The present disclosure relates to a system for optimizing energy consumption required by an industrial process. Particularly, the present disclosure relates to operation of an industrial plant in a manner such that the cost of operation/energy consumption of the industrial plant to carry out the industrial process is minimized.
Background
Industrial plants like oil refineries have internal Captive Power Plant (CPP) for generation of utilities like steam, power (electricity), BFW (Boiler feed water). CPP is having various equipment like Boilers, STG (Steam Turbine Generator), GT-HRSG (Gas Turbine- Heat recovery steam generator). In addition, industrial plants include, Condensing Turbines, Back Pressure Turbines, Dual Drive Turbines, Motors, Flash Drum, Thermo-compressor, Pressure Recovery Desuperheater (PRDS).
The above components of the industrial plant have various requirements or need various resources to run said components such as pressurized steam, fuel, electrical power and motive force (mechanical energy). The above requirements or resources may be sourced from various components available in the industrial plant. However, utilizing each of the components incurs a respective cost in terms of fuel/energy spent to operate said components.
Therefore, there is an unresolved need for a process controller to optimally utilize the above components for meeting the requirements or resources required by the industrial process in the industrial plant.
Object of the Invention:

The object of the invention is to optimally utilize the above components for meeting the requirements or resources required by the industrial process in the industrial plant, such that the cost of operation of the industrial plant is minimized.
Summary of the Disclosure:
The method for optimizing energy in an industrial process carried out using an industrial plant comprises receiving, by a processor, requirements for carrying out said industrial process by said industrial plant (system). The processor then determines the energy requirements or resources for carrying out said process to meet said requirement. The processor then determines the energy cost model for each of a plurality of components of the industrial plant which may fulfill the energy requirements or resources. The processor further calculates the energy cost of operating one or more of said components to satisfy said energy requirements or the required resources. The processor based on the above calculation selects one or more of the components at full or partial capacity or selects one or more components to supply the required resource to satisfy the energy requirement or resource requirement at a minimum energy cost.
One of the process components of the industrial plant/system is a boiler and the energy cost model of the boiler is based on the efficiency of the boiler and the amount of steam produced by the boiler. The efficiency of the boiler is based on boiler stack temperature and the percentage of oxygen in the flue gas of the boiler stack. Another process component of the industrial plant/system is a gas turbine generator and the energy cost model of the gas turbine generator is based on the amount of fuel fired in the gas turbine, ambient temperature and auxiliary fuel fired in heat recovery steam generator, where the amount of fuel fired in gas turbine is based on electrical power required to be produced and the ambient temperature and the amount of fuel fired in HRSG is based on electrical power produced and the steam to be produced.

Yet another process component of the industrial system is a steam turbine generator and the energy cost model of the steam turbine generator is based on the amount of steam at various levels extracted, amount of steam condensed, and amount of mechanical energy required to be output from the generator.
Yet another process component of the industrial system is a turbine running on dual mode and the energy cost model of the turbine running on dual mode is based on full load steam requirement, steam load factor, and capacity of the motor.
Yet another process component of the industrial system is a Pressure Reducing and De Superheating System (PRDS) wherein the energy cost model of the PRDS is based on input high pressure steam temperature and pressure, output low pressure steam temperature and pressure and the amount of boiler feed water at a given temperature and pressure.
Yet another process component of the industrial system is a Flash Drum wherein the energy cost model of the Flash Drum is based on input water at high temperature and pressure, output steam temperature and pressure and the amount of steam required to be generated using the Flash Drum.
Yet another process component of the industrial system is a Deaerator wherein the energy cost model of the Deaerator is based on input demineralized water, temperature and pressure within the Deaerator, and the required amount of input steam at a given pressure and temperature and the amount of boiler feed water at a given temperature and pressure.
Yet another process component of the industrial system is a thermo compressor wherein the energy cost model of the thermo compressor is based on steam at high

temperature and pressure, steam at low temperature and pressure and the amount of steam required to be generated at medium temperature and pressure. Each of the process components consumes or produces energy or resources required by the industrial process and each of said components incorporates one or more sensors/ sensor devices, one or more process control components/devices. The process control components comprises one or more electrically controlled valves, actuators, and devices controlling the process.
The industrial process is controlled by a process controller coupled to said process components, said one or more sensors/sensor devices and said process control components/devices. The process controller comprises a processor wherein said processor is configured to receive requirements for carrying out said industrial process by said industrial plant (system). The processor then determines the energy requirements or resources for carrying out said process to meet said requirement. The processor then determines the energy cost model for each of a plurality of components of the industrial plant which may fulfill the energy requirements or resources. The processor further calculates the energy cost of operating one or more of said components to satisfy said energy requirements or the required resources. The processor based on the above calculation selects one or more of the components at full or partial capacity or selects one or more components to supply the required resource to satisfy the energy requirement or resource requirement at a minimum energy cost.
Abbreviations and definitions of terms used in the specification
• GT- Gas Turbine
• HRSG- Heat recovery Steam generator
• STG- Steam Turbine Generator
• PRDS- Pressure recovery Desuperheater
• HP steam- High pressure steam

