Use of Process Simulation in Ethylene Plant APC and Dynamic Optimization

Use of Process Simulation in Ethylene Plant

APC and Dynamic Optimization

Akitoshi Takinami, Ayumu Fujita, Takeshi Seki, Youichi Takeuchi

Showa Denko K.K., Oita, Japan

23rd Ethylene Producers' Conference

March 15, 2011

Soichi Iwamoto, Tomoo Niikura

Yamatake Corp., Tokyo, Japan

Paul Yap and Ravi Nath

Honeywell Process Solutions, Singapore and Houston

Agenda

• Introduction– Process Overview

• Technology Overview– MPC

– RTO

– Gain Updating (or Gain Scheduling)


March 15, 2011

• Project Details

• Conclusions

Introduction: Showa Denko

•Head Office : Tokyo, Japan

•Employee : approx. 11,500

•Consolidated Financial Highlights

Net sales 9,600 M US$ (2010)

Total assets 1,700 M US$ （¥83/US$）


March 15, 2011

Total assets 1,700 M US$ （¥83/US$）

•Major Products

Petrochemicals/Chemicals/Electronics

Inorganic Materials/Aluminum/Hard disk

Introduction: Oita Petrochemical complex

Location :

Oita Prefecture,

Kyushu Island,

Japan

Products : Olefins,

Organic chemicals,

Showa

Denko K.K.Oita Complex


March 15, 2011

Organic chemicals,

Polyolefins,

Plastics Products,

Liquefied Hydrogen,

Carbon nanofiber,

Aluminum cylinder

Introduction: Ethylene Plant

Fu

rna

ces

Pre

-fractio

n

de

me

tha

nize

r

de

eth

an

izer

de

pro

pa

na

izer

Eth

yle

ne

fractio

na

tor

Pro

py

len

e fra

ction

ato

r

de

pe

nta

nize

r

de

bu

tan

izer

Re

run

tow

er

hydrogen

methane

ethylenepropylene

Cracked

gasoline

C4

C2 C3 C4+C5

C6～～～～

Cracked Gas

Compressor

Raw materials

3 Feed Systems


March 15, 2011

de

me

tha

nize

r

de

eth

an

izer

de

pro

pa

na

izer

Eth

yle

ne

fractio

na

tor

Pro

py

len

e fra

ction

ato

r

de

pe

nta

nize

r

Re

run

tow

er

ethane C5Cracked

kerosene

C2～～～～ C3～～～～C4～～～～

C3LPG

CFO

15 furnaces

3 Quench Systems

Ethylene production capacity : 672 KTA

2 Deethanizers

3 Ethylene Fractionators

2 Depropanizer

3 Propylene Fractionators

Introduction: Project History

Advanced Control and Optimization (ACO) project

•2002 Completed ACO project with Honeywell and Yamatake.

•2006 ACO applications were updated

•2010 Upgrade project to use Process Simulation in ACO applications


March 15, 2011

The ACO applications have been continuously operational for last decade.

Next

1. Technology Overview

2. Project Details

What’s in a name?

Generic Trade Name Synonym

Real Time Optimizer (RTO) Profit Optimizer DQP

Model Predictive Controller (MPC) Profit Controller RMPCT


March 15, 2011

ACO : Advanced Control and Optimization

: MPC, RTO and other supporting functions

Technology Overview

• Real Time Optimizer: DQP

(RTO)

• Model Predictive Controller: RMPCT(MPC)

• Gain updating: Profit Bridge

• Process Simulation: UniSim Design

ACO


March 15, 2011

• Process Simulation: UniSim Design

• Yield modeling: on-line Spyro

• DCS: Yokogawa

• Data Historian: PHD

DCS

data link between

ACO & DCS

Technology Overview: Model Predictive Controller

RMPCT

– Funnel design & min. move solution• optimum reference trajectory

• inherently robust solution

Unforced response

– Local optimization (linear or QP)Economic data Optimization speed


March 15, 2011

– Local optimization (linear or QP)• Optimization passed as desired values

• Range Control Algorithm determines min. MV moves for control & optimization

MV moves

Optimization

RMPCT mdl

X*

– Parametric models• on the fly gain updating

• bumpless prediction updating

Technology Overview: Real Time OptimizerDQP

– Dynamic model, no model duplication

• Base model from controllers

• Additional structures (Bridge Models, Source Clones & Combined Constraints) for global perspective

