Applying advanced control to a VCM unit

Multivariable predictive control combined with real-time modelling enabled a vinyl-chloride-monomer unit to achieve signicant operational and economic benets, including improved control of cracking depth on each EDC furnace
Mark Novak Formosa Plastics Corporation Mike Yen, Ravi Nath, Rogier Pouwer and Anil Gokhale Honeywell Process Solutions

o nd areas of improvement at the Formosa Plastics Corporation (FPC) vinyl-chloride-monomer (VCM) plant at Point Comfort, Texas, Honeywell was asked to perform an advanced process control (APC) benets study. In 2004, the plant achieved signicant economic and operational benets through the implementation of Honeywells proprietary Prot Controller and Technips proprietary rigorous furnace model (EDCAPC) on the VCM unit. The project payback is estimated to be less than three months. The controller service factor has been greater than 99% since both controllers (liquid phase furnaces and HCl columns) were commissioned in December 2004. Post-project benets analysis indicates that the overall ethylene dichloride (EDC) cracking depth (conversion) has been increased or controlled to a target to help maintain the relative furnace pass coking rates to a desired prole; energy consumption has been reduced; and the unit is operating with improved stability since the implementation of advanced controls. The application of Honeywells proprietary robust multivariable predictive control technology (RMPCT) is suitable for the VCM unit due to the presence of signicant controlled variable (CV) interactions. The control of furnace feed ows and coil outlet temperatures is signicantly improved, as furnace inlet conditions can be set more precisely to maintain objectives. VCM is one of the many high-valued products made at the FPC plant, and VCM production must be adjusted to meet upstream and downstream requirements. As a result, there is great incentive to provide a control solution that would improve VCM production and improve the stability of the units operation.

Recycle HCI Import EDC Pure dry EDC VCM, HCI & EDC Pure VCM VCM purification

EDC dehydration & purification

EDC cracking

Storage

Recycle EDC

Wet crude EDC Water & EDC Oxychlorination Water & EDC Waste water treatment Water to bio-treatment

C2H4 O2

Figure 1 Process block diagram

several days. Initially, the study looked at only one of the furnaces and one HCl column, as they were the only ones on a DCS where history could be readily collected. However, the results of the study would make recommendations for all of the furnaces. The onus was on understanding the process issues and incorporating appropriate technology into the facilitys advanced control solution. The EDC furnaces are not the limiting factor during peak production periods at the plant. Fouled heat exchangers, aged catalyst and market conditions, among other things, can change that, but increasing production even a small amount, when the demand is there, pays out well. However, FPC was not maximising production at the time of the study, so no benets were identied from increased throughput. Nevertheless, benets from reduced steam usage and reduced fuel gas in the furnaces still indicated that an APC project would be an attractive investment. FPC personnel reviewed and agreed with the benets study. Based upon this, FPC moved ahead with bringing all the other EDC furnace areas into the DCS. It was agreed that Honeywells solution should focus on the EDC cracking furnaces operating in parallel and the HCl columns, as this was the area of most signicant benets.

Process description

Initial survey

Honeywell conducted a survey of the Point Comfort plant, collecting data and interviewing key plant personnel over

The FPC VCM process (Figure 1) consists of seven functional processes and three support processes. Those functional processes are oxychlorination, EDC purication, thermal cracking (EDC cracking), VCM purication, waste matter treatment, EDC and VCM storage, and incineration. The support processes are refrigeration, cooling tower and condensate recovery. The oxychlorination (OC) reactors react ethylene, dry hydrogen chloride (HCl) and oxygen over a coppercontaining catalyst to produce wet crude EDC (EDC plus water). Water and the heat from the reaction produce steam. The EDC purication area removes by-products that are formed during the production of the EDC and the thermal cracking of the EDC. These by-products are called light ends and heavy ends. The steam that is

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EDC cracker

From other furnaces

CW

CW CW Quench column

Coolant

Reflux drum From other furnaces Surge drum Product

EDC cracker CW

HCI to oxychlorination

Reflux drum Product

Quench column

Pure EDC storage

Figure 2 Simplied process ow diagram of licensors VCM technology (liquid phase furnaces and HCl columns)

Conversion target VCM production target

Operator

Profit toolkit
EDC APC

CV: VCM production CV: Conversion CV: Coking rate

Desired coking rate profile

Constraint CVs Process inputs

Furnace temperatures Pass flows Pressure Pass constraints Furnace constraints Valve positions

