Continuous Polymer Plant Control Using Real-Time Process 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 software calculation modules to optimize control parameters in real-time, calculating production potentiality, polymer concentration, oil flow-rate, chain terminator flow-rate, and other variables based on recipe parameters, laboratory analysis results, and predefined coefficients, ensuring deterministic and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If empirical control based on operator judgment and periodic laboratory analyses is used, then the control system is simple to implement, but production efficiency is significantly reduced due to non-deterministic regulations and delayed feedback
Solution Approach 1:
The patent replaces the mechanical/empirical control system (operator judgment and periodic lab analyses) with an automated electronic control system that uses on-line analytical instruments and microprocessors to determine control parameters in real-time, eliminating the need for manual intervention and periodic sampling
Solution Approach 2:
The control system performs self-regulation by automatically determining control parameters based on on-line analytical data and process variables, without requiring external operator intervention or periodic laboratory analysis, thus achieving continuous self-optimization
2Loss of time
If periodic laboratory analyses are used for control adjustments, then measurement equipment is simple, but time loss occurs due to periodic sampling and delayed feedback
Solution Approach 1:
The patent implements continuous on-line analytical measurement of product composition and properties throughout the production process, replacing periodic discrete sampling with uninterrupted real-time monitoring, ensuring control parameters are always based on current product state
Solution Approach 2:
The patent introduces on-line analytical instruments as intermediaries between the production process and control system, enabling direct real-time measurement of product composition without requiring periodic laboratory sampling and analysis
3Manufacturing precision
If non-deterministic empirical regulations are used, then operator experience can handle variations, but manufacturing precision deteriorates due to subjective judgment
Solution Approach 1:
The patent transforms control from subjective parameter adjustment based on operator experience to objective parameter determination based on on-line analytical data and predetermined relationships, ensuring consistent precise control regardless of operator skill level
Data Source
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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.