Advanced Control and Information Systems Handbook - 2003

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The following controls are utilized: Furnace controls include combustion control, coil steam injection control and firing balancing control. These controls improve efficiency and increase furnace run length. Quench temperature control minimizes quench. Coke drum cool-down sequence control minimizes coke drum switch time and achieves greater consistency. Product quality advanced controls ensure on-specification liquid products while maximizing the yield of the more valuable products. A proprietary boiling point model calculates the ASTM boiling point of naphtha and LCGO product without online analyzers.

Closed-loop, real-time optimization of the crude and vacuum unit with Aspen Optimizer uses rigorous, open-equation engineering models of the complete unit including the preheat system, heaters, lightends columns and naphtha splitter column. The model is calibrated before each optimization run using plant data to calculate the feed composition, heat transfer coefficients, furnace efficiencies, etc. The model is also used offline for engineering studies for feedstock selection or design studies, and to update planning and scheduling models.

Multivariable, model-predictive control (MVPC) strategies are applied to the alkylator and transalkylators, EB recovery, dehydrogenation and SM recovery areas. An overall plant production controller coordinates these controllers to maintain or maximize SM production. The combined strategy (typically, depending on base regulatory and analytical instrumentation) pursues the following objectives according to explicitly ranked operating priorities and economic trade-offs: • Enforce physical operating limits for reactors, columns, steam superheater, offgas compressor and critical base regulatory controllers • Stabilize alkylation and transalkylation reactor Ethyl benzene • Enforce maximum dehydrogenator velocity limit • Maintain dehydrogenator inlet temperatures and Styrene monomer Production controller DCS and logic MPC MPC MPC MPC Alkylation transalklation Benzene column Dehydrogenation reactors EB/SM splitter EB, benzene, and toluene recovery MPC MPC Ethyl benzene column SM column and thin film evaporator temperatures • Minimize DEB concentration in EB column overhead • Maximize separation between benzene and EB in the benzene column • Maintain PEB column tray temperature to minimize PEB loss in the flux oil • Enforce offgas compressor discharge oxygen limit conversion • Minimize dehydrogenator pressure • Minimize EB/SM splitter overhead SM concentration • Minimize EB/SM splitter bed 4 EB concentration • Enforce maximum EB/SM bottoms temperature (polymerization) limit • Minimize SM column overhead AMS concentration • Maintain thin film evaporator bottom temperature • Maintain EB recovery column tray temperature • Maximize SM production against all constraints.

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