Profit Controller

Process MVS
Feed flows Furnace outlet temperatures Damper positions

Figure 3 Advanced solutions diagram

produced in the OC area is used as the heat source for these distillation columns. The thermal cracking area heats up the pure dry EDC so that it will split into VCM and dry HCl (Figure 2). The VCM purication area separates the VCM and the HCl that is produced in the thermal cracking area. The HCl goes to the OC reactors to be reacted into EDC and the VCM goes to storage. Approximately 50% of the EDC that is sent to the thermal crackers is split. The EDC that does not convert into VCM will be removed and returned to the

EDC purication area. The process water that is produced in the OC section is sent to the water matter treatment section. This section removes any EDC that the water might contain. The EDC is returned to the EDC purication area and the water goes to the waste-water treatment unit for clean-up and recovery. The incinerator area is used to decompose vent gases that are produced in the other process areas. The vent gas consists primarily of hydrochloric acid and CO2. The storage area is used to store the water, EDC and VCM while waiting to be processed. The refrigeration process uses coolant to sub-cool the process gases. The subcooling allows for the separation of different types of chemicals during the distillation processes. The cooling water area supplies cool water that is used to remove heat during the distillation of VCM and EDC. The condensate recovery area collects the condensed steam. The condensate is then returned to the OC section to be reheated and turned back into steam. Advanced process control project scope involved the EDC cracking furnaces and HCl distillation columns. The objectives of the advanced control solution were to: Control EDC cracking depth on each furnace while not adversely affecting the VCM product quality Maintain a desired prole of furnace pass coking rates Maximise overall VCM production rate when economic demand allowed Maximise recovery of HCl from the EDC/VCM mixture Control the amount of VCM in HCl recycle Minimise the amount of HCl in EDC/VCM bottoms Stabilise HCl column operation by balancing feed rates (feed allocation) Minimise coolant consumption. To achieve the objectives, Honeywell applied the following technologies (Figure 3): Proprietary Prot Controller on the furnaces and HCl column Prot Controller with predict-back feature on the furnace Technips EDCAPC online model. These rigorous cracking models provided calculations for per-pass conversion and coking rates that were incorporated into Prot Controller as controlled variables The proprietary Prot Toolkit application, which calculated and validated the EDCAPC model input/ output variables, and continuously updated them in Prot Controller Process historian database (PHD), which provided reporting and trending of key data that enabled improved process plant analysis.

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RMPCT design

Honeywells Prot Controller is a robust multivariable predictive control technology that has been widely used in the rening and petrochemical industry. Its patented design enhances the robustness of the online controller by explicitly taking into account the uncertainties associated with models used by the controller. This design gives the best control for the worst case scenario, tolerating a considerable level of model error and maximising controller uptime. The patented Range Control Algorithm (RCA) is one of the core components of Prot Controller. It controls all CVs within their ranges, recognising that a setpoint (SP) is simply a special case of a range. RCA enables Prot Controller to explicitly constrain all of the CVs dynamically into the future. The number of CVs can be greater or fewer than the number of manipulated variables (MVs) output by RMPCT to achieve the CV constraints. RCA achieves the following: MVs are moved the minimum amount required to achieve the control objectives Almost-parallel CVs (CVs that have similar gains and dynamics) are controlled in a much more robust fashion than was possible with previous technology Unication of constraint control, regulatory control and process optimisation is inherent Constraints are active only when they are limiting Versatile control performance adapts to changing degrees of freedom when plant loads and constraints change CVs may have integrating dynamics (ie, tank levels). RCA keeps Prot Controller online in situations where other multivariable controllers become unstable. The proprietary product value optimisation (PVO) is a exible (linear and/or quadratic) objective function that allows users to specify optimisation in terms of unit economics or other custom objectives. Economic factors can be changed online. PVO is a dynamic rather than steady-state solution that lets Prot Controller optimise the entire unit faster and potentially offers a more precise nal solution, providing greater protability. PVO nds not only the steady-state solution, but also the optimal dynamic path to achieve that solution. PVO is treated as part of closed-loop control and is unified into the range-control algorithm. As a result, optimisation speed can be tuned independently of the speed of CV error correction. Advantages of Prot Controller include: Maximum process efficiency

Advanced algorithm balances performance and robustness objectives against process economics to minimise costly process movement Flexibility to meet process needs Congurable control response path allows tailoring of control performance to meet process needs Optimum control performance Independent feed-forward and feedback control tuning provides optimum control performance for changes in both control targets and process disturbances Enhanced robustness Funnel-based approach to range control delivers enhanced robustness versus target-only approaches Easy maintenance Range control design enables easier tuning and enhanced performance (robust control design reduces tuning needs).