MP steam- Medium pressure steam
LP steam- Low pressure steam
NG- Natural Gas
FO- Fuel Oil
LSHS- Low Sulphur heavy feed stock
BFW- Boiler Feed water
02- Oxygen
Power- Electricity
CPH- Condensate pre heater
MUH- Make up water heater
HOT- Industrial internet of things
Load/Throughput- these work as synonyms to understand how much is the
flow in term of mass/volume units.
Part load- The machine/equipment is operating at lower than its maximum
load.
Turn down load- The machine/equipment cannot operating below this load.
Full load- The machine/equipment is operating at its maximum load
Availability- whether this machine/equipment can be operated or not.
Brief description of the Accompanying Drawings:
Further aspects and advantages of the present invention will be readily understood from the following detailed description with reference to the accompanying drawings where like reference numerals refer to identical or similar or functionally similar elements. The figures together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the aspects/embodiments and explain various principles and advantages, in accordance with the present invention.

FIG. 1 exemplarily illustrates a schematic diagram of an industrial plant/system
carrying out the optimized industrial process of the invention;
FIG. 2 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a boiler;
FIG. 3 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a GT having an URSG;
FIG. 4 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a STG;
FIG. 5 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a flash drum;
FIG. 6 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a turbine running on dual mode;
FIG. 7 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a PRDS;
FIG. 8 exemplarily illustrates a process component of the industrial plant/system,
where the process component is a deaerator;
FIG. 9 exemplarily illustrates a process controller controlling the process in the
industrial plant/system;
FIG. 10 exemplarily illustrates the method for optimizing energy costs in an industrial
process carried out using an industrial plant/system.
Detailed Description of the invention:
It should be understood that the disclosure is susceptible to various modifications and alternative forms; specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It will be appreciated as the description proceeds that the invention may be used in various types of applications

other than as mentioned in the present disclosure and may be realized in different embodiments.
The terms "comprises", "comprising", "including", "includes", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device, apparatus, system that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device or apparatus or system.
The present invention will be described herein below with reference to the accompanying drawings. In the following description well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
FIG. 1 exemplarily illustrates a schematic diagram of an industrial plant/system having various process components and a process controller which carries out the optimized industrial process of the invention. In an embodiment the process components are a boiler (101), a GT (103) having an HRSG (105), a STG (400), a flash drum (106), a turbine running on dual mode (600), a PRDS (700), a deaerator (107) and an electric motor. Each of the process components comprise one or more sensors and process control components which measures various physical parameters such as temperature, pressure etc.
The industrial plant/system comprises various headers which supply resources such as fuel, steam, boiler feed water and electrical power. Each of the process components are coupled to receive resources or provide said resources to the resource headers.

Fuel Headers: There are various fuel headers supplying various fuels such as NG, Naptha etc. to process components which consume fuel such as the GT and boiler (101).
Steam Headers: There are various steam headers supplying steam at various pressure levels e.g. high pressure steam header, medium pressure steam header, and low pressure steam header. The process components generating steam such as the boiler (101) or HRSG provide steam to these headers and process components consuming steam such as STG, Deaerator draws steam from the steam headers. In an embodiment, a process component may consume steam from one steam header and supply steam to another steam header e.g. the STG make consume high pressure steam from high pressure steam header and provide low pressure steam to the low pressure steam header or the PRDS may draw steam from the low pressure steam header and high pressure steam header and supply the medium pressure steam to the medium pressure steam header.
Electrical Power Headers: are single/multiple electrical power transmission lines having various transformers for voltage level conversion. The process components generating electric power such as the GT or STG provide electrical power to these headers and process components consuming electric power such as an electric motor draws electrical power from the electrical power headers.
Boiler Feed Water (BFW) Headers: BFW headers are single/ multiple headers, where BFW is generated by Deaerators and various process components such as the Boiler (101) and PRDS consume BFW.
Description of the various process elements
FIG. 2 exemplarily illustrates a boiler (101). The boiler is generally employed for production of steam. The boiler consumes fuel in the form of NG, Fuel gas etc. or liquid

