With a production capacity of approximately 300,000 barrels per day, the plant owned by SARLUX (SARAS Group) in Sarroch (Cagliari, Italy) is the leading single-site refinery within the Mediterranean basin.
It has a high degree of complexity due to the presence within the production site of an integrated gasification combined cycle (IGCC) plant for power generation, as well as a petrochemical plant.
Part of the crude processed is used for energy needs, to feed the different core process and auxiliary units within the plant. Therefore, energy consumption optimization is directly linked to the production process performance.
The energy monitoring dashboard is an effective tool for controlling the plant’s operational efficiency on a daily basis, and it supports the identification of potential improvement areas over short, mid, and long term perspectives.
The calculation of energy consumption is performed using the data obtained from the plant unit sensors. The adopted technology enables an improvement in the quality and frequency of the analysis, making relevant data, trends, and gaps available in a timely manner to support the decision-making processes, at various organizational levels and functions.
In less than three months, and with a contribution from SARTEC (SARAS Group), the system has been designed and developed to monitor the energy consumption of the main core process and auxiliary plant units, enabling benchmarking analysis against industry indicators.
The energy consumption calculation for the main energy sources (electricity, steam and fuel) is performed starting from the operating variables of individual units, processing the real time data managed within the historical system. The new tool facilitates consumption analysis, enabling related optimization, and resulting in operating cost reduction, plant performance improvement, and reduction of environmental impact.
The initiative is a component of the innovative IT-OT integration program, working towards the adoption of the industry 4.0 within the production plant, and a key lever for continuous performance improvement.