Thermal Separation Control for Variable Energy Chemical Processes
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Solution Overview
Problem
Industrial chemical processes face inefficiencies in energy utilization due to unsteady electric energy availability and variability, with downstream plants often excluded from power plant cost/profit optimization systems, leading to missed profit opportunities.
Innovation Solution
Implementing methods and apparatuses to monitor and control thermal separation steps in aromatic amines and nitro chemicals production by utilizing energy data to adjust input mass streams in real-time, adapting to fluctuating energy supply and consumption patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal separation steps operate with fixed feed streams, then process stability is maintained, but energy efficiency deteriorates due to unsteady energy availability
Solution Approach 1:
The patent implements dynamic control of thermal separation processes by continuously adjusting feed stream parameters (flow rates, temperatures, pressures) in real-time based on current energy availability and prices. This transforms the previously static operation into a dynamic system that adapts to changing energy conditions, thereby improving energy efficiency without sacrificing process stability
Solution Approach 2:
The system incorporates feedback mechanisms where energy consumption data and energy availability information are continuously monitored and fed back to the control system. This feedback loop enables automatic adjustment of thermal separation parameters to optimize energy usage patterns, allowing the process to respond to unsteady energy supply while maintaining operational efficiency
2Device complexity
If downstream plants are excluded from power plant optimization systems, then system complexity is reduced, but profit potential is lost
Solution Approach 1:
The patent merges the power plant optimization system with downstream thermal separation plants, creating an integrated system where energy production and consumption are coordinated. This combination allows the downstream plants to receive real-time energy availability and pricing information, enabling them to adjust their operations to maximize profit while the overall system complexity remains manageable through modular integration
3Use of energy by moving object
If real-time energy data processing is implemented, then energy consumption optimization is improved, but measurement and control complexity increases
Solution Approach 1:
The patent introduces an intermediary control system that acts as a mediator between energy data sources and thermal separation processes. This intermediary layer processes raw energy data, translates it into actionable control parameters, and manages the complexity of real-time adjustments. By placing this intelligent intermediary in between, the system achieves energy optimization without directly exposing the full complexity of data processing and control mechanisms to the operational level
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances energy efficiency and profitability by allowing chemical plants to react to fast-changing energy prices, optimizing energy consumption and maximizing profit through real-time adjustments of feed streams.
Implementation Method 1
at least one thermal separation step in the production of aromatic amins and/or aromatic nitro chemicals
Data Source
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AI summary
The present disclosure relates to methods, apparatuses, systems and computer elements for monitoring and/or controlling energy consumption, monitoring and/or controlling emissions related to energy consumption and/or operating chemical processes in an energy and/or cost-efficient manner.