Smart Process Distillation Application Improves Recovery And Saves Energy
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Presented by Pete Sharpe at Emerson Exchange 2009.
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Smart Process Distillation Application Improves Recovery And Saves Energy
- 1. SmartProcess Distillation Application Improves Recovery and Saves Energy – A Case Study Pete Sharpe Director, Industry Solutions for Refining & Chemicals
- 9. Distillation Process Affect of Energy Lt Key Concentration Energy Consumption Feed Composition 100% 0% Overhead Composition Bottoms Composition At Constant D/F Ratio
- 10. Cost of Variability Precision Control Valves Loop Performance Digital Positioners Better Measurements IMPROVED PROFIT BY CHANGING TARGET REDUCED VARIABILITY POOR CONTROL $ PROFIT SPECIFICATION LIMIT Improvements from: Operator Safety Margin Advanced Control
- 11. APC Optimization Time Distillate Rate Recovery Opportunity Minimum OH Rate Operator Setpoint APC Objective: Minimize overhead product loss while controlling bottoms impurities to target
- 12. SmartProcess Applications – Tools vs. Solutions We have the best materials, craft skills, tools, and services. What can we build for you? We’ve developed a variety of houses to meet your specific needs. Products, Services, Expertise Applications
- 14. Applications Enable Faster, More Efficient APC Implementations Functional Design Det. Design, Config & Staging Step Tests & Model ID Commissioning Functional Design Det. Design & Config Step Tests & Model ID Commissioning Commissioning Step Tests & Model ID F.D. & Config Traditional APC Technology Embedded APC Technology SmartProcess ® Applications with Embedded APC
- 15. SmartProcess Distillation Control Module Standard Distillation Calcs Predict Block Preconfigured Neural Blocks Module Library
- 16. Standard Operator Display & Simulation
- 19. Reboiler Flow Variability Steam Condensate Drum Parallel Reboilers Tray Temps Spare Fouled Clean FC TC LC
- 20. Pressure Effects OH and Btms compositions show day-night swing due to column pressure Pressure looked fairly stable
- 21. Steam Step Tests Test Compromised due to OH pressure swings Btms Impurity OH Prod Loss Rebolier Out T OH Pressure Steam
- 22. Model Verification Btm PCT Btm Impurity OH Composition Top PCT
- 23. Initial Closed Loop Operation – Small Gains Both MV’s slowly reduced, but no observable control action
- 24. Initial Controller Results OH Prod Loss Btm Impurity OH PCT Btm PCT Steam OH Flow Step Tests APC ON
Notes de l'éditeur
- Main Points: DeltaV PredictPro has a powerful built-in optimizer which will push the process to the most profitable operation, within constraints. Often optimization can be as simple as maximizing one variable to the most limiting constraint. For example, huge benefits can be realized by maximizing throughput to an equipment constraint. Whereas the operator may only make moves occasionally, APC can make moves continuously, 24 hours a day. However, for complex processes, the optimization involves many variables and requires a more powerful tool, like DeltaV PredictPro.
- 14 Amp reduction due to lower discharge pressure, 329 days/year 49 Amp additional reduction due to lower minimum flow, 122 days/year [14A*0.9year + 49A*0.33year]*4160V*sqrt(3)* 0.95W/ VA * 1KW/1000W*24hr/day*364day/year *$0.05/KWH = $86,000/yr