Operation-Centric Process Model Calibration for Real-Time Plant Control
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Solution Overview
Problem
First-principles models are not widely used for online and operation-centric applications in the process industry due to their unsuitability for real-time decision-making, lack of easy calibration, and mismatch with physical plant equipment, making them challenging for real-time optimization and control.
Innovation Solution
A method to automatically construct, calibrate, and deploy online a first-principles model by transforming a wide process scope model into an operation-centric model, aligning it with real-time measurements from physical instruments, and tuning hydraulic models for accurate predictions and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a first-principles model is developed for offline use (design and rating), then the model possesses rigorous theoretical foundation and predictive power, but the model is not suitable for online real-time decision-making and lacks alignment with actual plant operations
Solution Approach 1:
The patent segments the plant-wide first-principles model into multiple operation-centric models, each representing a specific operating unit (e.g., distillation column, heat exchanger). This segmentation allows the rigorous theoretical foundation to be preserved in each unit model while making them suitable for online real-time decision-making at the operational level.
Solution Approach 2:
The patent transforms static offline models into dynamic online models by implementing continuous calibration mechanisms that adapt model parameters to real-time plant measurements. This dynamic adaptation enables the model to maintain accuracy and relevance for online applications while preserving its theoretical rigor.
2Measurement precision
If a first-principles model is used for operation-centric applications, then high fidelity predictions are required, but the model lacks easy calibration and does not closely match plant measurements in real-time
Solution Approach 1:
The patent implements self-calibration mechanisms where the operation-centric models automatically adjust their parameters using real-time plant measurements without requiring extensive manual intervention. This self-service calibration approach maintains high prediction accuracy while significantly reducing calibration complexity and effort.
Solution Approach 2:
The patent incorporates feedback loops that continuously compare model predictions with actual plant measurements and use the discrepancies to recalibrate model parameters. This feedback mechanism ensures the model closely matches plant measurements in real-time while maintaining ease of calibration through automated adjustment processes.
3Adaptability or versatility
If a first-principles model is developed for plant-wide scope, then the model captures comprehensive process behavior, but the model is not scalable for both hydraulic and thermodynamic calibrations at the operating unit level
Solution Approach 1:
The patent segments the comprehensive plant-wide model into modular operation-centric models for individual units. This segmentation enables the model to maintain comprehensive process scope coverage at the plant level while being scalable and manageable at the operating unit level for both hydraulic and thermodynamic calibrations.
Solution Approach 2:
The patent creates a universal framework where the same modeling and calibration approach can be applied across different operating units (distillation columns, heat exchangers, reactors). This universal operation-centric model structure maintains comprehensive process coverage while enabling scalable calibration procedures that can be consistently applied throughout the plant.
Data Source
AI summary
Computer-implemented methods and systems construct a calibrated operation-centric first-principles model suitable for online deployment to monitor, predict, and control real-time plant operations. The methods and systems identify a plant-wide first-principles model configured for offline use and select a modeled operating unit contained in the plant-wide model. The methods and systems convert the plant-wide model to an operation-centric first-principles model of the selected modeled operating unit. The methods and systems recalibrate the operation-centric model to function using real-time measurements collected by physical instruments of the operating unit at the plant. The recalibration may include reconciling flow and temperature, estimating feed compositions, and tuning liquid and vapor traffic flow in the model. The methods and systems deploy the operation-centric model to calculate KPIs (Key Performance Indicators) using real-time measurements. A processor employs the KPIs and automatically predicts and controls behavior of the physical operating unit at the plant.