Batch Process Control for Stable Plantwide Refinery Optimization
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Solution Overview
Problem
Existing industrial process control systems struggle to seamlessly integrate and optimize continuous and batch process operations in refineries, leading to inefficiencies and disruptions.
Innovation Solution
The implementation of an IoT platform for industrial process control and optimization, which uses real-time models and control for peak performance. This platform harmonizes plantwide optimization with batch operations, providing optimal recipes and minimizing disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch operation section is concatenated to continuous process section, then refined products can be produced using blending components, but the batch operation section disrupts the continuous process section
Solution Approach 1:
The control system is segmented into a continuous process controller for the continuous process section and a batch process controller for the batch operation section. Each controller independently manages its respective section, preventing disruptions from propagating between sections while maintaining overall system productivity through coordinated operation.
2Adaptability or versatility
If batch operations are performed with on-and-off functionality, then blending components can be processed in discrete batches, but the starting time and duration become unpredictable causing inefficiencies
Solution Approach 1:
The batch process controller receives real-time feedback from the continuous process controller regarding the availability of blending components and adjusts batch operation timing and duration accordingly. This feedback mechanism enables predictable scheduling of batch operations while maintaining flexibility to adapt to varying component availability, thereby improving processing efficiency without sacrificing operational versatility.
Data Source
AI summary
Various embodiments described herein relate to management of industrial process optimization related to batch operations. In this regard, an optimization request to optimize an industrial process that produces an industrial process product is received. Thereafter, a first time period and an optimization time period are determined to produce the industrial process product and to update industrial process product characteristics. In addition, blending component characteristics indicative of availability of one or more blending components are updated for the batch process. Furthermore, in response to completing the production of the industrial process product, product spent characteristics associated are determined to update demand data for the one or more feed products utilized for blending the one or more blending products based on the product spent characteristics. Finally, a control signal is transmitted to control the flow of the feed component.