Chemical Engineering September 2023 - 45

traps are working correctly, and
which are in failure mode. The software
estimates lost energy, and resulting
costs, as well as estimating
impact on CO2 production. Maintenance
personnel can see at a glance
which steam traps need attention
and plan activities appropriately, and
they can predict and deal with small
problems before they become serious
issues.
Process & energy management
Managing the actual manufacturing
process and overall energy usage is
necessary to keep the plant operating
stably and optimally. This in itself
reduces emissions because it eliminates
waste from end-to-end. Achieving
this condition is difficult because
mass and heat balancing is complex
with many variables. Effective process
automation is paramount to accomplish
these objectives, and new
digital tools make it possible to reach
a wide range of key performance indicators
simultaneously.
Implementing an energy management
system (EMS) supports optimization
of energy efficiency and
reduced energy consumption. It involves
a set of tools and procedures
for monitoring, controlling and optimizing
energy use - including electricity,
gas and water - to reduce costs,
improve energy performance and reduce
greenhouse gas emissions. An
EMS typically includes a control system,
historian and analytical software
designed to provide dashboards and
reports to the right people, who can
use this improved information to analyze
and set priorities.
A digital twin is also an excellent
platform to analyze complex relationships
because it provides a mechanism
to simulate a range of what-if
scenarios, so decision makers can
evaluate the predicted results and
risks of various changes to overall
plant performance and revenue. For
example, plant personnel may suggest
an equipment change to help
increase production and reduce energy
consumption. A digital twin can
provide a detailed analysis to determine
how the change will affect the
overall operation, and if the project
goals will be met as expected. Decision
makers can use this tool to
maximize the economics of business
decisions by going beyond the
equipment level and accurately predicting
future asset performance of
the entire production process.
Integrated solutions
Launching a sustainability initiative,
with either a series of incremental
changes or a major capital project, is
much more successful when working
with the right partner able to
bring a portfolio of products to the
effort, combined with deep domain
expertise. Success requires effective
strategy and planning, and the right
partner makes a huge difference. ■
Edited by Gerald Ondrey
Acknowledgment
All figures courtesy of Emerson.
Authors
Don Fregelette is the vice president
for the chemical industry at
Emerson (7070 Winchester Cir.,
Boulder, CO 80301; +1-888889-9170;
Email:don.fregelette@
emerson.com),
overseeing the
global chemical and sustainability
business at Emerson. His team
develops and supports the global
measurement solutions chemical
industry and sustainability initiatives. Its focus is on developing
and delivering solutions across the entire industry,
with an emphasis on sustainability, digital transformation
and safety. Since joining the company in
1994, Fregelette has held several roles, including vice
president of the Americas, vice president of global lifecycle
services and vice president of strategic accounts
and projects. Prior to joining Emerson, Fregelette
worked for Moore Products. Fregelette earned his bachelor
of science degree in chemical engineering from the
University of Buffalo, and an MBA in technology management
from Rochester Institute of Technology.
Aurélien Tissot is the Europe
marketing director at Emerson (8
Imp. de la Madelon, 69800 SaintPriest,
9170;
Email:
France; +1-888-889aurelien.tissot@
emerson.com)
looking after product
lines encompassing valves,
actuators and regulators. In the
past two years, he has led sustainability
programs globally, covering
energy and emission for the petroleum-refining
industry; carbon emissions capture, utilization and
storage; and renewable natural gas. Since joining the
company in 2007, he has held several roles in engineering,
product development, strategic planning and
business development. Tissot earned a master's degree
in mechanical engineering from the University of
Troyes in France, and an executive MBA from La
Sorbonne in Paris.
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