Resource Efficiency of an Integrated Petrochemical Complex

Copyright INEOS/Oliver Brenneisen

Copyright INEOS/Oliver Brenneisen

Overview of the case:


INEOS in Köln operates a typical integrated petrochemical complex, processing mainly naphtha and natural gas as major feedstock to produce a large number of important base chemicals. The site located in Cologne is of high complexity and is characterized by a large number of products and a deep integration of the different plants with respect to products and energy. Large amounts of energy are required for feed conversion and product purification. Only a part of this energy is supplied as primary energy (electrical power, natural gas), a significant portion is generated on site from the by-products of the chemical processes, mainly used as fuels.

INEOS in Köln will use the improved online analytics the decision support system, and the REIs developed in the MORE project and to monitor and improve the real-time resource efficiency of the whole production site. For this purpose the REIs developed and displayed will be used to steer plants and the site towards a commercially viable resource efficient production by looking at:

  • The whole site: It is important to understand the resource efficiency of the whole site. Real time for the whole site is a time frame between one day and one month for site planning based on resource efficiency. The site is to be analyzed topologically from bottom-up.

  • Acrylonitrile plants: These plants have a major impact on the site resource efficiency. The highly exothermic reaction is a good example for the integration of raw material and energy streams.

  • Ethylene oxide plant: EO is produced in an exothermic reaction. The highly exothermic reaction is a good example for the integration of raw material and energy streams.

  • Cooling towers: Cooling towers are a typical piece of equipment strongly influenced by environmental factors. At the same time they consume a lot of electricity. The interplay between plants and cooling towers is a multicriterial optimisation problem.

  • Power plant: The power plant uses plant off-gases to produce steam and electricity. The resource efficiency is to be analysed with improved analytical methods.

  • Crackers: The crackers use naphtha to produce all required base chemicals for the rest of the site. The site resource efficiency depends strongly on optimal cracker operation. Online naphtha analysis and resource efficient operation based on this analysis will be one of the key points of the case study.

Expected Achievements of the case:

The main objectives of the partner INEOS in Köln are to improve the energy management of an industrial site and achieve significant saving of energy and raw material resources.

The case study is considered successful if the successful evaluation of resource efficiency in chemical plants in one integrated REI showing energy and material resource efficiency is possible using a site wide structuring of plant hierarchy and site wide bottom-up aggregation of REIs. The visualization on a dashboard is a further success criterion and the REIs should define the best operating point based on historical data and should spawn further resource efficiency projects.