Predict-back feature on furnace controller

The predict-back technology provides more advanced capabilities. It gives additional feed-forward information and disturbance rejection to CVs when the process variable (PV) of a MV or a disturbance variable (DV) deviates from its SP. Predict-back is particular useful when the disturbance rejection of the MV or the DV is slower than the effects of the unrejected (leak-through) disturbances on the CVs.

When an MV is the SP of DCS-based PID controllers, it is usually good practice to keep the PID cascade closed if the control loop performs well and use their SPs as MVs within a Prot Controller design. Keeping higherlevel cascades closed can help linearise the process, improve disturbance rejection and thus improve Prot Controllers performance across different operating conditions. Examples include heater outlet temperature, tower overhead temperature and accumulator pressure. Honeywell applied the predict-back feature on the furnace Prot Controller. The dynamic response of higher-level PID (ie, preheat temperature controller, reboiler steam controllers and coil outlet temperatures) cascades is generally slower than the basic regulatory controller (ie, steam ow controllers and fuel pressure controllers). As a result, disturbances leak through these MVs and can take longer to reject. In a traditional MPC (model predictive control) controller, where only the SP of the MV is considered, process disturbances that result in a deviation of the MV-PV from its SP are not detected until the CVs are affected. When the CVs do respond and violate their limits, Prot Controller will move the MVs accordingly, even though the MV-PV may have already returned to its SP.

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After APC

Before APC

Less steam

More steam

Figure 4a Steam ratio

After APC

Before APC

Less fuel

More fuel

Figure 4b Fuel ratio

PVO analysis tool

Engineering personnel use an Excelbased PVO analysis tool to understand the optimisation moves the application is making. The tool uses the current gain and pricing information from the plant, and then calculates the equivalent LP costs for each MV, as well as the decomposition matrix represented as MV priorities. In addition, the tool is used to predict and validate the optimisation direction. The objective function in general can be linear, quadratic or non-linear. For most applications, a steady-state quadratic objective is versatile enough, which is the default objective function form in Prot Controller, as follows:
J = cx t xss + cy t yss + (xss xo)t Dx (xss xo) + (yss yo)t Dy (yss yo) Subject to: CVL yss CVH MVL xss MVH Where: J is the unit optimisation cost objective function cx is MV cost coefcient cy is CV cost coefcient xss is MV steady-state value yss is CV steady-state value

xo the MV desired value yo the CV desired value Dx is the cost of deviating from MV desired value Dy is the cost of deviating from CV desired value.

Yield predictions model

EDCAPC is an online version of Technips EDC Crack model. This rigorous model provides yield predictions of H2 to C6 components, based upon more than 300 kinetic reaction mechanisms. The model was used to accurately predict the conversion of EDC and coking rate per pass of each of the furnaces. These coking rates and individual conversion calculations were then used by Prot Controller to set the furnace feed rates and coil outlet temperatures. The predicted furnace parameters are the furnace tube skin temperature, coke build-up, heat ux, coil pressure drop and coil outlet temperature. Based on furnace geometry, the model is congured by the independent variables, such as feed composition, hydrocarbon ow rate, coil inlet pressure, coil outlet temperature and coke thickness, and dependent variables, such as coil outlet temperature, absorbed heat duty,

pressure drop, maximum tube metal temperature and maximum coking rate. Honeywells VCM Prot Toolkit is an ensemble of generic programs that have been specically developed to enhance the proprietary Prot Suite applications for VCM plants. The operation of EDC cracking furnaces is inherently non-linear due to complex chemical reactions in the crackers. It is desirable to keep the furnace operating for a fairly long period of time (typically over a year). As furnace operation continues, coke (a by-product of cracking reactions) deposits on the inside of the cracking tubes. These coke deposits increase resistance to heat transfer and pressure drop in the coil. This changes the EDC conversion, VCM yield and coking rate characteristics, further adding to operational non-linearity. Although EDC conversion, VCM yield and coking rate optimisation are important (controlled) variables in a VCM plant operation, there is usually no direct measurement of these variables. Using the EDCAPC model from Technip, VCM Prot Toolkit can provide an accurate estimation of these variables (CVs in the controller) and thus provide a continuous feedback to Prot Controller. In addition, a coke thickness prole in each coil is maintained, which is also an unmeasured quantity. Software components of the VCM Prot Toolkit suite are used to collect process data; schedule execution of the VCM Prot Toolkit application, which performs cracker simulations; deposit results from VCM Prot Toolkit to the process; simulate current furnace operation using Technips EDCAPC module; and congure the facilitys furnace using the Technip EDC cracker model library. The toolkit can be executed in one of the following modes: ON mode For online closed-loop usage. This mode is congured to deposit the predicted CV values to the process for use by the controller. Execution in this mode is automatic at a frequency set in the toolkit application WRM mode For online open-loop usage. WRM mode is identical to ON mode, except that the results are sent back to the process but not used by the controller OFF mode OFF mode is similar in functionality to the other two modes, except that the process data is static and comes from the ofine directory, and simulation results are not sent to process.

