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Optimal heater targets are determined to operate against overall plant limits such as cracked gas compressor, refrigeration or column constraints. Commercial installations. Various technology modules from the SmartProcess Furnace advanced process control and real-time optimizer technology have been used in six olefins sites worldwide. Benefits. Stabilizing furnace severity, improving efficiency and maximizing charge rate can yield more than $1 million per year for a typical olefins plant. Real-time optimization can often add an additional $1 million or more to the annual benefits.
Pressure is normally minimized against operating constraints to increase reformate yield. Compensation for pressure changes aids in stabilizing catalyst deactivation rate. Economics. Reforming reactor controls typically increase yield, reduce octane number deviation by 40% to 50% and decrease fuel consumption. Stabilizer controls typically reduce Rvp standard deviation by 60% and result in lower tower duty. In addition, the ability to quickly line-out on new octane targets aids refinery flexibility.
The controller protects heater constraints such as maximum firebox temperatures and heater duties. Feed rate is maximized up to a desired target, subject to unit constraints. Trade-offs between severity and throughput are determined automatically with economic optimization. Unit pressure is minimized subject to compressor and coking rate constraints, to maximize reformate and H2 yields. H2 recycle rate is adjusted to maintain a selected target (H2 / feed, H2 partial pressure, or maximum H2 recycle).
Advanced Process Control and Information Systems 2005