No more energy loss
Braskem engineer wins Petrobras Technology Award
written by ◦ Simone Goldberg photos by ◦ Eduardo Moody

In 1980, when engineer Edgar Nunes de Almeida started working at the utilities department of the former Copene, now Braskem’s Basic Feedstocks Unit, he had his eye on a promising professional future. Now, after working in several sectors at the Unit and taking specialization courses, including a recently completed Master’s degree, he has received a major accolade for his relentless pursuit of improvement. His Master’s thesis, “Exergetic Analysis of a Cogeneration Thermal Power Plant at a Petrochemical Complex,” was one of the three winners of the Petrobras Technology Award in the Energy category. Edgar’s study, which stands out for its innovation – one of Braskem’s strategic pillars – is being put into practice and will save the company BRL 18.5 million a year.

Edgar analyzed the operations of Braskem’s Thermal Power Plant Unit as if he were viewing all its processes through a magnifying glass. As a result, he was able to detect the points where usable energy was being lost and find solutions to prevent it. To confirm the existence of energy loss, he had to carry out an energetic analysis, which was like taking a panoramic photo of the entire unit, and then use exergetic analysis to show the details in close-up.

“Energetic analysis tells you that there is an escape route for energy. Exergetic analysis shows where the loss is coming from,” explains Edgar, who now works in the Basic Feedstocks Unit’s Process Technology area. In light of his diagnosis, which found 19 bottlenecks at the thermal power plant, the company has begun replacing equipment and modifying operating processes at the plant, which generates 130 MW (megawatts). Edgar’s suggestions have also been included in the Braskem+ corporate competitiveness program.

Once the adjustments have been made, the unit’s efficiency will increase by 3.8% and the plant will require 35,000 tonnes per year less fuel oil. In addition to reducing costs, the proposal also has environmental advantages: burning less oil means cleaner production. When looking for bottlenecks, Edgar had an important helper: a virtual model of the plant created with a program he designed. “This was one of the most valuable parts of the project. The simulator is an accurate portrait of the unit that can identify and quantify recoverable losses in this specific unit,” says Edgar’s thesis advisor, Professor Ednildo Andrade Torres, from the Federal University at Bahia (UFBa) Polytechnic. He stresses the importance of the relationship between the company and the university. “As a result, the company can increase its members’ expertise and the university can bring in projects and prepare students and teachers for life in the business world,” he observes.

In addition to helping Edgar with his analysis, the simulator will be used as a tool to aid corporate decisionmaking. “This study proposes a new approach to the question of energy. We have come to see it in an integrated fashion, which will definitely add value,” says João Lins, the officer responsible for the Industrial, Energy and Essential Services area of the Basic Feedstocks Unit.

The practical business applications, innovation and technical quality of Edgar’s research project were the standards Petrobras used to award it the Technology prize, which is bestowed through a partnership with the National Council for Scientific and Technological Development (CNPq). There were 335 projects vying for the award in nine categories. “We encourage our members to seek the competitive edge of knowledge, which is fundamental for qualitative growth,” says the Basic Feedstocks Unit’s Industrial Director, Manoel Carnaúba.