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2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Dynamic Optimization of Profit and Olefin Production using Profit Controller and Profit Optimizer in Ethylene Plant
Byoungmin Lee, Sungchul Yoo, Changhun Kang and Howoo Lee LG Petrochemical Corporation Ltd.Sung-Mo Ahn and Ravi NathHoneywell Process Solutions
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Contents
Introduction of CompanyProject OverviewProject ProgressAPC & DQP DesignBenefits AchievedConclusions
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Company History
1978. 3 Established LG Petrochemical CO., Ltd.1991. 9 Dedicated Naphtha Cracking Center1992.10 Dedicated Aromatics & HDPE Plant1993.11 Acquired ISO 9002 Certification of HDPE Plant (DNV)1994. 5 Dedicated Pentane Plant1996. 8 Revamped NCC & HDPE Plant1997.12 Acquired ISO 14001 Certification1998. 9 Revamped BTX Plant 2000.12 Acquired Korea Energy Grand Prize
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Company Overview• Paid-up Capital • Employees • Annual Sales • Plant site • Business Activities: Manufac
: 226 KRW bn: 554 (As of Apr.2003): 1,286 KRW bn (in Fiscal Year of 2003): 462,043㎡ (In the Yeosu petrochemical complex)
turing,Selling and Purchasing ofPetrochemicals,Utilities and Electric Power
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Products and Capacity
NaphthaC4 LPGGas Oil
NaphthaCracking Center
(Unit : 1,000MT/YR)HDPE Plant Ethylene 750 HDPE 265
Propylene 370
C4 LPG
Butadiene 118Raffinate-1
Butadiene/ C4 HTU
Plant Mixed C4
Toluene 85Benzene 200
Aromatics Plant
PyrolysisGasoline Xylene 42
Mixed-C5
High Purity Pentane 20C5 Plant
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Petrochemical Business of LG GroupAccomplished the perfect vertical integration from oil refining to production of a large variety of petrochemical products.
(Unit : 1,000MT/YR)
Vertical integration
• Basic Petrochem 1,565- Ethylene- Propylene- Butadiene- BTX
• Polymers 265- HDPE
• Naphtha • Monomer 2,200- VCM- SM- MMA …
• Polymers 2,280- PVC- ABS- LDPE …
LG LG -- CaltexCaltex OilOil LG LG PetrochemPetrochem LG LG ChemChem
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
LG’s Participation in Yeosu Complex
Production Amount Employees
LG72%(15.6)
LG Petrochem
100%(21.6 trillion won)
LG28%(3,600)
3.8%(470)LG Petrochem
100%(12,600 employees)
5%(1.1)
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Vision
To be a world class petrochemical company growing with our customers by creating differentiated value
Vision
• Trust & Teamwork• Challenge & Breakthrough• Abiding by Principles
Shared Value
Management Policies
• Enhancing the talents of each employee• Development of core technologies• Implementation of Cash flow-oriented management
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Goal & Strategy for Existing BusinessGoal Strategy
2000 2005
1,0741,262
91133
CAGR3.5%
CAGR7.9%
(Unit : KRW bn)
Sales
OrdinaryIncome
• Achievement of the world’s best cost competitiveness
• Implementation of strategic new business and high-value-add by-product business
• Development of core technologies
NCC
• Development of specialty products and increase of sales ratio of specialties
• Achievement of cost leadership• Pursuit of M&A and strategic
alliance to promote competitiveness
HDPE
☞ CAGR : Compound Annual Growth Rate
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Goal & Strategy for New Business – BPA(Bis Phenol A)
▶ S Korea S/D balance ▶ Asia S/D balance, ex-JPN
PhenolAcetone
BPA
PhenolAcetone
BPA
Benzene: 160,000 tons/yearPropylene: 87,000 tons/year
35
135 135
259
201
127
2001 2003 2005
CapaDemand
Demand CAGR 16.3%
Demand CAGR 16.3%
1,155
600
1,188
651
2002 2007
CapaDemand
Demand CAGR 11.3%
Demand CAGR 11.3%
< Valuation >
• Capex : W200bn
• Coming out 1Q05
• Feasibility : IRR 19.5%, sales W205bn
• Expected operating income: 30%
Cumene: 240,000 tons/yearCumene: 240,000 tons/year
Phenol/Acetone: 180,000 tons/yearPhenol/Acetone: 180,000 tons/year
BPA: 120,000 tons/yearBPA: 120,000 tons/year
NCCNCCLG PetrochemicalLG Petrochemical
PolycarbonatePolycarbonateLG-DOWLG-DOW
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Core Competence
Ethylene production capacity(1,000MTA/YR)
850750
(754)
385
600Revamping
(150)
Capacity up : 195%
20061996 20011992
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Core Competence Specific energy consumption
(Kcal/kg,Ethylene)
6,130
5,3504,649
3,990
World best level
1996 20011992 2005
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Innovation Activities
