Master-Slave APC for CCR Reformer Coke and Octane Control
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Solution Overview
Problem
Current advanced process control (APC) systems for continuous catalytic regeneration (CCR) reformers do not effectively optimize both the reaction and regeneration sections simultaneously, leading to suboptimal coke control on spent catalyst and octane production in heavy reformate.
Innovation Solution
A master-slave (M-S) configuration within the APC system is implemented, linking a reactor APC and a regenerator APC to a master APC, which controls coke on spent catalyst and maximizes heavy reformate octane barrel using online inferential methods, incorporating interlocks for robustness and automatic adjustments to prevent reverse actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate APC systems are used for reaction and regeneration sections, then each section can be controlled independently, but the overall process optimization is compromised due to lack of coordination
Solution Approach 1:
The patent merges the reaction section APC and regeneration section APC into a single integrated master APC system. The master APC receives data from both sections, coordinates control actions, and ensures synergistic optimization. This integration allows the system to achieve overall process optimization while maintaining the ability to control each section independently through modular control logic.
2Adaptability or versatility
If manual control methods are used for catalyst regeneration, then operational flexibility is maintained, but consistent optimization is unachievable
Solution Approach 1:
The master APC implements automated feedback control by continuously monitoring process parameters from both reaction and regeneration sections. The system uses real-time data to automatically adjust operating conditions, ensuring consistent optimization without manual intervention. The feedback mechanism maintains reliability while the automated decision-making preserves operational flexibility through programmed response strategies.
3Reliability
If coke on spent catalyst is reduced, then catalyst performance is improved, but heavy reformate octane production may be compromised
Solution Approach 1:
The master APC dynamically adjusts multiple process parameters including reactor inlet temperatures, catalyst circulation rates, and regenerator operating conditions to achieve the optimal balance between coke reduction and octane production. By coordinating parameter changes across both sections, the system maintains catalyst performance while maximizing heavy reformate octane production through synergistic effect.
4Productivity
If advanced process control is implemented in both reaction and regeneration sections, then process optimization is achieved, but system complexity increases
Solution Approach 1:
The patent segments the APC system into a master controller and separate reaction/regeneration section controllers. This hierarchical segmentation reduces overall system complexity by dividing the control logic into manageable modules. The master APC coordinates between sections while each section has dedicated control logic, making the complex integrated system easier to design, implement, and maintain.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves sustainable optimization of the CCR reformer process, reducing coke on spent catalyst, increasing heavy reformate octane production, and minimizing utility consumption, while maintaining process stability and avoiding catalyst attrition.
Implementation Method 1
controls coke on spent catalyst and maximizes heavy reformate octane barrel using online inferential
Implementation Method 2
the catalyst changes atmosphere from hydrogen-hydrocarbon, to small amount of oxygen in a nitrogen carrier gas for carbon burn
Implementation Method 3
continuous catalytic regeneration reformer where a reactor advanced process controller and a regenerator advanced process controller are linked to a master advanced process controller
Data Source
AI summary
The present invention relates to an advanced process control system (APC) for a continuous catalytic regeneration reformer with master-slave configuration to control coke on spent catalyst while maximizing heavy reformate octane barrel using online inferential, both for coke content of spent catalyst and octane of heavy reformate. Further, the present invention relates to provide an APC system for a continuous catalytic regeneration reformer with master-slave configuration, which comprises of a master APC, a reactor APC, and a regenerator APC, wherein, the reactor APC and the regenerator APC are linked to the master APC.