Pressure stability and optimized management of process gases are essential to the operating performance and profitability of many industrial processes, including chemical, petrochemical, oil and gas production, and steelmaking applications.
Process gas networks are typically controlled using multiple independent controllers acting on gas sources, consumers, and the flare to maintain the system in balance. A lack of coordination between these controllers can result in:
- Pressure instability during normal operation, caused by different setpoints and uncoordinated corrective actions, resulting in control-valve cycling and interactions between process units;
- Emergency shutdowns of critical equipment caused by network pressure instability, particularly at burners, reactors, or other process equipment;
- Increased operating costs resulting from the loss of valuable process gas to flare and increased consumption of purchased fuel.
Enero Solutions uses its Instantaneous Mass Balance Controller™ (IMBC™) technology to coordinate gas sources, consumers, and the flare system using a single controller and a single setpoint.
A continuous mass balance allows the network to be managed as a single energy system, anticipating imbalances and making it possible to:
- Improve plant availability and reduce manual intervention during production changes, equipment trips, and abnormal operating conditions.
- Stabilize and coordinate high-, medium-, and low-pressure gas networks to reduce controller interactions and the propagation of disturbances;
- Reduce flaring and purchased fuel consumption by maximizing the use of process gases and their integration with Enero multi-fuel combustion systems;
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