Polymer Plant Control Using Real-Time Reactor and Stripper Calculations
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Solution Overview
Problem
The existing control systems for polymer production plants, such as those producing EPR and EPDM rubbers, are non-deterministic and rely on subjective operator experience, with adjustments based on periodic laboratory analyses, leading to inefficiencies in production processes.
Innovation Solution
A method and system utilizing distributed control devices and calculation modules within a central electronic processing unit to optimize control parameters in real-time, based on recipe parameters, laboratory analysis results, and predefined coefficients, ensuring deterministic and repeatable adjustments for efficient polymer production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If empirical control based on operator experience and periodic laboratory analyses is used, then the plant can operate with simple control systems, but production efficiency is significantly reduced due to non-deterministic regulations and delayed adjustments
Solution Approach 1:
The patent implements a closed-loop feedback control system where control parameters are continuously adjusted based on real-time analysis of production data. The system collects data from multiple sources including laboratory analyses, process measurements, and historical production records, then uses this feedback to automatically optimize dosages and process parameters, replacing manual empirical adjustments with automated deterministic control.
Solution Approach 2:
The patent replaces manual operator judgment and subjective experience with an automated electronic control system that uses computational algorithms to determine optimal control parameters. This substitution of mechanical/manual control with automated electronic processing eliminates the non-deterministic nature of human decision-making and enables consistent, repeatable regulations based on objective data analysis.
2Loss of time
If adjustments are based on periodic laboratory analyses, then the control system remains simple to operate, but the timing of adjustments is delayed and not in real-time
Solution Approach 1:
The patent implements continuous control parameter optimization by constantly analyzing production data and automatically adjusting dosages in real-time, rather than relying on periodic discrete adjustments. The system continuously monitors process variables, laboratory results, and production trends, making ongoing adjustments to maintain optimal conditions throughout the production process.
Solution Approach 2:
The system performs preliminary analysis of production data trends and predicts optimal adjustment timing before deviations occur. By analyzing historical data and current process conditions, the control system anticipates when parameter adjustments will be needed and prepares optimal settings in advance, enabling proactive rather than reactive control.
3Reliability
If control parameters are adjusted based on subjective operator experience, then the system requires minimal automation, but the regulations become non-deterministic and cannot be replicated
Solution Approach 1:
The patent transforms the control approach by changing from static, experience-based parameters to dynamic, data-driven parameters that automatically adapt to current production conditions. The system uses computational algorithms to calculate optimal dosages and process parameters based on real-time data, replacing fixed operator-derived settings with flexible, context-dependent parameter optimization.
Solution Approach 2:
The control system performs self-optimization by automatically analyzing its own production data and adjusting its control parameters without external intervention. The electronic control unit independently processes laboratory results, monitors process variables, and modifies dosages and settings based on its own accumulated knowledge and analysis, eliminating dependence on external operator judgment.
Data Source
AI summary
A method for the control of a plant (10) for the production in continuous of a polymer, wherein the plant (10) comprises at least one reactor (11) fed with at least a first monomer and a second monomer, a first stripper (12), a second stripper (17), a third stripper (18), at least one recycling vat (13) of the fine products, measurement equipment (14) and a control system comprising distributed control devices (15) controllable by at least one electronic processing and control unit (16) based on a plurality of control variables, the control method comprising the following steps: collecting data comprising recipe parameters, laboratory analysis results and predefined coefficients stored in a database (40); collecting the data measured by the measurement equipment (14); determining, by means of a first calculation module (20) a production potentiality value of the at least one reactor (11); determining, by means of a second calculation module (21) the polymer concentration in the at least one reactor (11), in the first stripper (12) and in the at least one recycling vat of the fine products (13); determining, by means of a third calculation module (22) the flow-rate of oil for feeding the second stripper (17); determining, by means of a fourth calculation module (23), the flow-rate of the chain terminator (TERM) for feeding the at least one reactor (11), controlling the plant (10) on the basis of the plurality of control variables.