The Value of Model Predictive Control - Rockwell Automation · PDF fileThe Value of Model...
Transcript of The Value of Model Predictive Control - Rockwell Automation · PDF fileThe Value of Model...
PUBLIC
PUBLIC
www.rockwellautomation.com www.us.endress.com
The Value of Model Predictive ControlIndustrial Applications – CT505
Name – Maina MachariaTitle – Process Technical ConsultantDate – March 25/26,2015
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
MPC – Web Enabled
Composition Controller views
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Typical Project KPI – Monitor& Tracking
3
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
MPC – Performance Metrics
4
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
NGL Fractionation ROI Example
5
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Biofuel ROI Example
6
Estimated Capital Investment Justification Calculations Margin Calculations (€/m3)year 0 year 1+ Selling Price of EtOH + DDGS 746.60$
Pavilion Project 1,096,190$ Budgeted Capacity 240,000 m3 per year Corn Cost 519.40$ Maint. Agreement 75,275$ Avg Ethanol Price 528$ /m3 Gas Cost 0.08$
PLC/DCS programming -$ Corn Price 186$ /MT Enzyme Cost 10.50$ Instrumentation -$ -$ DDGS MT/M Liters 0.90 MT/M Liters Electrical Cost 10.00$
PC Hardware/Comm. 7,000$ -$ DDGS $/Ton 243$ /MT Denaturant Cost 15.18$ Internal Engineering -$ Denaturant Costs 0.76$ /Liter Total Variable Cost 555.16$
Travel and Living 46,200$ -$ Denaturant Percentage 2.0% Gross Margin 191.44$ Total 1,149,390$ 75,275$ Enzyme Costs 10.5$ /kL
Capacity Increase Est Margin BTU/gallon 265003.0% 7,200 m3/Y 25% Kj/BTU 1.0550564.0% 9,600 m3/Y 191.442$ gallon/litre 0.2641721
Natural Gas 7385.983517 kJ/lit 7385.983517Natural Gas Costs 0.01040$ /MJ Increase Ethanol yield Base Yield (lit/kg)
Est. Annual Costs for natual gas 18,427,503$ per year 0.80% 1,014,421$ per year 0.35711.20% 1,521,631$ per year 2.800 kg/lit
Natural Gas Savings0.0% -$ per year0.0% -$ per year
Benchmark MetricsNew Plant Capital Investment 700€ per m3 0.0% -$ per year
APC Capital Investment 160€ per m3 0.0% -$ per yearAPC Benefits Metric 8€ per m3
Estimated Production Margin 951,020$ per yearEstimated Yield and Energy Savings 1,014,421$ per year
Expected Savings 1,965,440$ per year
Moisture Increase in DDGS yield
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Chemicals and PolymersProcess Types
– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants
CPG– Spray Dryers– Evaporators– Energy CentersProcess Types
– Milk Powder– Coffee– Laundry Detergent– Conc. juice
CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types
– Cement– Minerals– Fertilizer– Ammonia
Bio-fuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types
– Corn Ethanol– Cane Ethanol– Bio-diesel
Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction
Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction
Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction
Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase
Large Markets – Project Results
7
Typical Project Payback: 3 to 9 months!
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Chemicals and PolymersProcess Types
– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants
CPG– Spray Dryers– Evaporators– Energy Centers– Crystallizers– French Fry MachinesProcess Types
– Milk Powder– Coffee– Laundry Detergent– Conc. Juice– French Frys– Sugar
CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types
– Cement– Minerals– Fertilizer– Ammonia
Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types
– Corn Ethanol– Cane Ethanol– Bio-diesel
Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction
Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction
Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase
Large Markets – Project Results
8
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
9
Dryer Moisture Soft Sensor Results
Product In8-15% solids
Product Out45 -55% solids Cold Air
Hot Air
Hot Air
Powder Out
Solids In
Moisture Results = 49% Improvement
The Business Value isAchieved by
“raising the bar” with ConfidenceBefore MPC After MPC
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
10
Dryer and Evaporator Balance – Value
Product In8-15% solids
Product Out45 -55% solids
Plant Obedience (reduced variability) enables:
Moisture – Lift moisture targets to Limit or revised uplift
Evaporator capacity – Optimize Solids to current UCL to reduce variability
Dryer capacity – Improve evaporation capability within proven heat envelope
Reduce Rework - Product & Cost
Reduce Energy – Dryer & Evaporation Balancing reduces the energy cost profile per tonne of product produced .
Improve Quality & Consistency Optimize Evaporator & Dryer Efficiency
Squeeze more value from the existing asset
Produce more product with the same operating profile
Reduce Variable Cost Sell more free water Enable product mix flexibility to gain
more higher value products
Cold Air
Hot Air
Hot Air
Powder Out
Solids In
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Dairy spray dryer• Inlet temp controlled with gas valve• Exhaust temp controlled with feed pump speed• Feed is pumped through nozzles and the backpressure from the nozzles is a key
constraint• Inlet temp sp to valve output, response of pid algorithm• Inlet temp to nozzle press, response of exhaust temp pid algorithm rejecting
disturbance from inlet temp change. • Exhaust temp to nozzle press, response of exhaust temp pid algorithm. As with Inlet
temp, omitting the overshoot will cause cycling and possibly trip the dryer.
