Yokogawa supports Shell with their Energy Transition

Shell logo

The Shell Skyline project contributes to the energy transition by reducing the energy consumption and greenhouse gas emissions of the Shell Moerdijk site. The Yokogawa team in the Netherlands is proud to be the Industrial Automation partner for this project, which is of great importance for the energy transition towards net-zero emissions. Yokogawa is responsible for the delivery of the DCS control layer and the SIS safety system, using customized Remote IO boxes

10% reduction in CO2; how does Shell achieve that?
In the coming years Shell will replace sixteen old furnaces that were built in the early seventies with eight new, much more efficient furnaces. The total capacity will remain the same, but Shell will considerably reduce energy consumption at Moerdijk. The company will soon see this reflected especially in gas consumption. Because the more efficient furnaces require less fuel gas from the cracker, there is more of it left for the boiler house to produce steam. Moreover, the heat exchange improves, which means that less steam is needed from the boiler house as well. This will reduce Shell Moerdijk's CO2 emissions by around ten percent.

Status of the project

Project Manager Jan van Ee: ‘After going through a definition phase in which we determined the basic design philosophy in close cooperation with Shell, Fluor and Technip, a prototype of the Remote IO box (RIO box) was created. Both the Yokogawa Centum VP Distributed Control System and the ProSafe-RS SIS Safety System are based on a generically designed RIO box that will be installed in the field, close to the furnaces. They will be integrated into the already existing Yokogawa system at Shell Moerdijk.’

 

 

RIO box: super-efficient connection with Fibre Optics
By using RIO boxes, only a glass fibre connection to the system cabinets is needed. The RIO boxes are installed close to the field instruments, allowing them to be connected directly. This approach - compared to a conventional approach* - provides great advantages:

  • better weight distribution around the instruments
  • large savings on field cables and installation of field cables
  • standardisation by using typical RIO box designs
  • test capabilities at an early stage without software configuration.

Focus on the implementation

System Sales Engineering Derrick Gibbs: ‘We have recently started the project execution of the automation part, focusing first on the final design, construction and delivery of the required hardware for both DCS and SIS. Before proceeding with the production of the hardware, we will build a Typical RIO box for both DCS and SIS after which we will test it extensively based on an ATEX certification (zone 2 requirements). During this process we will start with the software part for the integrated Yokogawa DCS/SIS System.’

 

 

Video Shell Skyline project
Watch the video from Shell about their investment in new furnaces to reduce emissions from its Moerdijk Chemicals plant:

More information Shell Moerdijk Skyline project
For more information, visit the Shell website

* In a conventional approach, there would be multicore field cables laying in the ground from the System cabinets (equipped with DCS and/or SIS controllers) in a building to a junction box in the field, and from there again to other junction boxes or maybe directly to the Field equipment.

Industries

  • Chemical

    Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.

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  • Oil & Gas

    Yokogawa has a wealth of experience in every part of the oil and gas business, from offshore and onshore facilities to pipelines, terminals, and deepwater operations. We provide solutions that enhance safety, ensure accurate and reliable operation, and increase plant efficiency.

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  • Renewable Energy

    Renewable energy helps protect the environment and brings both society and industry closer to the goal of achieving sustainability. However, compared to conventional energy sources, there are certain challenges that stand in the way of its rapid adoption, such as higher production costs and greater instability in the supply of power to the grid. As a leading company in the control and instrumentation business, Yokogawa has always striven to help its customers in various industries achieve stable operations and improve productivity in their plants. We provide solutions for renewable energy applications worldwide, thus contributing to the sustainable development goals.

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Related Products & Solutions

  • CENTUM VP

    CENTUM VP has a simple and common architecture consisting of human machine interfaces, field control stations, and a control network.

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  • SIS (Up to SIL 3) ProSafe-RS

    The ProSafe-RS is a Safety Instrumented System that is certified by the German certification organization (TÜV) to meet Safety Integrity Level (SIL) 3 specified in IEC 61508. 

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  • Energy Management

    • Even with significant reductions on the cost of energy, energy is still typicall one-third of industrial facilities operating costs. Due to this, significant gains can be made by ensuring the efficient and effective use of energy whilst still achieving your production goals.
    • Yokogawa provide a comprehensive array of energy measurement, analytics, control and financial optimization solutions. This covers the full scope of consulting, implementation, execution and support.
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  • Operations Management

    Operations Management, as it applies to the industrial automation industry, is the process of designing, visualizing, and orchestrating plant production and business systems.

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