Console

14 4. Pemanfaatan Teknologi 4 a. PI Coreseight apps (Memonitor secara real time operasi pabrik melalui komunikasi mobile) Real Time Monitoring Mobile Tool Seeing plant data on any device, wherever we are, whenever we need it Chandra Asri has been utilizing such apps enables data analyzing in multiple ways supporting fast data-driven decisions and provide insights into operations and business

15 4. Pemanfaatan Teknologi 4 b. Contoh tampilan monitoring pabrik secara real time melalui komunikasi mobile Eye Catching Dashboard

16 4 c. OPTIENCE (Mengoptimalkan operasi pabrik berdasarkan perubahan input) Condition data link ( PI-System ) Actual plant operating condition Yield Simulator(Spyro apps) Raw Materials Specification P : Paraffin contents O : Olefin contents N : Naphthene contents A : Aromatic contents Sg :Specific Gravity ASTM-Boiling point Laboratory data OPTIENCE Market Price (fluctuate dynamic market price Constraint (Frequently change) Maximum Profit 16

17 4 d. Advance Process Control (APC) & Real Time Optimizer (RTO) apps Mengoptimalkan proses produksi secara otomatis berdasarkan perubahan imput

18 4c. Learning Machine Finding the Patterns Humans Can t See Flooding Having numerous high valuable assets, Chandra Asri will utilize machine learning as advanced early warning & risk detection software that identifies process & equipment problems Emission Vibration Contamination Fouling Cavitation Corrosion

19 Conclussion 1. PT. Chandra Asri Petrochemical Tbk merupakan industri hulu yang bahan bakunya dari Oil & Gas, dimana produk-produknya merupakan bahan baku untuk industri-industri hilirnya, yang akan menghasilkan produk yang bernilai tambah tinggi (semua jenis bahan baku plastic dan synthetic rubber) 2. Untuk meningkatkan produktivitas, effisiensi, profit margin, quality & Safety, Perusahaan (sudah/akan) menerapkan teknologi process Control & digitalisasi dengan memakai. a. Pi Coreseight b. Optience c. APC/RTO d. DCS e. SAP f. OCS g. Machine learning yang merupakan rangkaian road map menuju industri 4.0

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