Method and apparatus for managing industrial gas production
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Solution Overview
Problem
The variability and intermittency of renewable energy sources, such as wind, solar, and tidal power, pose challenges for maintaining consistent power supply in industrial gas production facilities, particularly in ammonia synthesis, which is sensitive to energy fluctuations.
Innovation Solution
A method and system utilizing a model-based controller, specifically model predictive control, to manage industrial gas production facilities powered by renewable energy sources. This involves receiving time-dependent power and operational data, defining constraints, and generating control set points to optimize production parameters, including energy storage management, to achieve predetermined production goals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If renewable power sources are used to power industrial gas plants, then environmental sustainability is improved, but power supply stability deteriorates due to natural variability and intermittency
Solution Approach 1:
The control system performs preliminary actions by predicting future power availability from renewable sources and pre-adjusting operational parameters of gas production units. This allows the system to proactively respond to expected variations in renewable energy supply, maintaining stable production output before disturbances occur.
Solution Approach 2:
The system dynamically adjusts operational parameters of industrial gas plants in real-time based on actual and predicted renewable power availability. This dynamic control enables the plant to adapt its operation to varying energy inputs while maintaining production stability, resolving the contradiction between reliability and adaptability.
2Productivity
If operational parameters are adjusted to maximize utilization of variable power sources, then productivity is improved, but production consistency deteriorates
Solution Approach 1:
The control system continuously monitors actual power availability, production output, and operational parameters, using this feedback to adjust control actions. This closed-loop control ensures that productivity maximization efforts do not compromise production consistency, as deviations are detected and corrected in real-time.
Solution Approach 2:
The system changes operational parameters (such as feed rates, temperature, pressure) in a coordinated manner to maintain production consistency despite variable power input. By adjusting multiple parameters simultaneously, the system maximizes productivity while preserving output stability.
3Productivity
If aggressive control actions are taken to maintain production targets, then productivity is improved, but system stability deteriorates due to sensitivity to energy fluctuations
Solution Approach 1:
The control system takes preliminary control actions based on predicted power availability, avoiding aggressive corrective actions that could destabilize the process. By preparing in advance for expected energy variations, the system maintains both productivity and stability without requiring large, disruptive adjustments.
Data Source
AI summary
A method of controlling an industrial gas production facility comprising: receiving time-dependent power data receiving time-dependent operational characteristic data; defining one or more power constraints for the operational parameters of the power network; defining one or more process constraints for the operational parameters of each industrial gas plant; generating, based on the power data, the operational characteristic data, the one or more power constraints and the one or more process constraints, control set point values for the one or more industrial gas plants to achieve a pre-determined production parameter for the industrial gas production facility; and sending the control set point values to a control system to control the one or more industrial gas plants by adjusting one or more control set points of the industrial gas plants to achieve the pre-determined production parameter for the industrial gas production facility.