• No wait for steady state

• Minimum move trajectory

x

x

x

xx

x

x x

x

xx

x

x

x x

x

x

x

x

x

y y y y y y y


March 15, 2011

• Time coordinated implementation

– Global constraint coordination

– On the fly gain updating

Process data

QP

RMPCT

QP Targets

MV moves

mdl

X*

DQP Multi-unit process model

Economic data Optimization speed

QP

RMPCT

QP Targets

Process data MV moves

X*

mdl

Process data

Technology Overview: Gain Updating

• Profit Bridge

– Validates process data

– Links to UniSim Design for inferentials and gains- UniSim design links to Spyro

– Gains are deposited to controllers and optimizer– Gains are validated and filtered


March 15, 2011

Next: Project Details

U n iS im

M od e l

Tecnip’s

On-line

Spyro

Process data

Simulation results

Gains

DQP

RMPCT RMPCTRMPCT

Project details: original design

DQP Gain-schedulingNonlinear optimizer

Every 2 hours

Every 5 minutes

DQP is linear model

But Cracking yields, Utility Consumption → non linear

≒≒≒≒


March 15, 2011

MPCUNIT MPC MPCMPC

Feed maximizer

(LP)

MPC MPC

Every 2 hours

Every 1 minute

Every 1 minute

Conventional optimizer DQP

Project Details: Yields gain scheduling


March 15, 2011

C1-MC2

C1-LC1

C1-LC2

C1-MC1

LOAD

COT

STM/HC

COP

Project Details: Utility Gain Updating

Update not only yields gains but also utility consumption gains

DQP

Price, cost, constraintYields prediction

program SPYRO

Gain scheduling Utility

Gain calculation


March 15, 2011

Refinementcompressor

RMPCT

Refinement

compressor

RMPCT

RMPCT

Gas

chromatograph

DeethanizerPre-

fractionatorCompressor Depropanizer

RMPCTRMPCTRMPCTRMPCT

De-

methanizerRaw

materials

RMPCT

Furnace Depentanizer Debutanizer

Propylene

fractionator

Rerane

tower

RMPCT RMPCT

Ethylene

fractionator

Ethylenefractionator

Condensatestripper

RMPCT

RMPCT

Project details: 2010 upgrade

DQP


programSPYRO

Gain

scheduling

Utility

Gain

calculation

Main modification points

1. Major change of Gain scheduling method

2. Model change because of process modification


March 15, 2011


RMPCT

Refinement compressor

RMPCT

RMPCT

Gaschromatograph

DeethanizerPre-


RMPCTRMPCTRMPCT

DQP

RMPCT

De-

methanizerRaw

materials

RMPCT


Propylene

fractionator

Rerane

tower

RMPCT RMPCT

Ethylene fractionator


Condensatestripper

RMPCT

RMPCT

Project details: 2010 upgrade: Gain Scheduling


program SPYRO


Gain calculation

Pre-DQP

Custom-made program

Profit Bridge+

Unisim Design

Commercially available program

Gain scheduling


March 15, 2011


RMPCT

Refinement

compressor

RMPCT

RMPCT

Gas

chromatograph

DeethanizerPre-


RMPCTRMPCTRMPCT

DQP

RMPCT

De-

methanizerRaw

materials

RMPCT


Propylene

fractionator

Rerane

tower

RMPCT RMPCT

Ethylene

fractionator


Condensatestripper

RMPCT

RMPCT

Project details: 2010 upgrade: UniSim Model

Distillation SectionFurnace Section

Rigorous model with SPYRO (yield generator)


March 15, 2011

Project details: 2010 upgrade: MPC modeling

RMPCT RMPCTRMPCTRMPCT

DQP


program SPYRO

RMPCT RMPCT RMPCT RMPCT


Gain calculation


March 15, 2011


Refinement

compressor

RMPCT

RMPCT

Gas

chromatograph

DeethanizerPre-

fractionatorCompressor DepropanizerDe-

methanizerRaw

materials


Propylene

fractionator

Rerane

towerEthylene

fractionator


Condensatestripper

RMPCT

RMPCTProfit Stepper

Project details: 2010 upgrade: Profit Stepper

Controlled


March 15, 2011

Controlled

valuables

Manipulated

valuables

Project details: System OverviewW indows 2003W indows 2003W indows 2003W indows 2003W orkstation1 W orkstation2 W orkstation3Unisim ,ProfitBridge RM PC T(C O LD) O RAC LEDevelopm ent SysytemDevelopm ent SysytemDevelopm ent SysytemDevelopm ent Sysytem DQ P PHDRM PC T(HO T) Visual PHDW indows 2003W indows 2003W indows 2003W indows 2003W orkstation4 PHD dataUnisim ,ProfitBridgeSPYRO license DQ P Remodeled at TAM

