Coker Feed Rate Predictive Control for Foam-Over Prevention

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Solution Overview

Problem

Oil refinery processes face challenges in optimizing coke production, particularly in accurately controlling the rate of coke accumulation in coke drums, leading to inefficiencies and potential operational issues such as foam-over and reduced productivity.

Innovation Solution

A control system utilizing a neural network to predict and optimize the coker feed rate based on historical data and real-time system conditions, integrating model predictive control (MPC) to adjust feed rates and maintain optimal coke production within operational constraints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional control methods are used to manage coker feed rate, then operational simplicity is maintained, but coke production optimization and productivity are insufficient

Engineering Contradiction:

Improvecoke production rateVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical control systems with an artificial neural network-based intelligent control system. The neural network processes historical and real-time data to automatically determine optimal coker feed rates, substituting complex manual operational procedures with an automated intelligent system that improves productivity while managing complexity through software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system dynamically adjusts the coker feed rate parameter based on neural network predictions and real-time conditions. By continuously optimizing this key parameter, the system achieves improved coke production rates while the neural network handles the complexity of coordinating multiple process variables, resolving the contradiction between productivity improvement and system complexity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If higher coker feed rates are used to increase productivity, then coke production increases, but foam-over risk and operational safety deteriorate

Engineering Contradiction:

Improvecoke productionVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The neural network control system incorporates real-time feedback from process sensors to continuously monitor conditions that indicate foam-over risk. The system adjusts the coker feed rate dynamically based on this feedback, allowing high productivity operation when conditions are safe while automatically reducing feed rates when foam-over risk is detected, thus resolving the contradiction between productivity and operational safety.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary risk assessment by analyzing historical data and real-time conditions through the neural network before adjusting feed rates. This predictive capability allows the system to prevent foam-over conditions by proactively adjusting feed rates before dangerous conditions develop, enabling sustained high productivity while maintaining operational safety.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If manual control of coker feed rate is used, then system simplicity is maintained, but measurement precision and control accuracy of coke accumulation rate are insufficient

Engineering Contradiction:

Improvecoke accumulation rate measurementVSAvoidcontrol system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual measurement and control methods with an artificial neural network system that processes sensor data to precisely determine coke accumulation rates. The neural network analyzes multiple process variables simultaneously to infer accurate measurements of coke accumulation, achieving high measurement precision while the automated system manages the complexity of coordinating sensors and control actuators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If frequent adjustments to coker feed rate are made to optimize production, then productivity and optimization are improved, but operational stability and system wear increase

Engineering Contradiction:

Improvecoke production optimizationVSAvoidoperational stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The neural network control system implements dynamic feed rate adjustment that adapts to changing process conditions while maintaining operational stability. The system uses smooth transition algorithms and considers equipment constraints when adjusting feed rates, enabling continuous optimization of coke production without causing excessive operational instability or equipment wear through frequent abrupt changes.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11886154B2Systems and methods for optimizing refinery coker process

Publication Date: 2024.01.30 IMUBIT ISRAEL LTD

AI summary

A control system for automatic operation of a coker includes a drum feeder operable to modulate a feed of oil into a coke drum of the coker and a controller. The controller is configured to obtain an objective function that defines a control objective as a function of one or more controlled variables affected by modulating the feed of oil into the coke drum and use a predictive model and the objective function to generate a target coker feed rate indicating a target rate at which to feed the oil into the coke drum. The predictive model is configured to predict values of the one or more controlled variables predicted to result from the target coker feed rate. The controller is configured to operate the drum feeder using the target coker feed rate to modulate the feed of oil into the coke drum.