(Fuel oil, LSHS etc.) fuels. The fuel is used to heat BFW to generate super-heated water or steam. The fuel and air mixture are provided to a boiler which combusts to produce flue gas at high temperature. This flue gas exchanges its heat with BFW and in turn steam is generated. The flue gas after exchanging its heat is dissipated to atmosphere through a stack. Sometimes the flue gas exchanges heat with air in an air preheater before going to stack. A small portion of hot BFW is always taken as blow down to keep the boiler healthy.
The boiler has certain design constraints such as Turndown load, full load and also the boiler may have maintenance or down times. The efficiency of the boiler has the following key parameters that impacts the efficiency of the boiler e.g. the temperature and 02% of flue gas in stack, steam load (how much of steam is generated compared to its design). For example, as the boiler generates less steam than designed capacity, the efficiency comes down.
The historical operating data of the boiler is recorded and in an embodiment the boiler performance relation is obtained as:
Efficiency = f (Boiler Stack temperature (T), Oxygen % in flue gas); and Fuel Fired = f (Efficiency, Steam Produced)
FIG. 3 exemplarily illustrates a GT coupled to an HRSG (300). The GT generates power, HRSG is mainly for steam generation. In other words, the GT combusts fuel for generation of electricity and the hot exhaust gasses from the GT is used by the HRSG for further utilizing the heat in the exhaust gasses to produce steam. The HRSG in addition to the hot exhaust gasses may further require minimal amount fuel to generate steam. Hence, the HRSG harvests the energy from the hot gasses of the GT.

In an embodiment the flue gas exchanges heat with water/ condensate in a CPH/MUH (condensate pre-heater/ make up water heater) before going to stack. A small portion of Hot BFW is always taken as blow down to keep the HRSG healthy.
The GT and HRSG has certain design constraints such as Turndown load, full load, also the GT and HRSG may have maintenance or down times. The efficiency of the GT and HRSG at least depends upon the ambience temperature. The fuel consumed in GT & HRSG depends on the electric power and the additional steam to be produced.
The historical operating data of the GT and HRSG is recorded and in an embodiment the GT and HRSG performance relation is obtained as:
Fuel Fired in GT = f (Power produced, Ambient Temperature)
Steam Produced in HRSG = /(Fuel Fired in GT, Ambient Temperature,
Auxiliary Fuel fired in HRSG)
FIG. 4 exemplarily illustrates a STG (400). The STG consumes high pressure steam for generating electrical power and/or mechanical power and produces medium pressure steam, low pressure steam, very low pressure steam and condensate (in a condensing section) based on design and requirement. The high pressure steam is drawn from high pressure steam header and lower pressure steam extracted is injected back to the lower pressure steam header. Further, the condensate is collected back to deaerators or to DM tanks.
The STG has certain design constraints such as turndown load, full load, also the STG may have maintenance and down times. The key parameter that impacts STG is the Temperature and pressure of various steam levels.