Process historian database

The process historian database (PHD) is an advanced plant information management system that collects,

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stores and replays critical plant data. PHD and Prot Controller online software were installed on the APC computer. Prot Viewer, the proprietary software that provides a graphical user interface to Prot Controller, was installed on operator stations. Once the APC computer was connected to the control network, Prot Controller was ready to be turned on.

After APC

Before APC

Results

Prot Controller with the EDCAPC model combined enabled FPC to raise the VCM cracking depth without fear of over-cracking in any of the furnace passes. This resulted in less EDC recycle, and hence reduced fuel gas consumption per pound of VCM produced. At times, when demand allows peak production, the reduced recycle means increased furnace capacity and higher peak production rates. In the HCl columns, improved stability helped reduce steam usage while maintaining HCl recovery. There were upsets on both HCl columns in daily operations before APC was implemented. The major sources of HCl column upsets were changing feed composition due to variations in cracking depth and variations in allocating feeds to the two columns. Another major source of HCl column upsets was the high non-linearity of the process at the top zone section of the HCl column. After implementing Prot Controller on the cracking furnaces, the rst source of variations was reduced. The second source was reduced by xing the unreliable feed ow meters and by including a feed ow allocation-control strategy to manage one vapour feed and two liquid feed ows equally distributed into the HCl columns. Then, Prot Controller on the HCl columns was able to control the top zone temperature using temperature prole control to separate HCl from VCM. EDC cracking furnaces Figure 4a shows reduced steam usage per pound of VCM produced and Figure 4b shows the reduced furnace fuel gas consumption per pound of VCM produced. HCL distillation columns Figure 5 shows a reduction in steam usage at balanced feed ows to the HCl columns. Figure 6 shows a reduction in column reux ows at balanced feed ows to the HCl columns.

Less fuel

More fuel

Figure 5 Steam/feed ratio

After APC

Before APC

Less reflux per ton of steam

More reflux to tons of feed

Figure 6 Reux/feed ratio

on cracking furnaces and HCl columns has been compared to the performance prior to the APC implementation. FPC has realised signicantly fewer utilities and raw material consumption per ton of product.

Keys to project success

Key to the project success was operator acceptance throughout the project schedule and strong management support, allowing control engineers to fully participate and take responsibility for all project phases, including controller design, basic controller tuning, plant step testing, and implementation and commissioning of the multivariable predictive controllers. Rigorous attention and resolution of regulatory control problems before implementation of the advanced controls were major factors in achieving the high level of robust control.

Benets summary

The initial study predicted a six-month payback time at the inception of the project. The payout is currently estimated at three months. The performance of the advanced control

Acknowledgements The project team would like to thank the management and staff of Formosa Plastics VCM plant for their co-operation during the implementation of the project.

Mark Novak is the VCM assistant production manager for Formosa Plastics Corporation at Point Comfort, Texas, USA. Mike Yen is a senior APC consultant at Honeywell Process Solutions in Houston, Texas. Yen received his MEng in chemical engineering from Lamar University and MS in process monitoring & control from University of Houston at Clear Lake, USA. Email: mike.yen@honeywell.com Ravi Nath is a senior APC consultant at Honeywell Process Solutions in Houston, Texas. Nath has BS and MS degrees in chemical engineering from India Institute of Technology, Kanpur, and a PhD in chemical engineering from University of Houston. Email: ravi.nath@honeywell.com Rogier Pouwer is a senior business optimisation consultant for Honeywell Process Solutions in Houston, Texas. Pouwer holds a BS in chemical engineering from Brigham Young University. Email: Rogier.Pouwer@honeywell.com Anil Gokhale is the advanced service engineering manager for Honeywell Process Solutions in Houston, Texas. Gokhale received his BS in chemical engineering from University of Bombay and PhD in chemical engineering from Oklahoma State University. Email: anil.gokhale@honeywell.com

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