Matches' optimization analysis can point the ways to improved operation. Optimization can take many forms. Typically a change produces an increase in value. Often change requires an expenditure. The increase in value may be a cost reduction, an improved product or increased production. Typically changes are justified and optimized. When identified by existing operators, Matches' (third party) verification improves management acceptance and promotes implementation of change. Sometimes benchmarking with other facilities suggests changes that create value and keep a producer competitive.
Changes can include better instrumentation, better control, process improvement, debottlenecking, improved reactor performance, equipment cleaning, or adjusted process parameters. Better instrumentation may improve raw material utilization and may reduce production of off-specification material. Better control may improve process efficiency, may improve product quality and may increase plant throughput. Process improvement which include adding another unit operation or replacement of an existing unit operation may improve process efficiency and may increase plant throughput. A debottlenecking analysis identifies the limiting unit process and suggest methods for improving plant throughput. A wide range of reactor changes are possible. These include: 1. Timing of routine catalyst replacement/ regeneration, 2. Utilization of improved catalyst, and 3. Better reactor design. Each may improve plant efficiency, may reduce energy usage and may increase plant production. Equipment cleaning may reduce process energy consumption, material losses and pollution. Most plants are sensitive to ambient conditions and may need daily/ seasonal adjustment for optimal results. Often adjusting process control parameters can reduce energy consumption, improve raw material efficiency and increase throughput.
Optimization studies confirm the cost of change, provide a measure of benefits and justify change. Optimization requires maximization of the perceived value less the cost of the change. Determination of the perceived value is the key to optimization. The value of sales of more product or reduction in cost is relatively easy to determine. Where value is associated with timing, estimation of value may involve many factors including equipment spares, plant/ unit downtime, plant shutdown/ start-up expenses, demand for product, and other factors. Often the value of improved product quality, ease of operation, improved process reliability or improved safety is difficult to quantify. An optimization study identifies the best changes.
Matches provided optimization assistance improve the performance of processing units. Optimization analysis allows operating units to produce more/ better products, to increase operating efficiency, to reduce costs, and to improve process reliability and safety.