Online Performance Monitoring

Transcription

1 Online Performance Monitoring by Johan Tiesnitsch (feel A free S P to E N use T E graphics C H U S here E R and S C on O all N F of E the R E following N C E FRANKFURT slides) February 27,

2 Outline Introduction to Products and Process Business Problem Advanced Process Control Project Value Proposition Demonstration of OnLine Calculations Conclusions / Learning Points 2

3 DSM Gelsenkirchen Unipol Reactor 3

4 DSM Products: Stamylan Flexible -applications 4

5 Products: Stamylan Rigid -applications 5

6 Process Overview recycle stream nitrogen catalyst feeder Free board Fluid bed Pressure: ~25 bars Temp.: ~85 C Sup. vel. ~0.6 m/s compressor heat exchanger distributor plate polymer discharge Degassing and Extrusion (co)monomer and hydrogen feed 6

7 Business Problem Complex polymerization process (highly exothermic and nonlinear) difficult to operate / control PROCESS CONTROL off spec product Which Package? We choose AspenTech because: ¾ DSM-review: best control software available (5 years ago) ¾Experience with IP21 ¾Additional software packages (Presentation Jan Versteeg) 7

8 Placement of AspenTech software tools DSM Aspen e-supply Chain Suite Supplier Aspen Engineering Suite Aspen Framework Customer Aspen Manufacturing Suite We are here Partner 8

9 Advanced Process Control (APC) Project AspenTech Software Tools OnLine Calculation Calculation of process and product parameters (e.g. Dew Point, Gas Density, Duty Cooler different Production Rates, etc.) Aspen IQ Prediction of Melt Index and Density (continuously being corrected by means of measured Powder values). 9

10 APC Project DMC + Multivariable controller (Reactor) Uses data from OnLine Calculation and IQ Recipe & Transition Manager RM: writes set-points during Steady State TM: writes set-points during grade changes (Preprogrammed based on best practices). 10

11 Periodic forecast Material resource planning Process orders Material consumption & confirmation Finished goods Customer Business Administration Plant Administration Planning Scheduling Operating Directives Process Recipes Material Balance Batch record Product Classif. Planned vs actual Model calcs APC Process History: IP21 Compliance monitoring DCS: Distributed Control System Distributed Control System LIMS OnLine Calculation Aspen IQ DMC + Transition Manager Recipe Manager 11

12 APC Project time-line May - August: testing the OLC, IQ & DMC-structure, communication, operator interfaces July - August: collecting data during plant startup First commissioning calcs of OLC First Commissioning IQ Testing data transfer DMC+ to DCS 12

13 APC Project time-line October - December: Second commissioning OLC Planttesting for IQ Planttesting for the DMC-controller December - February (2001): Third commissioning OLC Commissioning of IQ, DMC-controller & RM / TM March (2001) end of project 13

14 Value Proposition Infer the Process Performance Properties ¾Calculate key variables such as: ¾ Dew-Point, determining the liquid fraction in the recycle ¾ Gas-Density, resulting in the Superficial Gas Velocity ¾ Melt Index (MI) and Density, based on first principles (kinetics) ¾ MI and Density Drop (Reactor-powder and Extruder-granulate) ¾ Heat Exchanger Duty, and Heat Transfer Coefficient (fouling) ¾ Production Rate, leading to Catalyst Productivity, etc. Guide the operators and plant engineers in making important decisions about running of the plant Run the process well ¾ higher on stream factor ¾ less off-spec product ¼, ¼, ¼, ¼ 14

15 Advanced Process Control 15

16 Online Calculation Communication DCS Database IP21 Trending of calculated process parameters in Process Explorer OnLine Calculations Aspen/Polymer Plus 16

17 APC Computer Architecture Fisher Delta V DCS V AS 2 V AS 1 V CP V CP V CP PIMS DMC + IQ OnLine Calc OLC BU TM-RM IP21 for APC APC 17

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20 OnLine Calculation DCS-representation 20

21 Conclusions / Learning Points Software-communication is hard to accomplish, but... Now running for 6 months without a single OnLine Calculation Communication Failure Knowledge share (Res, ES, AspenTech) let to synergy First principles online performance calculations provide savings (better decisions, what-if analysis) Production organisation is hardware oriented Next step: use an Excel interface Planttesting DMC + is difficult Streamlining of implementation of generated knowhow wrt OnLine Calculations. 21