Case Study: a refinery in Asia Pacific achieves 1.5% energy cost reduction with KBC A Yokogawa Company and Visual MESA Energy Real Time Optimizer

Asia Pacific Refinery Decreases Energy Costs by 1.5% Visual MESA Energy Real Time Optimizer provides quick win solutions

KBC A Yokogawa Company worked with a leading MESA energy real time optimizer provider, a refinery in Asia Pacific producing 190,000 bpd that wanted to increase profit margins. The customer’s challenge was to improve both refinery performance and energy use, with plans focused on unit availability, cracking unit use, and broader energy optimization.

KBC A Yokogawa Company performed a gap analysis and used Visual MESA Energy Real Time Optimizer and Petro-SIM process simulation software to identify and prioritize quick-win utility projects. The solution included an online utilities digital twin, set point optimization for boilers, turbines, and deaerators, pump start-stop optimization, and later hydrogen and fuel system optimization, along with engineer and operator training. The refinery reduced energy costs by 1.5%, and after introducing a RASCI matrix, saved an additional 0.3%.