PT Aozora Agung Perkasa specializes in providing process design, applied chemical engineering, and process safety services to the petroleum refining, chemical production, alternative fuels, and all other process industries. PT Aozora Agung Perkasa personnel are experienced, highly-motivated chemical engineers with track records of significant achievement in the process engineering field. Our services range from a few hours of consulting to complete process design package preparation and construction oversight.
With market conditions ever changing, we bring special benefits to our clients by offering high value process evaluation and engineering work at an extremely affordable price. PT Aozora Agung Perkasa can do this because of our outstanding efficiency and focused effort. Check out a few of the Projects we have recently completed.
Conceptual and Preliminary Process Designs
Feasibility Studies and Conceptual Design
When clients are contemplating a new plant or major process expansion, they typically have more questions than answers. Will the idea even work? PT Aozora Agung Perkasa is able to assist by providing experienced and knowledgeable chemical engineers that can identify, and systematically narrow down, the possible technical options for a given process goal. By necessity this occurs at the major unit operations level. Once the viable technical options are identified, an economic evaluation is performed. Based on technical merits, system reliability, and economics (capital and operating), and other factors, a preferred choice is usually clear as to which direction the future process design should take. At this point a conceptual design can be done that includes preliminary process flow diagrams, mass & energy balances, and a list of major equipment. A very rough order of magnitude cost estimate can be provided as well.
Some industry segments, mainly refining, refer to this type of work as FEL-0 and FEL-1, where FEL refers to Front End Loading. It is widely recognized that this key front end work will have a major impact on the overall project and ultimate operation. If you don't get this right then your project is in trouble no matter how good the subsequent detail engineering, construction, and project management work are executed.
FEL 0 - Identification Phase
Project opportunities arise through outside proposals, management directives, or individual initiatives. These opportunities can target revenue growth, expense reductions, strategic growth, or improved reliability, efficiency or maintenance. We first identify the opportunities by evaluating their value and identifying key risks and uncertainties. It is important to evaluate these opportunities on a consistent basis for accurate relative comparison purposes. The basis for the first decision gate (sometimes referred to as MR-1) is typically a Class V cost estimate with premises for economic modeling typically ranging from â€“20% to +50%.
FEL 1 - Appraisal and Selection Phases
Each project that successfully gets MR-1 approval progresses to the Appraise phase, where a thorough set of development alternatives is prepared and further assessment of process value, risk, and uncertainty is conducted. From a facilities perspective, some engineering may be required to further refine cost and schedule deliverables, although these should be closely managed to expend funds only where value is added. The best development concepts are moved forward to the Select phase.
Further study of multiple development options occurs in the Selection phase with the objective of identifying a single process concept for progression to the Optimization phase and subsequent final detail process design package development. Preparation of work deliverables require that a single viable concept be selected and further developed during this phase. Well-defined selection criteria should be established at the beginning of this phase to ensure the most efficient use of resources (time, money, and manpower). Once a concept has been selected, the team will complete the level of detail necessary to develop a cost estimate and preliminary project schedule with a typical accuracy of â€“20% to +40%.
Detailed Process Designs
Front End Engineering Design (FEED)
The very front end of every large design project is critical to the long-term success or failure of the plant. While the business plan identifies the economic opportunity, the Front End Engineering Design (FEED) will establish the set of process operating conditions and equipment to achieve the level of reliability, efficiency, and safety required. This design phase sets the direction for the rest of the project. Because it is so critical to the future success or failure of the overall objectives, we feel our clients make the wise choice by purchasing proven licensed processes or selecting a firm like ours which specializes in process design engineering.
PT Aozora Agung Perkasa has learned to put great emphasis on the development of the design basis at the initiation of the FEED. When the design basis is complete, we typically have the following information defined:
- Raw material specifications
- Plant capacity requirements
- Product specifications
- Critical plant operating parameters
- Available utilities specifications
- Individual unit operations performance requirements
- Process regulatory requirements
- All other operating goals and constraints desired by the plant owners/operators/engineers
Once the design basis is in place, and agreed upon by our client, our team of chemical process engineers goes to work to create, analyze, and refine the many aspects of the plant design. The end result is process documentation that describes the process from which future, more detailed, design work can be done.
