Diesel Hydroprocessing Control System Optimization
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Solution Overview
Problem
Current control systems for diesel hydroprocessing units rely on manual experience-based interventions, limiting operational efficiency and profitability, especially when handling heavier charges or producing higher diesel outputs without exceeding sales specifications, often resulting in non-conforming products or reduced productivity.
Innovation Solution
A control system comprising a steady state optimization unit, a constrained supervisory model predictive control unit, and a constrained regulatory model predictive control unit that calculates and adjusts the T95 target point of the charge and bed exit temperatures, optimizing the operation of diesel hydroprocessing units by determining the optimum operation point and adjusting reactor inlet temperatures and charge components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual experience-based intervention is used to control reactor bed temperatures, then operational simplicity is maintained, but productivity and manufacturing precision deteriorate due to non-conforming products and reduced productivity
Solution Approach 1:
The patent replaces manual experience-based mechanical control with an automated computer-controlled system that uses sensors to monitor temperatures and a controller to adjust heating elements, thereby eliminating manual intervention while improving productivity and product conformity
Solution Approach 2:
The control system automatically monitors and adjusts reactor bed temperatures without external manual intervention, enabling the system to self-regulate and maintain optimal conditions for maximizing productivity and ensuring product specifications are met
2Device complexity
If manual experience-based intervention is used to control reactor bed temperatures, then device complexity is reduced, but manufacturing precision deteriorates due to non-conforming diesel products
Solution Approach 1:
The patent replaces manual control with an automated computer-controlled system that precisely regulates reactor bed temperatures through electronic feedback, thereby improving diesel product specification compliance while accepting increased device complexity
Solution Approach 2:
The system uses temperature sensors to continuously monitor reactor bed temperatures and feeds this information back to the controller, which automatically adjusts heating elements to maintain precise temperature control and ensure product specifications are met
3Ease of operation
If intervention in reactor beds is made based on experiences, then ease of operation is maintained, but reliability deteriorates due to inconsistent product quality
Solution Approach 1:
The patent replaces subjective manual judgment with objective computer-controlled temperature regulation that consistently maintains optimal conditions, thereby improving product quality reliability while keeping the system easy to operate through automated controls
Solution Approach 2:
The control system automatically monitors and adjusts temperatures without manual intervention, ensuring consistent product quality through reliable automated control while requiring minimal operator input
4Ease of operation
If no intervention is made in the inputted charge, then ease of operation is maintained, but productivity deteriorates due to limited workability with heavier charges
Solution Approach 1:
The patent replaces manual charge selection and processing decisions with computer-controlled optimization that automatically determines optimal charge compositions and processing parameters, thereby expanding capability to handle heavier charges and improve productivity while maintaining ease of operation
Solution Approach 2:
The system dynamically adjusts processing parameters based on the specific charge properties being processed, enabling flexible adaptation to different charge types including heavier charges, thereby improving productivity without complicating operator interaction
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 enables efficient and profitable operation of diesel hydroprocessing units by optimizing reactor performance, ensuring compliance with sales specifications and improving productivity while handling varying charge properties.
Implementation Method 1
It performs said intervention by means of a cooling gas introduced into the interspaces of the reactor beds
Implementation Method 2
hydrodesulfurization reactor beds where desulfurization reactions are performed using hydrogen
Implementation Method 3
hydrocracking reactor beds where larger molecules are cracked into smaller molecules using hydrogen
Data Source
Figure 1
Figure 2
AI summary
With the present invention, there is provided a control system used for modeling and optimizing an industrial diesel hydroprocessing unit (S). Said control system comprises at least one steady state optimization unit (1) that includes models of hydrodesulfurization and hydroprocessing reactor beds and a combined model of a plurality of supply flow components and calculates an optimum point at which the unit must operate using the models therein as well as the current charge components, product price information, operational constraints of the unit and planning instruction information; at least one constrained supervisory model predictive control unit (2) to which operation parameters at optimum point that is calculated in the steady state optimization unit (1) are conveyed and which determines T95 target point of the charge and the target values of the bed exit temperatures using the operation parameters conveyed thereto together with a model; and at least one constrained regulatory model predictive control unit (3) to which T95 target point of the charge and the target values of the bed exit temperatures obtained in the constrained supervisory model predictive control unit (2) are conveyed and which adjusts the amount of the components of the charge to be conveyed to the industrial diesel hydroprocessing unit (S) and the bed inlet temperatures of the reactors (5) in the industrial diesel hydroprocessing unit (S), based on the T95 target point of the charge.