Optimize FCC and catalytic polymerization units

The combination of technologies described provide the key ingredients for successful closed-loop plant wide optimization. Online properties estimation (OPE) provides continuous, accurate values of crucial process measurements. Optimal predictive control (OPC) enforces optimal targets while respecting the dynamic behavior and limitations of the process. Closed-loop reconciliation and optimization (CRO) increases plant profit through the use of rigorous steady-state models to calculate better target values. The PC-based packages for off-line design of estimators, controllers, and optimizer provide a user-friendly environment which permits rapid development of applications. Extensive testing of real-life scenarios within each design package results in short online commissioning times and robust performance. The development process is independent of the online DCS or computer platform in which the applications will run. This project has generated a return greater than 4% of the total profit generated by the unit. These benefits result from achieving increased yields of the highest-valued products, and reducing energy consumption. Additional profits are realized from the ability to maximize throughput.