Case Study: North American Refinery saves USD 2 million/year with KBC A Yokogawa Company’s Petro-SIM and HX Monitor

North American Refinery saves USD 2 million/year with KBC A Yokogawa Company

A North American refinery faced significant fouling in several heat exchangers following an unscheduled shutdown, leading to increased energy usage and online cleaning costs that typically exceed $1 million per year. To mitigate these costs, the operator reached out to KBC A Yokogawa Company for a solution.

KBC A Yokogawa Company implemented an integrated digital twin using its Petro-SIM and HX Monitor software to create a model of the entire heat exchanger network. This solution enabled the development of an optimized cleaning schedule, which improved profit margins and achieved best practice fouling monitoring. The refinery realized estimated energy cost savings of USD 2 million per year, with even greater savings from increased throughput.