Enterprise Resource Planning
SKILL (Problem Solving Process )
Six Sigma
2001
Responsible Care Knowledge Management Systeme - Trading
e – Procurement
1992 1994 1999
Total Productivity Management
11 / 11
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
BA101
Ethane Recycle
Naphtha
BA102
BA103
BA104
BA105
BA106
BA107
BA108
BA109
BA110
BA111
BA112
BA113
BA114
BA115
BA101 : Ethane- onlyBA102/111 : Co- crackingBA112/113 : Split- cracking
EthaneEthane
EthaneEthane
Ethane
DA101
Fuel Oil
DA104
DA207
DA202
DA401
DA301
DA402
FF201
DA404/414
DA406/407
GB201
GB601 GB501
C2H2 Conv.
H2, CH4
DA415 MAPD
Conv.
C2H4
C3H6
C3 LPG
RPG
Manual
Manual
DA101 : Gasoline Fractionator GB201 : Charge Gas Compressor DA402 : Ethylene FractionatorDA104 : Quench Tower DA301 : Demethanizer DA404/ 414 : Depropanizer No.1/ 2DA207 : Dryer Feed Wash Tower DA401 : Deethanimzer DA415 : Depropanizer No. 3DA202 : Condensate Stripper GB501 : C3- R Compressor DA406/ 407 : Propylene FractionatorE- FF201 : Charge Gas Dryer GB601 : C2- R Compressor DA405 : DebutanizerDA201: Gasoline Stripper
DA201
DA405
Mixed- C4
Dynamic Optimization in an Ethylene Plant
2004 Users Group Americas Symposium • Partners in Innovation14
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
PROCESS CHARACTERISTICS• Significant feed quality variations• Furnace decoking• Periodic operations (e.g. dryer switching)• Others
Filter plugging, catalyst breakthroughAmbient condition variations
Process is very dynamic, seldom steady !
2004 Users Group Americas Symposium • Partners in Innovation15
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
APC History1st implementation by the E&C Company
• Not successful becauseStead state optimizer,
– Maintenance issueProcess seldom steady,
– Infrequent optimizationOverall low benefits, high maintenance cost
Still convinced of the benefits decided to give it a second try in 2000
2004 Users Group Americas Symposium • Partners in Innovation16
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Current APC projectKicked off in March 2000 with the following objectives
• Stabilize fractionators operation• Energy Savings • Increase Olefins production• Develop internal expertise
2004 Users Group Americas Symposium • Partners in Innovation17
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Solution Technology SelectionConsidered all available offerings, and chose Honeywell
• Robust controller• Simpler controller tuning• Ease of adding optimization layer• Dynamic Optimization• Local support
2004 Users Group Americas Symposium • Partners in Innovation18
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Project TeamComposed of limited internal resources and Honeywell staff
• LGPC resources has actively taken part in
LGPCProject Manager
HoneywellProject Manager
LGPC EngineersLGPC Engineers
Team
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Project Progress (1)2000 - 2003
• Training of in-house staff• Cold side controllers to stabilize column operation
Step testing, model identification and commissioning of the following;– Demethanizer / C2 Refrigerant– Deethanizer– Ethylene fractionator / C3 Refrigerant– Depropanizer– Propylene fractionator
2004 Users Group Americas Symposium • Partners in Innovation20
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Project Progress (2) Sept. 2003
• Attention shifts to hot side control Step testing, model identification and commissioning of the following;
– 1 Ethane only heater– 11 Naphtha only heaters– 2 Naphtha and ethane co-cracking heaters– 1 Ethane and naphtha selection heater
2004 Users Group Americas Symposium • Partners in Innovation21
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Project Progress (3) Nov. 2003 – March 2004
• Attention shifts to dynamic optimizer On-line execution of customized furnace yield model
– for calculation of severity and yield gainsSeverity gain mapping Closing of 2 still open loopsBridge Model identificationProfit Optimizer
– configuration / gain updating / closed loop commissioning
2004 Users Group Americas Symposium • Partners in Innovation22
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
System configuration
PHD(Database)
Custom HTR model Cold section APC
Hot section APC
GMPC toolkit
GEMPO toolkit
Pre_dqp
Profit Optimizer
TCP/IP Network
LCN
APP 23Workstation forcustomized heater model
US/GUS
APP 25
2004 Users Group Americas Symposium • Partners in Innovation23
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Profit Controller Overview
2004 Users Group Americas Symposium • Partners in Innovation24
