HEROHybrid Energy system Re-Optimization
Consulting Service contributing to further Energy Savings
beyond Conventional Limits

Process-Utility Overall Systematic Assessment via
Mathematical Optimization
Remarkable energy savings ofagainst existing plants

39.7%

HERO’s mathematical optimizer is able to process and examine amuch greater number of alternative configurations compared toconventional approaches which results in unexpected and promising energy-saving options. HERO has been demonstrated throughapplication to several Japanese petrochemical plants, which havealready been highly process-intensified after the oil crises in a national project. As illustrated in the summary below, HERO provided remarkable solutions for further energy-savings. For example,
an aromatics plant reduced total energy consumption by 39.7%.
HERO can meet various demands:reduction of steam boiler duty,
increase of steam exportation, and/or increase of electric power
selling, etc. Based on each client’s business environment, HERO
provides economically attractive solutions.
Case 1Case 2

Case 3

Boiler Duty

MPS Export

Hot oil Duty

31.3 MW2.7 MW

12.3 MW-39.7%+473%-22.8%

18.9 MW15.5 MW

9.5 MW

HERO benefits clients both Technicallyand FinanciallyThrough the dedicated diagnosis of the client’s plant using tailormade optimization models, HERO benefits the client TECHNICALLY. Not only are the characteristics of the facilities analyzed but
also operation philosophy, equipment modification constraints,
and investment policy are fully embedded into the optimization
model, so that the resulting solutions perfectly fit the client’spreference.
With only a minimum initial charge, the client benefits FINANCIALLY from low consulting fees that result in a reduction ofoperation costs and greater profit. Only when the benefits are
realized the performance-based reward system is initialized.
TOYOClientMin. initialchargeFacility conﬁguration(Process & Utility)
Operation/design data
Operation philosophy✓Optimal operation

target: PFD,UFD,MHB✓ Modiﬁcation
contents

Performance-based reward

HERO Hybrid Energy system Re-Optimization

Combined Mathematical Optimizer Minimizes Energy Input
such as Boiler Duty, Electricity, etc.

Combined
Mathematical
OptimizerO
ch pean . P
ge res? s.

Process System

Utility System
Ope. Press.
change?

Heat-pumpdistillation?

New heat exchange?

HeatConnection

Modifyturbine?
BoilerfeedwaterPower
Connection

Process-utility systems simultaneousoptimization via plant-wide model―For eﬀective and practical conservationof net energy consumption ―HERO discovers hidden energy-saving solutions as a result of simultaneous optimization of the process system and utility system.
Since simultaneous optimization involves numerous and complicated trade-off relationships, conventional methodologies usually
only cover partial optimization on either the process or the utility
system resulting in minimal local optimization. In contrast, when
Mixed Integer Linear Programming is applied with the HERO optimizer, plant-wide optimizations can be achieved.
HERO suggests the steady-state target and the corresponding
modifications, which enable effective and practical energy savings. For effectiveness, the net energy input to the plant is selectively minimized:e.g. energy obtained from off-gas is kept thesame. For practicality, operability is comprehensively examinedwith TOYO’s engineering knowledge.
In addition, HERO does not interfere with previously installedadvanced control systems or monitoring systems – while such
software contributes to the real-time operation through managing
dynamic behavior, HERO finds a new steady-state target.

Toyo Engineering Corporation
2-8-1 Akanehama, Narashino-shi, Chiba 275-0024, Japan
TEL: +81-47-454-1517
E-mail: hero@toyo-eng.com
https://www.toyo-eng.com/jp

BoilerSuperior process-system optimization―Beyond Pinch Analysiss ―For process-system optimization, HERO outperforms conventional
methodologies such as pinch analysis. HERO of course, considers
all possible combinations of heat exchanges as the pinch analysis
does. In addition, HERO also considers:▶ Drastic change of operating pressures,temperatures, and heat duties▶

Implementation of new heat exchanges

Further energy-savings can be realizedwith SUPERHIDIC®, TOYO’s own heatpump distillation system. Since applied
to a column in a commercial petrochemical plant in 2016, energy savingsof 50% has been achieved.

Flexible utility system optimization
HERO can handle various utility system configurations suchas steam systems, hot oil systems, etc. For each type of utilitysystem, adequate options are prepared;e.g. setting new operating pressures for steam headers. In addition, HERO can examine
equipment modification such as mechanical modifications ofsteam turbines which conventional tools cannot analyze but may
lead to significant energy savings.
2019.10.10①FP