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LÍVIA TIZZO, June 01 st 2018 DMC3 APPLIED TO C3 FRACTIONATORS
LÍVIA TIZZO,June 01st 2018
DMC3 APPLIED TO C3 FRACTIONATORS
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
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
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
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.
• 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
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
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
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
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
C o n t r o lM a t r i x
Control design12
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
✓ 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
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.
Results and benefits16
Manual corrections on bottom flow
Reflux on reg. PID
Top composition
Results and benefits17
Minimized bottom flow
Reflux on APC
Top composition