Process Integrity Oversight During Detail Engineering & Construction Phases
More and more, PT Aozora Agung Perkasa is requested to remain on during the detail engineering and construction phases of projects for which we have performed the process design. In this oversight role, any process change requests are routed through our engineers for approval or comment. This helps ensure that the client understands what the impact may be on the process as changes and alternatives are suggested. Many times there is great pressure to hold down costs as the civil, mechanical, electrical, and instrumentation details of the plant are developed. The temptation to remove seemingly inconsequential process components can lead to off-spec product, inadequate throughput, high operating costs, etc. We are able to help prevent such problems simply by serving as the process integrity watchdog.
In addition, many times PT Aozora Agung Perkasa is asked to provide vendor technical and cost proposal evaluations to assist the client in making the best technology selection possible. Since we are not aligned with any equipment companies, we provide these services in a completely objective manner and make what we feel is the best recommendation based solely upon the technical and economic aspects of the options. We can also provide valuable assistance during the construction phase of a process related project.
Process Technical and Economic Evaluations
We are often called upon by clients to evaluate process options aimed at achieving one or more specific goals. These goals run the gamut from improved throughput, quality, or consistency, to emissions reduction, energy recovery, or waste minimization. In such cases we begin by determining the current state of the process. This is done through a series of interviews and discussions with the client's technical, engineering, and plant operating personnel. Additionally plant process data is collected in various forms, some of which include P&IDs, batch sheets, DCS data logs, heat and material balance information (if it exists), operation logs, etc. Our engineers then begin to analyze the situation via experience, calculations, simulation techniques, and consultation with other engineers at PT Aozora Agung Perkasa as needed. The outcome is a technical engineering critique of the current process with a focus on the areas which need the most improvement. The economic cost implications of the current process are modeled to establish the baseline from which all potential improvements will be evaluated. Many times we are asked to further identify viable technical options and provide an economic comparison between them. Based on technical process option merits, economic cost implications (capital/operating, fixed/variable), and our experienced based evaluation of the relative suitability of each process option, a final solution is recommended. Although more detailed engineering effort is required to make the best option a tangible operational solution, our clients can do so with confidence knowing they have made an intelligent, thorough, systematic, and informed decision.
Process Design Components
Any of the design services listed above may include some or all of the following components. The items included and level of detail will vary depending on clients desires or on which phase the project is in. The more mature the process design, the more of these components will be included.
- Process design basis development
- Regulatory basis development
- Process computer simulation
- Advanced spreadsheet-simulation-spreadsheet user interfacing
- Mass and energy balances
- Technical and economic process alternatives evaluation
- Conceptual process design
- Detail process design
- Process control system design
Complete process design packages normally include:
- Design basis
- Mass and energy balance computer simulations
- Process simulation models for client use
- Process flow diagrams (PFDs)
- Process control logic and process control diagrams (PCDs)
- Capital cost estimate
- Operating cost estimate
- Piping and instrumentation diagrams (P&IDs)
- Equipment plot plans
- Utility flow diagrams
- Equipment lists
- Equipment sizing and specifications datasheets
- Preliminary process hazards analysis documentation
- Plant layouts
- Preliminary process operating manuals
Process Modeling and Simulation
PT Aozora Agung Perkasa uses long-term or short-term licensed commercial process simulation software (CHEMCAD, Aspen, Hysis, Pro/II, Simsci) and/or in-house simulation programs to perform:
- Detailed mass and energy balances
- Unit operation design/evaluation
- Piping system hydraulics calculations
- Relief and flare system design/evaluation
- Heat exchanger design/evaluation
Why Use Process Simulation?
In this modern age of powerful computers, it often makes no sense to put pencil to paper like in the old days. Now, new software can perform repetitive chemical engineering calculations in a fraction of the time it takes to execute them by hand. Imagine you have been tasked to design a distillation column to produce a 90% benzene overhead product and a 95% toluene bottoms product. You look up the VLE data for benzene-toluene, carefully construct your x-y diagram, draw the feed line, and step off your McCabe-Thiele trays. Estimate tray efficiencies. Then you calculate your mass and energy balance, product and bottoms dew points and bubble points, and estimate your overhead condenser and column reboiler duties. Wrestle with those tedious hydraulics equations to determine the column diameter. Then dust off the old heat transfer equations and some time later you have your condenser and reboiler sized. Finally - the system is designed.
