Steam and Power Optimizer, ExxonMobil Baytown, Texas

The ExxonMobil Baytown complex is a large user of both steam and power, and over time, multiple cogeneration facilities have been installed to satisfy the complex demands. The highly integrated complex, consisting of a refinery, chemical plant and olefins plant, has always attempted to most efficiently dispatch the steam and power-generating equipment to satisfy the demand of power and steam, at multiple pressure levels. There are six distinct steam pressure levels across the complex, all of which, as a result of needs to be flexible, have multiple means to satisfy demands. In June of 2008, the complex commissioned a Real Time Optimizer to balance steam and power loads to minimize energy consumption for the complex by most efficiently simultaneously satisfy all of the steam system demands. No physical facilities other than computer hardware were required for implementation. The optimizer runs every 15 minutes and the solution is implemented by the distributed control system (DCS) across the complex.

This project is unique for the ExxonMobil Baytown complex in that it optimizes a utilities system across numerous boundaries, both physical and organizational. From a global perspective, the energy savings demonstrated are significant, and this project provides a model for future projects in other multi-business unit sites for ExxonMobil around the world.