Spray Dryer
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Chemicals and PolymersProcess Types
– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants
CPG– Spray Dryers– Evaporators– Energy CentersProcess Types
– Milk Powder– Coffee– Laundry Detergent– Conc. juice
CMM– Crushing/Grinding– Preprocessing– Kilns & Drying– Stockpile BlendingProcess Types
– Cement– Minerals– Fertilizer– Ammonia
Bio-fuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types
– Corn Ethanol– Cane Ethanol– Bio-diesel
Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction
Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction
Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase
Large Markets – Project Results
12
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Rotary Cement Kiln Typical LayoutRaw Material Feed Stream
Fuel Addition
Fuel Addition
Fuel Addition
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Production Rate 4 Months Before/ After MPC
With Pyroprocessing MPC Solution
Without Pyroprocessing MPC Solution
220 tph
220 tph
190 tph
220 tph=+14 %
Multiple Slowdowns
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Chemicals and PolymersProcess Types
– Polymers– PE, PP, PS,
PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants
CPG– Spray Dryers– Evaporators– Energy CentersProcess Types
– Milk Powder– Coffee– Laundry Detergent– Conc. juice
CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types
– Cement– Minerals– Fertilizer– Ammonia
Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types
– Corn Ethanol– Cane Ethanol– Bio-diesel
Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction
Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction
Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase
Large Markets – Project Results
15
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Before & After APC Comparison
variables(PV-SP)
Before APC STD After APC STD APC Improvement
AIC201 12.23 4.48 63%AIC202 148.5 46.03 69%DIC241 2.540 1.29 49%DIC251 2.402 1.58 34%PIC402 0.01739 0.0032 82%AIC402 0.00254 0.000296 88%AIC403 0.00535 0.002977 44%
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
AIC201/AIC202)H2 concentration in Loop 1&2 reactor
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Transition:V30GZ30S, APC OFFtime: 7.5 hours
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Transition: V30GZ30S, APC ONtime: 3.3 hours
19
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Chemicals and PolymersProcess Types
– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants
CPG– Spray Dryers– Evaporators– Energy CentersProcess Types
– Milk Powder– Coffee– Laundry Detergent– Conc. juice
CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types
– Cement– Minerals– Fertilizer– Ammonia
Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types
– Corn Ethanol– Cane Ethanol– Bio-diesel
Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction
Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction
Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction
Large Markets – Project Results
20
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT 21
BioEthanol Process Overview
Distillation/Sieves MPC
Fermentation MPC
Waterbalance MPC
Dryers/Evap & TO MPC
MPC Objectives:• Optimize plant throughput • Maximize ethanol and DDGS yield• Minimize energy/gallon ethanol
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
The Challenge: Cascading Dryers
22Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Natural gas Dryers A, B
Natural gas to Dryers C, D
Optimize NG energy in drying – 2 lines, 2 dryers/line, 2 parallel
lines
Dryer A Dryer B
Dryer C Dryer D
Wet Cake
DDGSProduct
Dryer Amoisture
Dryer Dmoisture
Dryer Cmoisture
Dryer Bmoisture
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Dryer Operations Snap-shot
Inlet Dryers Outlet Dryers
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
The Challenge: Cascading Dryers
24Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Dryer A Dryer B
Dryer C Dryer D
Wet Cake
DDGSProduct
Dryer Amoisture
Dryer Dmoisture
Dryer Cmoisture
Dryer Bmoisture
0.0201 MMBTU/lb
0.0275 MMBTU/lb
0.0221 MMBTU/lb
0.0354 MMBTU/lb
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
The Solution: Natural gas Dryer Optimization
Task MPC Operator
Minimize the Natural gas use
Automatically computes dryer loading to minimize Natural gas
Not done because it was too complex
Controlling moisture targets of each dryer
Targets incorporate current moisture levels and are proactively adjusted
Targets set at installation and reactively changed once out‐of‐spec
Dryer constraint handling Uses models of the process to proactivelymanage constraints
Only reactively changes moisture if equipment alarms are triggered
Recording of moisture levels
Once per minute Every 2 hours
Frequency of Natural gas target change
Once per minute Depends on the operators judgment
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Actual plant Results: Reduced Variability & Increased Stability
Plant Key Performance IndicatorsMean Value
ChangeSTD Value
Change
Abs Rel Abs Rel
• Plant Production Rate
Total Corn Grain Feed [lbs/min] +15.30% -34.71%
200 Proof Flow [gpm] +17.61% -41.99%
• Specific Energy Consumption
Total Gas [BTU/gal-EtOH] -11.70% -44.16%
Natural gas for Dryers [lbs/gal-EtOH] -3.73% -38.56%
Total Natural gas [lbs/gal-EtOH] -8.53% -46.50%
• Ethanol Yield
Gallons of Ethanol per Bushel of Grain +0.59% -48.49%
Significant reduction in
standard deviation of all variables
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Fermenter Data – Reduced Residual Sugars (USA)
Fermenter MPC online
Without Fermenter MPC
27
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Fermenter data – Increased Ethanol Conc.
Fermenter MPC onlineWithout Fermenter MPC
28
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Who is Windsor Utilities?
29
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Pressure Locations
30
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Drinking Water -System Overview
• Total daily supply capacity: 349 ML (92MGD)
• Reservoir storage capacity: 118 ML (31MG)
• Number of treatment plants: 2• Number of pumping stations: 3• Number of Elevated Storage Tanks: 2• Length of water main: 1,100 km
(690 Miles)• The Albert H. Weeks Water Treatment
Plant supplies an average of 140 ML (37 MG) of water to City residents per day.
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
The Opportunity
• 238 Main Breaks per year (average)
• 44 average age of distribution water main (one of the oldest in Ontario/Canada)
• Increasing Electricity costs• Inconsistent system
pressures during peak/low demand periods
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
APC Faceplate in FTView
VSD
VSD
P = Pressure ControlM= Manual Control
R = RunningS = Stopped
O = OptimizedM = Manual
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Before MPC
Pump start/stop cyclesPump start/stop cycles
PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT
Results – After with MPC
When were the pumps started?When were the pumps started?
PUBLIC
PUBLIC
www.rockwellautomation.com www.us.endress.com
Thank You! Questions?