lÍvia tizzo, · 2018. 6. 15. · corporate presentation 2. braskem apc applications 3. motivation...
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LÍVIA TIZZO,June 01st 2018
DMC3 APPLIED TO C3 FRACTIONATORS
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A G E N D A
1. Corporate Presentation2. Braskem APC Applications3. Motivation and Objectives4. Project Main Steps5. Control Design6. Results and Benefits
BRASKEM | DMC3 APPLIED TO C3 FRACTIONATORS
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Plastic Converters
E X T R A C T I O NRaw Materials
PETROCHEMICAL INDUSTRY3
COMPETITIVE INTEGRATION
Basic Petrochemicals Thermoplastic Resins
NAPHTANATURAL GASETHANOLSALT
ETHYLENEPROPYLENECHLOR-ALKALI
PEPPPVC
1 s t G E N E R AT I O N 2 n d G E N E R AT I O N 3 r d G E N E R AT I O N
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INDUSTRIAL FOOTPRINT5
USA (KT/YEAR)
PP: 1.570
Mexico (KT/YEAR)
PE: 1.050
Brazil (KT/YEAR)
Basic Chemicals: 3.752PE: 3.055PP: 1.850PVC: 710
Europe (KT/YEAR)
PP: 545
PROJECTS
INDUSTRIAL FOOTPRINT
Pennsylvania
West Virginia
Texas
UNITED STATES
1 PP
1 PP
3 PP | 1 UTEC
Veracruz
MEXICO
North Rhine
Saxony-Anhalt
GERMANY
BRAZIL
Bahia
Alagoas
São Paulo
Rio de Janeiro
Rio Grande do Sul
1 CRACKER | 3 PE
1 PP
1 PP
1 CRACKER | 4 PE | 1 PP | 1 PVC | CHLOR-ALKALI
2 PVC | 1 CHLOR-ALKALI
2 PE | 2PP | 1 CRACKER | 1 SPECIALTIES
1 CRACKER | 1 PE | 1 PP
2 CRACKER | 5 PE | 2PP
41 INDUSTRIAL UNITS WORLDWIDE
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Braskem APC Map6
2 1 0 D M C C o n t r o l l e r s
BAHIA113 Applications
623 MVs
80 MPC
1 LINEAR OPT
15 RTO
17 IQ
SAO PAULO28 Applications
270 MVs
28 MPC
RIO DE JANEIRO1 Application
2 MVs
1 MPC
RIO GRANDE DO SUL70 Applications
346 MVs
65 MPC
1 LINEAR OPT
4 IQ
Braskem 2018 APC Program:
8 simultaneous projectsamong Brazilian sites
Recent autonomous projects had allowed new investments
on APC developments and revamps.
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• SCOPE: Apply DMC3 strategy in both C3fractionators columns - they operate in parallel,receiving feed from the same vessel.
• CHALLENGES:➢ High losses of propylene on bottoms flow.➢ Columns with high time constants (~15h),
regulatory PIDs were not able to deal with it.➢ Hard quality control.➢ Feed flow changes a lot.
Motivation and objectives7
C3= 90%
C3= 99.5%
Polymer grade
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MINIMIZE PROPYLENE LOSSES
OBJECTIVE: Propylene lossesreduction on columns bottom
flow
Bottoms are sold as LPG or used as monomer to
(smaller price)
Control propane on final product (column top)
$$$ Economic and quality benefits: losses are minimized and final product is under specification
Control design8
DA-215
1
110
FIC2461
FRC2462
ARC2050D
ARC2105D
SP
EA-202P EA-201PQW
T32245
T32244
FRC2468
QY001
PV
PV
PV
QIC2009
PV
SP
PIC2681
FA-281
LIC2684
PRC2682
EA-200P
GA-260SP
EA-204P
FA-280
FRC2466
SP
QY002
PV
PV
OP
SP
LRC2680
120
COMPOSITION CONTROL
Less valueable stream:- GLP- Nonene- Tetramer
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C 3 f r a c C o n t r o lP h i l o s o p h y
Drive bottoms composition (losses) to the minimum desired
Drive top composition on spec limits
Manipulate reflux flow setpoint
Manipulate bottoms flow (minimize)
Constraints: Total pressure drop in columns
Measured disturbances: Feeds flow and composition Columns pressure
Do not manipulate any utilities, only massflows.
Control design9
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Control matrix design
Loops diagnostics
Step test and model identification
Control and optimization configuration
Model calibration
Full Startup
~1 month spentfor each column
Project main steps10
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A P C B U I L D E R
Collect data Build seed model Configure controller and optimizer (Smart Tune) Deploy applications
Control design11
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C o n t r o lM a t r i x
Control design12
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Management of change
Documents Review
Operational Instruction
Training
LIC12226
DA-1205
FIC12227
LIC12232
FIC 12226
x
30
21
1
PARA DA-211
65
DA-1204
EA-1216
Propileno
HIC12230
FY12227
FY12226B
x
100-AA
APCDA1205
EA-1218/HA-1214
FIC12228
Vapor
AR12219
ACV
FIC12229
TIC12277MV
DV
DV
TI12269
DV
AR12219
BCV
FA-1212
PARA DC-1202 / DA-209
FIC12225
MV
PIC12237
B
DV
C o n t r o l l e rC o m m i s s i o n i n g
Control design13
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✓ Servers already available
✓ Virtual servers environment
✓ APC/DCS: OPC communication
✓ DCS display configuration
✓ Web interface
C o n t r o l l e rC o m m i s s i o n i n g
Control design14
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Results and benefits15
31%
35%
8%
16%
0%
5%
10%
15%
20%
25%
30%
35%
40%
FRAC1 FRAC2
%C3= bottoms (losses)
before APC
with APC
Additionally:
✓ Standard deviation reduction on top composition
✓ Better usage of hot and cold utilities
✓ Total mass flow reduction on bottoms
✓ Great acceptance from operators
✓ 95% of service fator Mean composition reduction = 63%
Simple strategies can be used to achieve great results.
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Results and benefits16
Manual corrections on bottom flow
Reflux on reg. PID
Top composition
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Results and benefits17
Minimized bottom flow
Reflux on APC
Top composition