(April, 2010)

DQP

DQP/RMPCT RMPCT Database/SDK applications

Remodeled by end of 2009


March 15, 2011

Real systemReal systemReal systemReal system W orkstation5 W orkstation8RM PC T(HO T) O RAC LEPHDPHDPHDPHDW orkstation6RM PC T(C O LD)W orkstation7Visual PHDW orkstation9Unisim ,ProfitBridge backup W orkstationW orkstation10RM PC T backup W orkstationW orkstation11PHD ,VisualPHD backup W orkstation

ExaO PC⇔DCSExaO PC⇔DCSExaO PC⇔DCSExaO PC⇔DCSBackup

SDK applications

RMPCTDatabase

Project details: Operator Interface


March 15, 2011

Bottle neck

point

Project details: Daily Optimization reportﾈｯｸ上位 1 CR11CV11.PV 下超 C2T9179X T931 21段温度(℃) 74%ＤＱＰ稼働率 96% 2 CR11CV10.PV 上超 C2A9525C T932ｴﾁﾚﾝ中C2H6(PPM) 54%ＤＱＰ最適化割合 96% 3 CR10CV08.PV 下超 C1A4531A T431 BTM C2H4(%) 46%（最大負荷運転） 96% 4 CR13CV09.PV 下超 C1L4446 V452液面[%] 42%（最大負荷移行中）[ﾈｯｸなし] 0% 5 CR16CV05.PV 上超 C2P4282_MV T-481 圧力のPCV開度 38%ＤＱＰ調整中割合[ﾈｯｸ回避 ]0% 6 CR09CV02.PV 上超 C2A9520A T-921 BTM C2H6 ppm 34%7 CR13CV09.PV 上超 C1L4446 V452液面[%] 34%Ｎｏ TAG名 < サービス名 > DQPA.M< DQP ON-OFF ON=3/OFF=2 >DQPA.T_19< DQP Status 1=最適化 0=調整中 >DQPA.CPAISF09_9< ﾄｰﾀﾙHC現在値 >DQPA.CPAISF10_9< ﾄｰﾀﾙHC予測値 >DQPA.CPAISF02_9< ﾄｰﾀﾙHC上限値 >CR19CV01.PV< Grossｴﾁﾚﾝ現在値 > CR19CV01.T_24< Grossｴﾁﾚﾝ予測値 > FURNACE_ROOM.PV_CC2T9179X< 分解炉余裕度(T/H) >(Ａ)(B)(Ｃ)(Ｄ)Trends graph of operation index


March 15, 2011

下超C2A9525C上超C1A4531A下超C1L4446下超C2P4282_MV上超C2A9520A上超C1L4446上超(Ｋ) < V452液面[%] >(Ｉ) < T-481 圧力のPCV開度 >(Ｊ) < T-921 BTM C2H6 ppm >(Ｇ) < T431 BTM C2H4(%) >(Ｈ) < V452液面[%] >(Ｅ) < T931 21段温度(℃) >(Ｆ) < T932ｴﾁﾚﾝ中C2H6(PPM) >

250

275

Trends graph of bottle neck points

Project details: Benefits: Production Maximization

Refrigerant compressor speed maximum limitRaw material

feed rate Compressor Raw material

feed rateCompressor speed Refrigerant compressor speed maximum limitThe results of DQP introduction

(maximizing ethylene production)


March 15, 2011

Ethylene production rate

feed rate Compressor speed

Before

Ethylene production rate

After

Project details: Benefits: Energy Minimization

DQP select the Furnace that can be loaded up economically.


March 15, 2011

Conclusions

Use of ACO at SDK has been a success story

• Continuous use since 2002

• Production increase as well as energy reduction

• Solomon Survey APC Index: First rank in 2003 & 2007

Drivers for success have been


March 15, 2011

Drivers for success have been

• Technology: dynamic opt. with gain scheduling

• Innovation: custom operator interface & daily reporting

• Use of a development system

Use of Process Simulation will ease future maintenance and

enhancements.

Q & A


March 15, 2011

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Use of Process Simulation in Ethylene Plant APC and Dynamic Optimization

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