Case Study: a North American 300 kbpd refinery saves over USD 2 million/year with KBC A Yokogawa Company’s Petro-SIM and HX Monitor

Petro-SIM and HX Monitor integrated digital twin improves profit margins

KBC A Yokogawa Company worked with a North American 300 kbpd refinery that faced an unscheduled shutdown and significant fouling in several heat exchangers after a typical start-up. The refinery wanted to reduce the high costs of online cleaning and extra energy use caused by fouling.

KBC A Yokogawa Company implemented an integrated digital twin using Petro-SIM and HX Monitor to model the heat exchanger network, connect to the plant historian, and monitor fouling over time. The solution helped the refinery identify which exchangers to clean and develop an optimized cleaning schedule, leading to improved throughput, better profit margins, and estimated energy savings of USD 2 million per year.