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Production control utilizing real time optimization

  • US 20080243310A1
  • Filed: 03/28/2007
  • Published: 10/02/2008
  • Est. Priority Date: 03/28/2007
  • Status: Active Grant
First Claim
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1. A method of controlling the operation of a plant that produces products through processes, including at least one chemical reaction process, to optimize production of products produced by the plant in response to a variable demand, said method comprising:

  • determining predicted current production rates of products and predicted consumption rates of raw materials used in the production of the products;

    the predicted current production rates and the consumption rates being determined with the use of models that include semi-empirical process models operating on the basis of mass balances, energy balances and pressure balances and including adjustable modeling parameters that influence the predicted current production rates and the predicted consumption rates;

    at least one of the semi-empirical process models containing a chemical process model of the at least one chemical reaction process, the mass balances for the chemical process model being a function of the mass balances of each of the chemical species taking part in the at least one chemical reaction, the mass balances being based upon an extent of reaction of the at least one chemical reaction and at least one equilibrium expression derived from an outlet pressure of the reactor and at least one equilibrium constant that is in turn a function the difference between the outlet temperature and an approach to at least one equilibrium temperature, the adjustable modeling parameters for the chemical process model comprising the approach to the at least one equilibrium temperature and an assumed pressure drop within the reactor;

    determining errors between the predicted current production rates and actual current production rates and applying said errors to the semi-empirical process models by adjusting the adjustable modeling parameters such that the predicted and actual current production rates are about equal and therefore, the semi-empirical process models are corrected semi-empirical process models;

    optimizing production of the products through real time optimization utilizing the corrected semi-empirical process models to yield targets for process parameters that at least influence the production of the products and the consumption rates of the raw materials, the optimization being conducted on a basis of cost of the raw materials and selling price of the products and the production being optimized such that the variable demand is met and such that a variable margin gained upon sale of the products is maximized; and

    controlling the processes conducted within the plant in accordance with the targets.

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