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ABB CUSTOMER DAY, JAKARTA, 15 NOVEMBER 2023

ABB Ability™ Energy Management & Optimization – OPTIMAX®

Steam & Power Optimization

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Introduction
Steam & Power Optimization
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Steam & Power Optimization
A complex coordination problem

Steam & Power Control Gap

Utilities Industrial Process
• Complex control and optimization problem

• Site Wide
On- site power Electrical
• Process has priority over Utilities generation consumers

• Steam & Power is a significant contributor Grid/

to site operation costs Energy
Market

Steam
Steam consumers
generation

November 13, 2023 Slide 3 © Copyright [2021] ABB. All rights reserved.
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Steam & Power Optimization – Rationale
Industrial steam networks are very complex
TSO
CC

HRSG
Multiple equipment VHP
GT
Steam
Cracking
• Different age/size
B1 B2
• Different fuel types
• Different efficiency
• Different dynamics (fast/slow) HP Users
ST1 ST2 ST3

Strong Disturbances PRV1

• Steam/Power demand changes Vent

MP Users
• Energy recovery disturbances
TP1 TP2
• Steam/Power events
• Changes in fuel availability LP Users PRV2

• Variable Energy Market prices

ST4

November 13, 2023 Slide 4

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Steam & Power Optimization
Challenges and opportunities
CC

HRSG
GT
Further challenges Steam VHP
Cracking
• Steam and power are strongly interconnected B2
B1

• Different automation systems, different control

rooms, different organizations
ST1 ST2 ST3
HP Users
• Renewables Variability

Opportunities PRV1

• Tradeoffs between power and steam are often Vent

possible. BESS flexibility MP Users
TP1 TP2
• Depending on energy price and fuel costs optimal
conditions change LP Users PRV2

• Coordinated Control considering explicit

economics provides significant, tangible benefits ST4

November 13, 2023 Slide 5

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Steam & Power Optimization
Areas of improvement

• Turbines have different efficiency curves

• Boilers have different efficiency curves and may use

different fuels

• Minimize
• Venting
• Minimize use of Pressure Reduction Valves (PRV)
• Optimize use of Condensation
• Optimize Pressure & Temperature on headers
considering steam quality close to users
• Optimize CO2/Emission economics p, T
• Optimize use of Renewables & BESS

• Optimize Energy Market interaction

User #1 User #n

November 13, 2023 Slide 6

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Steam & Power Optimization – Load Shedding
Integrated solution – Process Power Management

• Steam & Power Optimization can be integrated with Steam

Shedding. Benefits:
• Fewer critical events
• Coordinated management of Steam Network - avoid steam
crisis after disconnection

• Steam & Power Optimization will provide steam network

control, handling longer time constants

• Steam & Power Optimization reduces number of electrical

events and mitigates impact if the event happens

November 13, 2023 Slide 7

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Technical Solution – OPTIMAX®
Steam & Power Optimization
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Steam & Power Optimization – OPTIMAX®
Automation hierarchy view
Energy Market

• Optimizer computes the optimal operating point Forecasting OPTIMAX

considering non-linear models (e.g., equipment
curves) and explicit economics. ENERGY & REAL TIME
OPTIMIZATION Target writes

• Steam Coordinator based on Advanced Process

Control (APC) technology STEAM APC
• Implements real-time control of steam
network Set Point writes
• Implements optimal balancing from Real Time
Optimization DCS 1 DCS n PPM

• Allows to adjust real-time control considering

actual costs and equipment efficiency. INSTRUMENTATION
ACTUATORS

November 13, 2023 Slide 9 © Copyright [2021] ABB. All rights reserved.
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Energy & Real Time Optimization
Technology

OPTIMAX Dynamic Optimizer uses Dynamic models for

explicit economic Optimization.

• Linear and Non-linear models

• Mixed Integer Linear Programming
• Virtual Sensors & Inferentials e.g. Python based

Built-in solver, using Modelica generated FMU.

