Case Study
Petrochemicals
Challenge
Pyrolysis furnaces in ethylene production were undergoing frequent decoke cycles (~50 days), leading to downtime, loss of coil life, and yield reduction.
Solution
Ingenero implemented a no-code, real-time burner management system that tracked CPR, TMT, and PTLE temperature deviations. Daily coil-specific monitoring allowed uniform coking and heat distribution across passes.
Outcome
- Run-length extended from 50 to 90 days
- 3 decoke operations avoided
- 1,055 tons/year additional ethylene
- Improved coil life and lower NOx emissions
Challenge
A plant with cyclic ethylene use was experiencing losses across process units, resulting in batch inefficiencies and yield penalties.
Solution
Ingenero performed a detailed concept and engineering study, identifying loss points and designing a low-cost recovery scheme.
Outcome
- Ethylene loss cut to 1.5 tons/day
- Standard operating practices improved
- $650,000 in annual savings
Challenge
A leading Middle East petrochemical major faced bottlenecks, yield loss, and poor asset utilization across two ethylene facilities.
Solution
Ingenero deployed a rigorous digital twin integrated with ML-based analytics for daily remote performance tracking and process optimization insights.
Outcome
- 250M saved over 5 years
- Sustained improvements in throughput, efficiency, and plant reliability
Challenge
A plant in Louisiana faced off-spec production and inefficient product transitions, limiting throughput and requiring external tolling.
Solution
A hybrid analytics solution using real-time plant data, digital twins, LP modeling, and machine learning was deployed with daily Decision Insight dashboards.
Outcome
- +30% capacity
- +11% first-pass quality
- $300,000 annual savings
- Tolling completely eliminated
Challenge
Two VCM plants in Lake Charles were limited by aging infrastructure, poor documentation, and constrained compressor loads.
Solution
Using Aspen Plus models tuned to live plant data, Ingenero evaluated expansion feasibility and recommended infrastructure adjustments.
Outcome
- Debottlenecking schemes implemented
- Compressor efficiency improved
- $2 million/year projected savings
Challenge
A petrochemical plant in Jubail needed to improve VOC removal and minimize wastewater treatment footprint amid regulatory pressure.
Solution
A simulation model was used to evaluate technology options. A comparative matrix led to best available technology selection and detailed project planning (PDP).
Outcome
- Compliance with effluent discharge norms
- Avoided regulatory penalties
- Executable PDP delivered and implemented
ImpactX
Energy Audit Yields $7M Savings at LAB Facility
Challenge
High energy consumption across utility and process units in a LAB complex required urgent attention.
Solution
Ingenero conducted an on-site energy audit, generated simulation models, and performed pinch analysis to redesign utility flows.
Outcome
- $7 million energy cost reduction
- Process streams reused for heating/cooling
- Lower dependency on external utilities
ImpactX
40% Pump Load Reduction in Hot Oil Network
A hot oil circuit at a petrochemical plant in Jubail was consuming excess power due to high pressure drops across control valves. Ingenero developed a steady-state hydraulic model that optimized the network, reducing pump discharge load significantly.
Verified Benefit: 2.1 MW → 1.22 MW; ~$314,000 annual energy savings
