Kesiapan Industri Kimia Dalam Implementasi Industri 4.
0
(Case study PT. Chandra Asri Petrochemical Tbk)
Indonesia Industrial Summit 2018
April 4-5, 2018, Jakarta Convention Center
Prepared by
Helmilus Moesa
(Advisor PT. Chandra Asri Petrochemical Tbk )
The only one & The largest Integrated Olefin Petrochemical Company in Indonesia
In Cilegon – Banten Province - Indonesia
Agenda
1. Company Introduction PT. Chandra Asri Petrochemical Tbk.
a. Site Location (Where We are & What We are doing)
b. Business Process, supply & demand and multiplier efek.
2. Road map peningkatan Kapasitas Produksi (2018 – 2030).
3. Peningkatan Effektivitas , Produktivitas, Efisiensi, Quality & Safety
melalui process control dan digitalisasi.
4. Pemakaian Teknologi Process Control & Digital.
a. PI Coreseight.
b. Optience.
c. Advanced Process Control (APC) & Real Time Optimizer (RTO)
d. OCS
e. Machine learning.
5. Summary
1a. Site Location
PT. Chandra Asri Petrochemical Sites Locations In Cilegon (120 KM from Jakarta)
Consists of 3 Locations, 9 Plants with total area=156 Hectares
Location-3
20 Hectares
(Bojanegara)
2 Plants
Head Office
(Jakarta)
LOCATION-1
(120Hectares-Anyer)
4 Plants
CAP
3
1b. Overall Block Diagram Business Process
PT. Chandra Asri Petrochemical Tbk.
external
Customer
1c. Multiplier Effect Of BBM Application Of
PT. Chandra Asri Petrochemical Tbk Petrochemical Products
VAM PVA
Plant Plant
LPG & Lighter Acetic Acid Ethyl Acete
Blue Sky Plant Plant
Plant
Balongan & EDC VCM PVC Packaging Bottle Cling rap film
Cilacap Plant Plant Plant
Ethylene
Naphtha
Battery case
REFINERY
Gasoline
EO/EG Aromatic PET/PES
Plant Plant Plant
Kerosine Glass aqua
Ethylene Dash board/
Diesel Olefin Ethyl Ben SM Polystyrene Automotive parts
Cracker
Plant
Crude Plant Plant Plant
Oil Plant
Polyethylene
PT. Chandra Asri Plant
Petrochemical Tbk
Residu Crude C5 Piperylene DCPD Refrigerator CPU Comp Remote Control
Plant Plant
Propylene Polypropylene
Plant
Acrylic Acid Super Absorbent
Insulation cable Tyre Pempers
Plant) Plant
Crude C4
LNG LNG
Butadiene SBR MTBE BUTENE-1
Natural PLANT Export Plant Plant Plant
Plant
Gas Pygas
Condensate Benzene Alkyl-Benz Al-Benz Formulation
Plant Plant Sulfo-Plant Plant
Pipes Infus Textiles Polyester
1d. Indonesian Polypropylene & Polyethylene supply and Demand
2. Peningkatan kapasitas PT. Chandra Asri Petrochemical Tbk
(2018 - 2030)
Total Production (KTA)
KTA
9,000
KTA
8,000
8,000
7,000 6,500
6,000 KTA KTA
KTA KTA
5,000
3,938 4,171
4,000 3,301 3,458
3,000
2,000
1,000
0
2016 2018 2019 2020 2025 2030
New SSBR = 120 KTA
Expansion BD= 37 KTA Debottle necking Second Complex CAP New Plant
- Ethylene = 40 KTA - Ethylene = 1000 KTA Coal to Pet-Chem = 450 KTA
New PE = 400 KTA - Propylene = 20 KTA - Propylene = 550 KTA NG to Pet-Chem = 850 KTA
Note: Expansion PP = 80 KTA New MTBE =130 KTA - C4 = 262 KTA PX, PET, PES = 200 KTA
KTA : Kilo Ton per Anum New Butene-1 = 43 KTA - BD = 175 KTA
1 KTA : 1,000 Tons/Year - Benzene = 363 KTA
3. Peningkatan Produktivitas dan Effisiensi
(Through Optimization of Process Control & Digitalisation)
ADVANCED PROCESS CONTROL
(APC) ADVANCED PROCESS CONTROL
REAL TIME OPTIMIZER
REAL TIME OPTIMIZER
APC :
CONSTRAINTS MAXIMIZE CAPACITY, PUSH CAPACITY UNTIL
REACHES CONSTRAINT, STABILIZE QUALITY
RTO :
MAXIMIZE PROFIT, DRIVEN BY ECONOMIC
SET POINTS
REGULATORY CONTROL
DISTRIBUTED CONTROL SYSTEM PID CONTROLLER
(DCS) SEQUENCE CONTROL DISTRIBUTED CONTROL SYSTEM (DCS),
MOTOR START/STOP COMPRESSOR SURGE CONTROL (CCC)
INTERLOCK LOGIC TURBINE SPEED CONTROL (TRISEN
CONTROL TS410),
EMERGENCY SHUTDOWN SYSTEM
