Redução do consumo de vapor de alta pressão na turbina de compressor em uma planta de MVC

Abstract

Vinyl chloride monomer (VCM) is a chemical compound with the formula C₂H₃Cl, a colorless and flammable gas at room temperature, serving as one of the primary precursors for the production of polyvinyl chloride (PVC), widely used in pipes, coatings, and plastic products. Industrial utilities play a crucial role in the efficient operation of a VCM plant, as resources such as electricity, water, and steam are indispensable for enabling various production processes. V-42, a high-pressure steam (42 kg/cm²), is extensively utilized in VCM plants, playing a vital role in processes requiring high temperatures and enhanced thermal efficiency, being essential for heating, power generation, and precise temperature control in industrial applications like distillation and sterilization. Optimizing steam usage in industries is critical to improving efficiency and reducing waste, as excessive steam use results in environmental impacts such as greenhouse gas emissions and high water consumption while increasing operational costs due to higher energy usage and maintenance demands, making efficient steam management indispensable for minimizing these impacts and ensuring the sustainability and economic viability of operations. This study was conducted at a VCM plant, referred to as "PetroFlex" for confidentiality, which employs V-42 in its R134a refrigerant liquid compressor—a centrifugal compressor with two sections and three stages in each section, connected to a turbine where steam is injected to generate rotation, driving the turbine and operating the compressor. In 2023, a significant increase in V-42 consumption was observed, ranging from 9.0 t/h to 9.6 t/h in July, leading to high operational costs for the plant. The objective of this study was to optimize V-42 consumption in the machinery, reducing costs through the standardization of operational procedures and implementing improvements, while also contributing to decarbonization and sustainability. To achieve this, the DMAIC methodology, a problem-solving approach focused on continuous improvement and process enhancement, was employed. This methodology comprises five phases—Define, Measure, Analyze, Improve, and Control—aiming to identify and address the root cause of the problem, which in this case was the excessive V-42 consumption in PetroFlex's VCM plant system. In the Define phase, problems or improvement opportunities were identified; in the Measure phase, process performance and problem causes were assessed; in the Analyze phase, the main causes were determined based on data; in the Improve phase, solutions were developed and implemented to address the identified causes; and in the Control phase, results were monitored to ensure the sustainability of the improvements over time. This project significantly reduced V-42 consumption in the compressor turbine, stabilizing it within the range of 8.0 t/h to 8.5 t/h. In just two months, savings of approximately 9.47% in September and 9.68% in October were achieved, resulting in financial gains of R$ 295,148.78, with expectations to exceed the projected savings of R$ 823,583.09 over one year of DMAIC Control phase monitoring, positively impacting sustainability and reducing CO₂ emissions.