Can integrate APC and RTO data into a single environment.

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Advanced Process Control
Technology

ABB Advanced Process Control software uses State-Space

technology to describe models and control process
ABB APC software features an Observer Based Model
Predictive Controller, using Kalman filter technology

APC Objectives:
• Stabilize process operations/Reduce process variability
• Reposition key process variables
• Reduce energy consumption
• Better rejection of disturbances/events e.g. equipment
trips
— Option

Steam & Power Optimization EM

Architecture
• Minimal Hardware – just an
additional Server and a Thin client

• Connectivity via OPC

Project Scope

• Applicable to ABB and non-ABB

OPC Server Steam & Power Client OPC Server systems. References on:
Optimization

• Emerson Delta V
Firewall Firewall
• Emerson Ovation
• Honeywell
• Siemens
• Yokogawa
• Schneider / Invensys
DCS 1 DCS n
• Rockwell
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Monitoring and Control
User interface

WEB
DCS
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Customer Benefits
Reduce total cost of steam up to 5% and much more

Direct Benefits Additional Benefits ABB Experience

Increased Energy Efficiency, Use of OPTIMAX models for Refining, Petrochem, Chem
Reduced CO2 Footprint scheduling/planning sites

Coordinated management of Cogen with integrated District

Production Cost Minimization steam/power related-events Heating

Review and revision of Paper, Metals, Minerals, Food,

equipment control strategies etc.
Active Participation to Energy (ex. Boilers, Turbines, etc.)
Market (more profits or lower
costs)
Optimize Renewables & ABB and 3rd party DCS systems
BESS
Typical benefits: 2-5% of total
steam cost and CO2
ROI < 1 year

November 13, 2023 Slide 14

 — References around the globe

>200 installations
in

5 Continents
29 Countries

November 13, 2023 Slide 15

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Customer Benefits
Reduce total cost of steam up to 5%
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Steam & Power Optimization
Benefit – Sample case

Typical case:

• Save 2-5% of total steam production costs OPTIMAX

• Typical values

• Steam production 300 ton/h

• Steam savings (2%) 6 ton/h
• Steam value 60 USD/ton

• Benefits 2.88 MUSD/year

• CO2 Savings 8900 ton/year
• CO2 Savings 0.6 MUSD/year

• Energy Market benefits: potential, significant additional

value

November 13, 2023 Slide 17

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Sample Cases
Steam & Power Optimization
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Reference Case
BARK COAL
BLACK BLACK
CRF-2 LIQUOR PFB LIQUOR CRF-1
M

FI-008 8965 kPa FI-004 FI-101

Medium-small sized site FI-007 FI-015

CV ECV
PRV1
FI-028 FI-027

CRF-2 ID CV
FI-001 PRV2

FI-012 1520 kPa

Fans 1&2

TG1 G TG2 G
8965/1100
PRV3
FI-041

FI-026

FI-025

1100 kPa

• Stabilization
FI-013

• HP Steam Temperature 415 kPa

HP Steam Pressure
D/A

• 415 kPa Process Steam Users 1100 kPa Process Steam Users 1520 kPa Process Steam Users

• Steam Production

• Savings >4 % on Steam costs

• Steam output HP Boiler 
• HP Header Steam press/temp 
• Increase efficiency and power out

• Better management of fast dynamics e.g., paper

breaks (i.e. DCS strategies limited by Boiler
response time)

November 13, 2023 Slide 19 © Copyright [2021] ABB. All rights reserved.
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Reference Case
Large site, large steam network

• Stabilization
• Steam headers pressure
• Steam headers temp

• Optimal balancing for Boilers and Turbines

• Optimization of PRV use (open at low energy
prices)
• Optimization of Venting (open at very high
energy price)
• Optimize use of NG Fuel Blocks

• Management of trips/events

November 13, 2023 Slide 20 © Copyright [2021] ABB. All rights reserved.