(TRICONEX),
FIRE & GAS DETECTION SYSTEM
PLANT & EQUIPMENT
TRANSMITTERS, CONTROL VALVES,
FRACTIONATION COLUMNS,
COMPRESSORS , TURBINES, PUMPS
REACTORS, CRACKING FURNACES
CONTROL VALVES TRANSMITTERS
CONFIDENTIAL
3 a. Peningkatan Yield
2025
WORLD CLASS
Yield
Product Yield Q1
Optimization (Quartile-1)
Product Yield
2014
2014
66.3 %
66.3 %
TAM
Q2
2016
2016 2017
68.0 %
2017 (Quartile-2)
68.0 % 68.1
68.1%%
2013
2015
65.5 % 2015
2015
65.5 % 64.6
64.6 %
%
APC
Implementation
Year
9
CONFIDENTIAL
3 b. Pengurangan pemakaian energy
APC
Implementation
Furnace
2013 Revamping
18 GJ/T-HVC 2016
17.9 GJ/T-HVC
2017
17.2 GJ/T-HVC Utility
Energy Consumption
Optimization
2025
WORLD CLASS
Energy Consumption Q1
Year
10
3 c. Optimalisasi Profit margin
CAP complex simulation by optience It optimizes Operating Rate
& Max Profit
Feedstock Ranking
SP Qty Rank
Main Product Yield
Naphtha A 10 55 KT 1 Maximum
Naphtha B (20) - 5 Profit
Naphtha C (5) - 3
Margin
Naphtha D - 7 KT 4
Naphtha E 9 35 KT 2
Naphtha D (14) - 6
LPG 1 30 -
LPG 2 40 -
LPG 3 60 -
3d. Peningkatan kualitas produk
(dengan teknologi OCS)
Pelletizer machine BATCH READING
12 pc film ~ 30 gr
(Field) ~0.2% sample is inspected
BATCH SAMPLING
1 sample of 15 Kg every 4 Hr
3.75 Kg/Hr
CONTINUOUS READING
100% sample is inspected
CONTINUOUS
SAMPLING
Trickle 100 g/10 sec
~36 Kg/Hr
80
Total Defect Area
60 Bad Good Limit
(mm2)
40
20
0
1 2 3 4 5 6 7 8 9 10
3 e. Continuous Emission Monitoring System (CEMS)
Gas
Turbine CCR
Exhaust
Field
DCS
DCS-Console
4. Pemanfaatan Teknologi
4 a. PI Coreseight apps (Memonitor secara real time operasi pabrik melalui komunikasi mobile)
Real Time Monitoring
Mobile Tool
“Seeing plant data on any device,
wherever we are, whenever we need it”
Chandra Asri has been utilizing such apps
enables data analyzing in multiple ways
supporting fast data-driven decisions
and provide insights
into operations and business
4. Pemanfaatan Teknologi
4 b. Contoh tampilan monitoring pabrik secara real time melalui komunikasi mobile
Eye Catching
Dashboard
4 c. OPTIENCE
(Mengoptimalkan operasi pabrik berdasarkan perubahan input)
Plant Condition
Plant data link
( PI-System )
Actual plant operating condition
Yield Simulator(Spyro apps) Maximum
Raw Materials Specification
OPTIENCE Profit
P : Paraffin contents
O : Olefin contents
N : Naphthene contents
A : Aromatic contents
Sg :Specific Gravity
ASTM-Boiling point
Plant
Laboratory data Market Price Constraint
(fluctuate dynamic market price (Frequently change) 16
4 d. Advance Process Control (APC) & Real Time Optimizer (RTO) apps
Mengoptimalkan proses produksi secara otomatis berdasarkan perubahan imput
4c. Learning Machine
“Finding the Patterns Humans Can’t See”
Having numerous high valuable assets,
Chandra Asri will utilize machine learning as
Flooding advanced early warning & risk detection software
that identifies process & equipment problems
Vibration
Emission
Fouling
Contamination
Cavitation
Corrosion
Conclussion
1. PT. Chandra Asri Petrochemical Tbk merupakan industri hulu
yang bahan bakunya dari Oil & Gas, dimana produk-produknya
merupakan bahan baku untuk industri-industri hilirnya, yang
akan menghasilkan produk yang bernilai tambah tinggi
(semua jenis bahan baku plastic dan synthetic rubber)
2. Untuk meningkatkan produktivitas, effisiensi, profit margin,
quality & Safety, Perusahaan (sudah/akan) menerapkan
teknologi process Control & digitalisasi dengan memakai.
a. Pi Coreseight b. Optience c. APC/RTO d. DCS
e. SAP f. OCS g. Machine learning
yang merupakan rangkaian road map menuju industri 4.0
20