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Graphical User Interface
Dynamic Optimization in an Ethylene Plant
• Profit Viewer for Engineer / User Station standard graphics for Operator
2004 Users Group Americas Symposium • Partners in Innovation25
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Profit Controller Design(1)
Hot section• Typical controlled variables
Severity or conversionTube outlet temperatureCross over temperatureValve positions
• Typical manipulated variables Coil outlet temperatureFeed flow rateSteam to HC ratio
2004 Users Group Americas Symposium • Partners in Innovation26
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Profit Controller Design(2)
Cold section• Typical controlled variables
Overhead purityBottom purityCompressor speedDischarge pressurePressure differenceTray temperatureValve positions
• Typical manipulated variables Steam flow rateReflux flow rateSide draw flow ratePressure
2004 Users Group Americas Symposium • Partners in Innovation27
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Customized Heater Model Design (1)• Step testing, model identification and commissioning of 15 heaters• Customized Heater Model was developed by internal resources.
SCM
Stand AloneStand Alone
PISNIR,…
DCS
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Customized Heater Model Design (2)
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Pre_DQP for Customized Heater Model
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Profit Optimizer Design(1) One for all controllers
• 15 Hot section controllers• 6 Cold section controllers• 4 Dummy controllers
More than Summation• 9 Bridge models• 39 Combined constraints
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Profit Optimizer Design(2) Bridge model
• Dynamic model between column feed and heater MV• Dynamic model between olefin production and heater MV • Obtained from step test and historical operation data
Combined constraint model• Total hydrocarbon flow• Furnace yield and overall propylene / ethylene ratio• Coking rates• Total fuel consumption and total steam generation
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Profit Optimizer Design(2) Bridge model
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Benefits achieved (1):Cold side controllers : Ethylene fractionator
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Benefits achieved (2):Cold side controllers : Ethylene fractionator
Comparison ethane composition of ethylene product before APC with after APC
The Productivity Increasment of ethylene fractionator after APC application
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Benefits achieved (3):Cold side controllers : Depropanizer
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Benefits achieved (4):Cold side controllers : Deethanizer & Depropanizer
The Energy savings of deethanizer after APC application
The Energy savings of depropanizer after APC application
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Benefits achieved (5):Cold side controllers : Benefits Summary
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Benefits achieved (6):Cold side controllers : Operator satisfaction
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Benefits achieved (7):Dynamic Optimization : Constraint handling
2004 Users Group Americas Symposium • Partners in Innovation
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene PlantDynamic Optimization in an Ethylene Plant
Benefits achieved (8):Dynamic Optimization : Olefin maximization trend
2004 Users Group Americas Symposium • Partners in Innovation41
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Benefits achieved (9):Dynamic Optimization : Comparison before DQP with after DQP
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
Benefits achieved (10):Dynamic Optimization : Comparison before DQP with after DQP
Stabilization & about 0.4% Increase ofOlefins Production and Naphtha Feed
2004 Users Group Americas Symposium • Partners in Innovation0
Dynamic Optimization in an Ethylene Plant
CONCLUSIONS• APC and dynamic optimization of the entire Olefins plant
Using limited internal resourcesSome consultation from Honeywell
• Sustained APC and optimization benefitsstabilized plant operation with all loops closeduptime > 95%olefins production increase of 0.97% (1.25T/hr)
• Now considering other measures of productivity improvement Automation of furnace transientsASMOperator training
Dynamic Optimization in an Ethylene Plant
2004 Users Group Americas Symposium • Partners in Innovation44