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Kaneka CorporationOptimization of Control Strategy Helps BTG Plant Save Energy and Operate More EfficientlyAbout Kaneka CorporationSpun-off from the Kanegafuchi Spinning Co., Ltd. in 1949, Kaneka Corporation’s initial main products were caustic soda, soap, cosmetics, edible oils, and electrical wires. Later the company diversified into polymers, fermentation, biotechnology, and electronics. Its business activities now span a broad spectrum of markets - from plastics, EPS resins, chemicals, and foodstuffs to pharmaceuticals, medical devices, electrical and electronic materials, and synthetic fibers. The company has been a leader among Japanese chemical companies in establishing overseas operations, beginning in 1970 with a subsidiary in Belgium and progressing to the establishment of operations in the United States, Singapore, Malaysia, China, Australia, and Vietnam.Kaneka Corporation is set on both staying globally competitive and protecting the environment, a stance that is consistent with its corporate philosophy. This states: “With people and technology growing together into creative fusion, we will break fresh ground for the future and tie in to explore New Values. We are also committed to challenge the environmental issues of our planet and contribute to upgrade the quality of life.” Specific initiatives undertaken by Kaneka Corporation include the reduction of energy consumption, complying with global environmental standards, reducing industrial waste, and reducing risk through the development of various production technologies.The BackgroundIn the midst of a global economic downturn precipitated by events such as the bankruptcy of Lehman Brothers, Kaneka Corporation is accelerating its efforts to reduce its operating costs. As the company’s Takasago Plant is a large consumer of energy, it currently is engaged in an “Advance 17” initiative to slash its energy costs. Almost all the fuel and electricity consumed by the Takasago Plant is for its boiler, steam turbine, and generator (BTG) facility. With the rising price of crude oil, Kaneka Corporation has urgently needed to implement countermeasures that would reduce this facility’s energy costs. And in keeping with its corporate philosophy, the company is intent on reducing its CO2 emissions. A further aim of the company is the improvement of efficiency and reduction of labor costs. The ChallengesThe BTG facility has two boilers and four sets of steam turbines and generators, and this equipment all varies in energy efficiency. In addition, the price of electricity fluctuates depending on the season and the time of day. The operation and maintenance of all this equipment has to be balanced in such a way that cost is minimized and the steam and electricity requirements of the Takasago Plant are fully met. Before this project, the BTG facility’s operators were kept busy around the clock monitoring all process values in real time and manually adjusting to load changes. Because the facility had a variety of operation patterns, each of which required different procedures for minimizing costs, operators were required to have very high level skills and their work was very stressful. Plant InformationLocation: Takasago, Hyogo Prefecture, JapanOrder date:January 2009Completion:February 2010Chemical (Base Chemical, Fertilizer, Petrochemical)27Success Story Collection

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