The Advantage of Simulation
For the example above, getting the initial solution using process simulation software would take....about the same amount of time. BUT, when the design conditions are changed - and has there ever been a design where they haven't? - the speed and accuracy of process simulation begins to save tremendous time and money. And not only for design changes. In the example above, you had to select your reflux rate based on some old rule of thumb about the optimum reflux being some multiple of the minimum reflux. Wouldn't it be better to be able to plot reflux rate versus energy usage? Versus number of trays? And automatically, with one software command?
Multiple runs - quickly. Process design optimization - quickly. Such is the power of process simulation. The example given above is for a distillation tower, but the same holds true for any number of chemical engineering unit operations - heat exchangers, reactors, heaters, absorbers, extractors, crystallizers, evaporators; even pumps, compressors, and piping systems. In fact, even an entire plant - in one model.
And operations. Have you ever wondered if that old packed tower or heat exchanger will work in this new application? Let's model it and see.
Our Commitment to Simulation
It is our opinion that process engineering services are no longer adequate or complete without the presence of comprehensive process simulation software and chemical engineers highly skilled in its use. In the ever more competitive world of manufacturing, it is no longer acceptable to determine just a correct answer - the BEST answer is required. And it is almost never possible to achieve the best answer within the confines of any client's project budget without the use of simulation software. Answers like:
- The feasibility of, and optimum operating conditions for utilizing a two-tower valve tray distillation system (originally designed for depropanizing and debutanizing gasoline) for the production of high-purity propane, iso-butane, and n-butane from various pipeline and refinery feedstocks
- The optimum process orientation and operating conditions for a multi-tower absorption system for producing maximum product concentration, minimum offgas concentration, and minimum operating costs
- The optimum reactor design and operating conditions for maximum product yield and minimum byproduct contamination
- The fact that despite energy savings as compared to a distillation system, a multi-effect evaporator was not technically feasible due to operational instability
- The optimum number of stages and operating conditions for minimizing energy consumption for a product-concentrating distillation system
- The best retrofit option for a solvent recovery condensing system, maximizing product recovery while eliminating downtime due to freezing events
- The best retrofit option for a fume incineration system, minimizing supplemental fuel usage.
- All real projects recently completed by PT Aozora Agung Perkasa. In all cases it was possible to get the BEST answer from process simulation
Our Choice of Simulation Software
In the beginning, PT Aozora Agung Perkasa took three months to evaluate the leading simulation softwares. At the end of the process, we selected Chemstations' ChemCAD simulation software product. To a large extent, we believe that the leading softwares are technically equivalent - but we wanted a partner in this endeavor, and it was our perception that Chemstations' customer and technical service personnel were superior to their competitions'. Our engineers have trained extensively on the proper use and application of the software. We have worked very closely with Chemstations over the past few years with the development of improvements to the software. But most importantly, we consult with their expert simulation engineers on a frequent basis, both as a check on our work and for assistance in solving unusual or complex problems.
The Benefits to You
- Accurate design information
- Software-produced mass and energy balances and process flow diagrams
- Multiple design cases at a fraction of the cost
- Process optimization, finding the process' maximum performance point
- Sensitivity analyses, determining the process' key control variables and degree of operating stability.
Call us with your application. It might be the most cost-effective thing you do all year.
Listed below are the types of plant operations support that PT Aozora Agung Perkasa typically provides to operating companies. Additionally, process engineering staff augmentation can be provided for operating facilities within reasonable commuting distance from one of our regional offices.
- Process evaluation, troubleshooting, optimization
- Control system startup, tuning, optimization
- Commissioning and startup assistance
- Existing operations design basis development
- Operating procedures, process documentation
- Operator and technical staff training
- Statistical process control
Third Party Evaluations, etc.
- Plant investment due diligence evaluation
- Process/equipment bid package preparation
- Vendor bid evaluations and recommendations
- Expert witness/legal team technical assistance