Further, using the design data of the STG and the STG performance relation is obtained as:
HP Steam required = f (MP steam extracted, LP steam extracted, Power
from STG)
When, the STG is used for generating mechanical power then the STG performance relation is
Power required = f (Full load steam requirement, Steam load factor);
where the Load factor is the ratio of operating load to design load of the fluid that is handled.
FIG. 5 exemplarily illustrates a Flash Drum (106). The flash drum is used for generation of low pressure steam from Blow-down/ condensate at high pressure and temperature. Condensate is generated from steam after steam gives it latent heat to the process equipments in reboilers/ turbines etc. The Blow-down/ condensate at high pressure and temperature is routed to a drum maintained at low pressure. This will create flashing of the liquid to steam. This steam is connected to steam header or directly sent to a consumer.
The Flash Drum has certain design constraints such as full load and the Flash Drum may have maintenance and down times.
The key parameter that impacts the efficiency of a flash drum is the Temperature and pressure of Blow-down/ condensate/ hot water and the steam that is generated.
Further, using design data of flash drum, performance relation is obtained as:
Flash Steam produced = f (Amount of Blow-down/ condensate/ hot water , Blow-down/ condensate/ hot water Pressure and Temperature, Flash Drum Pressure and Temperature)
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FIG. 6 exemplarily illustrates a Dual Drive Machine (600). The Dual Drive Machine has both Turbine & Motor. These drives are intended for generation of mechanical energy for driving machines (like pumps, compressors etc.) connected to them. The turbine of the dual drive machine consumes high pressure steam and produces low pressure steam/ condensate based on whether it is back pressure/ condensing type, whereas motors consume electrical power. One of the motor or turbine or both are operated simultaneously according to the requirements. The turbine consumes high pressure steam and the motor consumes electrical power.
The turbine works in the same principle of STG as disclosed above. The only difference is that it generates mechanical energy. Motors consume electrical power and generate mechanical energy and hence are used for driving any machine connected to them.
The dual drive machine has certain design constraints such as Turndown load, full load, availability (For both the turbine & motor).
The key parameters that impacts the efficiency of the dual drive machine is:
a) For the Turbine the key parameters are the Temperature and pressure of various steam levels.
b) For the Motor the key parameter is the load at which it is operating, i.e the performance varies with the load which is denoted by the load factor, where the Load factor is the ratio of operating load to design load.
Further, using Based on design data of Dual drive machines, the following performance relation has been obtained:
Power required = f (Full load steam requirement, Steam load factor, Full load Motor power)
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FIG. 7 exemplarily illustrates a PRDS (700). The PRDS is used for generation of Low pressure steam from high pressure steam by killing the pressure in a control valve and addition of BFW to meet the low pressure header requirements. As the temperature of the exhaust steam from the control valve increases above the header conditions, BFW is added to cool the same. In this process additional steam is generated. Thus the PRDS consumes high pressure steam and BFW.
The PRDS has certain design constraints such as Turndown load and full load, also, the PRDS may have down times or maintenance.
The key parameter that impacts the efficiency of PRDS is the Temperature and pressure of various steam levels.
Based on design data of PRDS, performance the performance relation has been
obtained as:
BFW requirement = f (High Pressure Steam temperature and Pressure, Low pressure Steam temperature and Pressure, BFW temperature and Pressure)
FIG. 8 exemplarily illustrates a Deaerator /Degasser (107). The Deaerator or Degasser is used for Boiler feed water from de-mineralized water/condensate. Boiler feed water is fed to Boilers, waste heat boilers for steam generation. The BFW water so generated has less amount of dissolved oxygen. Steam is used for stripping the dissolved oxygen from the de-mineralized water/condensate. The de-mineralised water/Condensate goes in to deaerator drum from top though various trays and steam is sent from the bottom for the purpose of heating and stripping of Oxygen from the de-mineralized water.
The Deaerator has certain design constraints such as Turndown load, full load, availability, also the Deaerator is subject to maintenance and down times.
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The key parameter that impacts the efficiency of the Deaerator is the Temperature and pressure of incoming de-mineralised water/Condensate, steam, and outgoing BFW.
Based on design data of Deaerator, performance relation has been obtained as:
Steam required = f (Deaerator Temperature and Pressure, Amount of DM water/condensate feed, Direct Steam & Flash steam Pressure and Temperature, amount of Flash steam)
FIG. 9 exemplarily illustrates a process controller (108) and FIG. 10 exemplarily illustrates the method for optimizing energy costs in an industrial process carried out using the industrial plant/system.
The process controller comprises a processor (901), a memory (902), a user interface (905), a sensor interface (904), driving circuitry (906) and a wired or a wireless transceiver (903). The processor through the sensor interface or through the wireless or wired transceiver receives sensor data coupled to the process elements. In one embodiment the sensor data from the process components are received from IIOTs coupled to the process elements.
The requirements for carrying out said industrial process by said industrial plant (system) is then received (1001) by the processor using the user interface or through the wireless/wired transceiver. The processor then determines the energy requirements or resources for carrying out said industrial process to meet said requirement. The energy requirements for running the process is predetermined and based on the batch size of the process or the required output of the manufactured product.
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The processor then determines (1002) the energy cost model for each of a plurality of process components of the industrial plant which may fulfill the energy requirements or resources depending upon their availability and various performance parameters of the process components as disclosed above.
The processor further calculates (1003) the energy cost of operating one or more of said components to satisfy said energy requirements or the required resources by staying within the constraints of each of the process components as disclosed above. The processor based on the above calculation selects one or more of the components to operate at a full or partial capacity or selects (1004) one or more components to supply the required resource to satisfy the energy requirement or resource requirement at a minimum energy cost. The selection of the one or more process components for operation is solved by a linear or a non-linear solver. The linear or non-linear solver configures the processor to select one or more of the process components for operation based on the performance relation of each of the selected process components and the sensor data received from the selected process components and the availability of the selected process components.
In an embodiment, the solver configures the processor to determine various scenarios by making a permutation or combination of the process components to be operated to meet the process requirements and within the constraints of the process components. The solver then determines the fuel or resources to be consumed by each of the scenarios based on the energy consumption model of the process components and the data received from the sensor coupled to the process components. The solver then configures the processor to select the scenario where the fuel or the resources required to carry out the industrial process is minimum.
According to the selected scenario the process components are operated using the driving circuitry coupled to the processor. The driving circuitry drives various
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actuators, relays, and valves to carry out the industrial process by using the minimum amount of energy, which in turn provides a significant saving of fuel or electrical power and thereby, effecting significant cost saving.
In yet another embodiment the processor provides a recommendation for a manual operator to operate each of said process components to carry out the industrial process.
Further, the present invention is described with reference to the figures and specific embodiments; this description is not meant to be construed in a limiting sense. Various alternate embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such alternative embodiments form part of the present invention.

