e-LOAD
e – Load Optimization Assessment using Digital twin
The modern Chlor-Alkali Process plants are based on the efficient membrane technology, which involves electrolysis of Brine, which is used as a raw material. During this electrolytic process, the Brine is decomposed to chlorine in the anode compartment, and to sodium hydroxide solution and elemental hydrogen in the cathode compartment.
Electrolyser Cell House is at the heart of Caustic-Chlor Plant. It is single largest energy sink of the manufacturing process and its operations directly impacts the Plant energy performance KPIs
The problem
Challenge
Chlor-alkali production is energy intensive: 50-70% of the variable cost is due to electricity, so the challenge is to minimize the energy costs
How we solve it
Solution
eLOAD, a digital twin of an electrolyser, uses the available measurements and basic relationships among variables to decide the optimal distribution on one or more electrolysers. It can be configured for any number of electrolysers in the plant.
What you gain
Benefits
- Easy to setup the model
- Minimal data required for initial setup and calibration. And it is fast too.
- Does not need expert engineers to run or maintain the model in future
- Easy to use for any new site. Ascertained results in quick time to issue advisory to operations
- Good availability of historical plant and lab data further facilitates model building and quality of prediction