Refinery Distillation Control Using Dynamic Product Value Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the petroleum refining industry, commercial refinery distillation units face challenges in dynamically calculating the monetary value of intermediate products, leading to suboptimal operation and profit due to competing economic objectives and the non-linear nature of product separation, resulting in inefficient separation of hydrocarbon compounds and lost product opportunities.
Innovation Solution
A process and system that dynamically calculates the monetary value of intermediate products by linking them to final products with fluctuating market values, using a model-based predictive controller to adjust operating settings of the distillation unit in real-time or near real-time, optimizing the separation of hydrocarbons to maximize economic profit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the distillation unit uses a fixed cut point temperature for separation, then the operating settings are simple to control, but the economic profit is suboptimal due to inability to respond to market price fluctuations
Solution Approach 1:
The system introduces an intermediary computational layer between market price inputs and distillation control outputs. The controller calculates the monetary value of intermediate products by tracing their contribution to final products, then uses this information to determine optimal operating settings, mediating between economic objectives and physical process control.
Solution Approach 2:
The invention replaces manual or static control mechanisms with an automated computational system. The controller uses algorithms to calculate optimal cut points based on market prices, substituting complex economic analysis and dynamic decision-making for simple fixed-temperature operation.
2Productivity
If the distillation unit implements dynamic optimization based on market prices, then the economic profit increases, but the system complexity and calculation requirements increase
Solution Approach 1:
The system segments the complex optimization problem into manageable components: (1) calculating the monetary value of final products from market prices, (2) tracing the contribution of intermediate products to final products, (3) calculating the monetary value of intermediate products, and (4) determining optimal cut point temperature. This segmentation makes the complex control task computationally tractable.
Solution Approach 2:
The system implements feedback by continuously monitoring market prices and adjusting distillation unit operating settings in response. The controller uses real-time price information to recalculate optimal cut points and adjusts the separation process accordingly, creating a closed-loop system that responds to economic conditions.
3Manufacturing precision
If the distillation unit separates hydrocarbons with strict segregation to avoid contamination, then the purity of each fraction increases, but the lost product opportunity increases due to inability to utilize valuable compounds in wrong fraction
Solution Approach 1:
The system applies partial segregation rather than complete separation. By allowing some contamination of valuable compounds in the 'wrong' fraction when market conditions favor it, the system recovers more total product value. The controller optimizes the tolerance for cross-contamination based on real-time price ratios.
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
This approach allows for real-time adjustment of distillation unit operations to minimize lost product opportunities and maximize overall economic profit by accurately valuing intermediate products and adjusting operating parameters based on current market prices, improving separation efficiency and reducing contamination between fractions.
Implementation Method 1
a refinery distillation unit operable to receive a feed stream comprising a mixture of hydrocarbons that have a boiling point that is in the range from 45° C. to 85° C. (at 1 atm), alternatively from 50° C. to 82° C., (at 1 atm) and further operable to separate the hydrocarbons according to their boiling point
Data Source
AI summary
Processes and systems for controlling operation of a commercial refinery distillation column and/or splitter operable to separate hydrocarbons. An automated process controller (APC) receives signal from at least one analyzer that provides information about the concentration of at least a first chemical in a first fraction and a second chemical in a second fraction obtained from the distillation column. The APC comprises programming in the form of an algorithm that calculates real-time monetary values for the first chemical and the second chemical and alters the operation of the distillation column to change either the percentage of the first chemical in the second fraction or the percentage of the second chemical in the first fraction, thereby maximizing overall operational profit for the distillation column.