We Claim:

A method for optimizing energy in a process carried out using a system, comprising:
receiving, by a processor, requirements for carrying out said process on said system;
determining, by the processor, the energy requirements for carrying out said process to meet said requirement;
determining, by the processor, energy cost model for each of a plurality of components of the system;
calculating, by the processor, the energy cost of operating at least in part one or more of said components to satisfy said energy requirements;
selecting one or more of said components for full or partial operation based on said calculation to satisfy said energy requirement at a minimum energy cost.
The method of claim 1, wherein one of the components of the system is a boiler and the energy cost model of the boiler is based on the efficiency of the boiler and the amount of steam produced by the boiler.
The method of claim 2, wherein the efficiency of the boiler is based on boiler stack temperature and the percentage of oxygen in the flue gas of the stack to heat the boiler.
The method of claim 1, wherein one of the components of the system is a gas turbine generator and the energy cost model of the gas turbine generator is based on the amount of fuel fired in the gas turbine, ambient temperature and auxiliary fuel fired in heat recovery steam generator.
The method of claim 4, wherein the amount of fuel fired in gas turbine is based on mechanical energy required to be produced and the ambient temperature.

The method of claim 1, wherein one of the components of the system is a steam turbine generator and the energy cost model of the steam turbine generator is based on the amount of steam at various levels extracted, amount of steam condensed, and amount of mechanical energy required to be output from the generator.
The method of claim 1, wherein one of the components of the system is a turbine running on dual mode and the energy cost model of the turbine running on dual mode is based on full load steam requirement, steam load factor, and full load capacity of the motor.
The method of claim 1, wherein one of the components of the system is a Pressure Reducing and DeSuperheating System (PRDS) wherein the energy cost model of the PRDS is based on input high pressure steam temperature and pressure, output low pressure steam temperature and pressure and the amount of boiler feed water at a given temperature and pressure.
The method of claim 1, wherein one of the components of the system is a Flash Drum wherein the energy cost model of the Flash Drum is based on input water at high temperature and pressure, output steam temperature and pressure and the amount of steam required to be generated using the Flash Drum.
). The method of claim 1, wherein one of the components of the system is a Deaerator wherein the energy cost model of the Deaerator is based on input demineralized water, temperature and pressure within the Deaerator, and the required amount of input steam at a given pressure and temperature.

The method of claim 1, wherein one of the components of the system is a Thermo compressor wherein the energy cost model of the thermos compressor is based on steam at high temperature and pressure, low steam temperature and pressure and the amount of steam required to be generated at medium temperature and pressure.
An energy optimized system for carrying out a process, comprising:
one or more process components, wherein each component consumes or produces energy and wherein at least one of said components comprise one or more sensors; one or more process control components; and
a processor coupled to said process components and process control components, wherein said processor configured is configured to:
receive requirements for carrying out said process on said system;
determine the energy requirements for carrying out said process to meet said requirement;
determine energy cost model for each of a plurality of components of the system;
calculate the energy cost of operating at least in part one or more of said components to satisfy said energy requirements based on inputs received from the sensors; and
select one or more of said components using said process control components for full or partial operation based on said calculation to satisfy said energy requirement at a minimum energy cost.
The system of claim 11, wherein one or more process components comprise one or more of a boiler, a gas turbine generator, a heat recovery system generator, a steam turbine generator, dual mode turbines, a PRDS, a flash drum, thermo compressor and a deaerator.

14. The system of claim 11, wherein the sensors comprise pressure and temperature sensors.
15. The system of claim 11, wherein the process control components comprise one or more electrically controlled valves, actuators, and devices controlling the process.