TO ERR IS HUMAN,

TO IMPROVE
IS NAPCON.
NAPCON AIMS TO LEAD
PROCESS INDUSTRIES TO A
SAFE AND SUSTAINABLE FUTURE
WITH DIGITAL SOLUTIONS
Introdution

Andreas Frejborg, Head of Customer Relations, NAPCON

andreas.frejborg@neste.com
V2019-11
WHAT IS NAPCON?
Simulation
tools
• NAPCON is a business unit of Neste
Engineering Solutions that improves
production, quality, energy and
safety for process industries.
Advanced Software
• 80 professionals automation development

• Applications delivered to globally

since 1986

• Our tools are independent of Process

automation and ICT platforms know-how
 WHAT IS YOUR GOAL?

AVAILABILITY ENERGY PRODUCTION

EFFICIENCY OPTIMIZATION

QUALITY SAFETY
 NAPCON WAS BORN FROM THE NEEDS OF AN INTEGRATED PLANT
IN PORVOO, FINLAND

Petrochemicals
Port
Storage
Refinery
Area

5
NAPCON - TYPICAL CUSTOMER INDUSTRIES

Petrochemicals Gas Industrial Infrastructure

Natural Gas – Biogas - LNG

Petroleum Refining Biorefining Food Industry

 OUR PRODUCTS

UNDERSTAND IMPROVE TRAIN

Turn the data provided Bring out the maximum Make operator training
by your plant into potential of your safe and exciting by
relevant information operations by optimizing bringing your real-life
that helps optimize both, production and plant into the virtual
your company’s capacity. world.
production.
NAPCON Controller NAPCON Simulator
NAPCON Informer NAPCON Optimizer NAPCON Games
NAPCON Analytics NAPCON Business
Optimizer
SNEAK PEAK ON
UNDERSTAND
NAPCON ANALYTICS – RANGE OF APPLICATION FOR PROCESS
INDUSTRIES

NAPCON Analytics NAPCON Analytics is built to

Operational Company / Sales / planning leverage operational intelligence
Business for process industries and turn
management Intelligence streaming data to multi-level
Business level

operational metrics for optimizing

Site / Plant plant profit. With turn-key delivery
management we help to define, generate and
deploy production-ready
dashboards which help to
Production line maximize human potential.
Supply chain
Traditional
NAPCON Informer enables turn-
Production unit Business key delivery for streaming data
Production Intelligence solutions without production
Sensor / interruptions and resilient process
Field device Automation / DCS data access with certified OPC UA
Second Minute Hour Shift Day Week Month Year Business life tools from IoT, process DCS and
many other systems.
Time scale
TYPICAL EXAMPLE OF ERP / BUSINESS INTELLIGENCE
TYPICAL EXAMPLE OF OPERATIONAL EXCELLENCE
SNEAK PEAK ON
TRAIN
 NAPCON GAMES
DISTILLER FURNACE

AD PICTURE HERE

Free trial available on www.napcongames.com

Unit Training Simulator
LEARNING
14
ENVIRONMENT 19.4.2017
SNEAK PEAK ON
IMPROVE
 IMPROVE

NAPCON Controller NAPCON Optimizer

controls one specific optimizes production in
process unit. a more holistic way.
NAPCON CONTROLLER AND NAPCON OPTIMIZER
OPTIMIZING BOTH PROCESS AND BUSINESS VARIABLES

“Then we installed NAPCON

“First we tried to keep the
specs by manually adjusting
temperature and flow rate set
points on our product”
Controller. Product variations
reduced dramatically and we got
closer to the specs!”
“After having stable
production we optimized
process according to the
market price variations
with NAPCON
Optimizer.”

NAPCON Controller NAPCON Controller NAPCON Optimizer

PLC or DCS
Process on upper limit, Maximum achievable
Operator Control
Variations minimized 10-15 % more profit profit, 5-10% more
6.5.2019
NAPCON PERFORMANCE ANALYSIS REDUCES RISKS
Estimated investment costs / $

Estimation before performance analysis

Estimation based
on NAPCON
Performance
Analysis

Estimated annual benefits / $

6.5.2019
SELECTED
REFERENCES
OUR SUCCESS STORIES
50% REDUCTION IN C6 PRODUCT QUALITY
VARIANCE CONTENT
$ 100M 10% OF THE TOTAL BENEFIT CAME FROM
MORE PROFIT ENERGY SAVINGS

78 % LESS WORKING HOURS SPENT

17% INCREASE IN TALL

OIL PRODUCTION
+8% MORE
MILK POWDER PRODUCTION
+ 10% MORE
PRODUCTION
CASE: BUTADIENE PROCESS OPTIMIZATION
WITH NAPCON CONTROLLER

Goal Increase the production of butadiene by 5%

No process or control system shut-downs due to installation and commissioning

Requirement No investments for new process equipment or instrumentation
Manage long process delays and slow process response.

