Chemical Reactor Transient Control Using Historical Process Paths
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Solution Overview
Problem
Transient processes in chemical manufacturing and petroleum processing are complex and prone to variability due to changing operational parameters, leading to inefficiencies, safety hazards, and frequent reactor shutdowns, resulting in wasted time and resources.
Innovation Solution
A method and system that provide paths and thresholds for operational conditions based on historical data, allowing real-time monitoring and adjustment of operational parameters to maintain desired conditions, reducing variability and mitigating upsets during transient processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If transient processes are implemented based on operating engineer's experiences, then operational flexibility is maintained, but variability between engineers results in wasted time and expense
Solution Approach 1:
The patent creates a digital model (copy) of the optimal transient process based on historical data and simulations. This digital twin captures the ideal operational path and can be replicated across different reactors and operating conditions, eliminating variability between engineers while preserving operational flexibility through parameter adjustment.
Solution Approach 2:
The system uses parameter optimization techniques to identify the optimal set of operational parameters for transient processes. By changing and optimizing these parameters based on historical data and simulations, the system establishes standardized best practices that reduce variability while maintaining flexibility for different operating scenarios.
2Reliability
If multiple operational parameters are adjusted during transient processes, then desired operating conditions can be achieved, but complexity of controlling interrelations between parameters increases
Solution Approach 1:
The patent segments the complex transient process into distinct stages or phases, each with specific target parameters and control strategies. By breaking down the overall process into manageable segments, the system simplifies the control of interrelated parameters while still achieving the desired final operating conditions through sequential adjustment.
Solution Approach 2:
The system implements feedback control by continuously monitoring operational parameters during transient processes and comparing them against the optimal path derived from historical data and simulations. This feedback mechanism automatically adjusts parameters to maintain optimal trajectories, reducing the complexity of manual coordination between multiple interrelated parameters.
3Reliability
If reactors are shut down periodically for maintenance and cleaning, then operational safety and product quality are maintained, but productivity is reduced due to frequent start-up transient processes
Solution Approach 1:
The patent applies preliminary action by preparing for transient processes in advance through digital modeling and simulation. The optimal transient process paths are pre-calculated and stored, so when shutdowns occur for maintenance, the reactors can be quickly and efficiently restarted using the predetermined optimal procedures, minimizing productivity loss while maintaining safety and quality standards.
Data Source
AI summary
Methods and systems for performing transient processes may include: providing a path and path thresholds for an operational condition as a function of progress of a transient process based on historical data of previously performed transient processes; performing the transient process in a chemical reactor using operational parameters; measuring the operational condition of the transient process as a function of the progress of the transient process; and adjusting one or more of the operational parameters during the progress of the transient process to maintain the operational condition within the path thresholds.