Manage long process delays and slow process response

Challenges Solvent concentration dynamics are known to be very slow making it
difficult for operators to control the process in real-time

Production capacity increased by 10%

Product impurity variation decreased by 60%
Benefits
Fast implementation, early start at 10 weeks and a full scale operation
16 weeks after project start
17% INCREASE IN
PRODUCTION
CASE: TALL OIL DISTILLATION OPTIMIZATION
WITH NAPCON CONTROLLER

Customer’s preliminary target was to improve Tall Oil Resin (TOR) yield and Tall Oil
Goal
Fatty Acid (TOFA) at one of the most modern and efficient tall oil distillation facility

No negative impact towards ongoing production

No investments for new process equipment or instrumentation
Requirement
Full turn-key implementation of NAPCON Controller in 8 months, for two
production lines including implementation and engineering services

Non-steady-state operation conditions

Challenges Tall oil distillation is complicated by the thermal sensitivity and the
overlapping boiling ranges of tall oil compounds.

17% sustainable production increase, 9% production increase by manual

control and 8% additional production increase after implementing NAPCON
Results Controller
8 months complete implementation, 5 ½ months Early Start partial
implementation for TOFA production
ANNUAL PRODUCTION INCREASE

” During the NAPCON Performance Analysis and

17 %
the subsequent NAPCON implementation, we
became convinced of Neste Engineering
Solutions’ expertise to carry out the production
optimization with NAPCON Controller. We are
very excited about the great results and the 2%
attractive payback of the investment in NAPCON.“

RISTO NÄSI
TARGET RESULTS
CEO OF FORCHEM
EXPECTED
10% MORE
WHEY POWDER
PRODUCTION
CASE: WHEY POWDER PRODUCTION OPTIMIZATION
WITH NAPCON CONTROLLER

To optimize spray dryer operation:

Goal increase production throughput, increase energy efficiency, stabilize product
quality and decrease maintenance downtime

No investment on new process equipment

Requirement No process down time during commissioning
Fast implementation (2+3 months)
Recipes for different product types

Outside humidity affects on spray dryer

Challenges
Multiple whey powder types

> 10% increase in whey powder production

Results No increase in energy consumption
More optimal and consistent whey powder quality
Less maintenance downtime in the process
ANNUAL PRODUCTION INCREASE

“The results from the first optimization project >10% 0%

made us so convinced of NAPCON expertise and
superiority to carry out high-end production
optimization projects that it was easy to partner up
again”

ANTERO YLITALO
PRODUCTION MANAGER FOR VALIO

PRODUCTION ENERGY
CONSUMPTION
INCREASE
$ 100M
MORE PROFIT
CASE: ETHYLENE CRACKER PLANT WIDE OPTIMIZATION
NAPCON OPTIMIZER

Maximize the profit of an ethylene cracker via plant wide real-time optimization
Goal
Utilize existing model predictive control (MPC)

No process or control system shut-downs due to installation and commissioning

Requirement
No investments for new process equipment or instrumentation

Non-steady-state operation conditions

Several different feedstocks
Challenges
Online changes to feedstock composition
Integration with nearby oil refinery, power plant and aromatics plant

Cumulative profits more than 100 MUSD in 8 years

Profit increase 12.5 million USD/a
Benefits
Increased ethylene production +9%
Usage 99.7% during running time
ANNUAL PRODUCTION INCREASE

” Our estimate is that the NAPCON Optimizer has 9% 12,5

MUSD / a
continued to produce the same amount of annual
profit ever since 2005, meaning that we have
passed the cumulative profit milestone of 100
million USD. “

DR. STEFAN SMEDS

PRINCIPAL OPTIMIZATION SPECIALIST, BOREALIS POLYMERS
2014

PRODUCTION PROFIT
78 % LESS WORKING
HOURS SPENT
WORKING HOURS

"NAPCON Informer enables us to work more 100 % 78 %

efficiently - after napconizing our production
tracking system, we have recorded a 78%
decrease in working hours to date. It is extremely
important to have a production tracking system that
is user friendly, trustworthy and flexible.”

MARKKO RAJATORA
MANAGER OF DECISION SUPPORT SYSTEMS AND PROCESSES
AT NESTE REPORT REDUCED
ON TIME REPORTING
TIME
SELECTED CUSTOMERS