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Advanced Process Control in HyCO Systems

This document provides a real world example of implementing advanced process control (APC) at an amine system to reduce corrosion. It summarizes: 1) The amine system removes CO2 from process gases using an absorber and stripper. Modeling identified control and disturbance variables affecting stripper corrosion. 2) A team developed first-order plus time delay models for how maniputable variables (stripper reboiler duty, temperature etc.) affect control variables (CO2 slip, pressures etc.). 3) The models were inserted into a model predictive controller. Post-implementation, stripper temperature average reduced 5°F to 220°F with 60% lower variability, reducing corrosion risk.

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Resky Ervaldi Saputra
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66 views26 pages

Advanced Process Control in HyCO Systems

This document provides a real world example of implementing advanced process control (APC) at an amine system to reduce corrosion. It summarizes: 1) The amine system removes CO2 from process gases using an absorber and stripper. Modeling identified control and disturbance variables affecting stripper corrosion. 2) A team developed first-order plus time delay models for how maniputable variables (stripper reboiler duty, temperature etc.) affect control variables (CO2 slip, pressures etc.). 3) The models were inserted into a model predictive controller. Post-implementation, stripper temperature average reduced 5°F to 220°F with 60% lower variability, reducing corrosion risk.

Uploaded by

Resky Ervaldi Saputra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

Advanced Process Control

A Real World Example

Jim English
UT Graduate, ChE 04
April 27, 2006

Introduction

Who am I?
Who is Air Liquide?

Why am I here?

Real World example


Some notes from industry

So whats the story?


HyCO = Hydrogen + Carbon Monoxide
How does the HyCO work? (Go to PFD)
Amine System (Go to Amine)

HyCO Process Flow


Natural Gas
+
Steam

Hydrogen

Reformer
Reformer

Amine
Amine
System
System

(Reactions)

(Details)

PSA
PSA

Cold
Cold
Box
Box

CO

Dryers
Dryers

Membranes
Membranes

Reformer Reactions
Natural Gas Reforming:
CH4 + H2O 3H2 + CO

Water Shift Reaction


CO + H2O H2 + CO2

Back to PFD

~60

Amine System
Process
Gas
Outlet

CO2

Reboiler

Amine
Amine
System
System
Stripper

Process
Gas
Inlet

Absorber

(Inside)

Heat
Exchanger

Pictures Inside
Top Wall

Reboiler

X
Stripper

Reboiler

Pictures Inside
Downcomer Tray

X
Stripper

Reboiler

Missing Clips

Pictures Inside
Steam Deflector Plate

Stripper

Reboiler

So What Next?

Form the Team


Research & Development
Engineering & Design
Process Control Experts
Plant Operations
HyCO Personnel

Whats our Goal?


Reduce corrosion in the stripper
While maintaining absorbers CO2 removal

But Why?
If we have to replace stripper packing
$50,000 for packing
Plant shutdown = lost product revenue
Packing degradation ruined 2 pumps ($$$)

Whats Important?...
Constraint Variables
Manipulated Variables
Disturbance Variables

Which Allows Us To
CV Target
CV Value
MV History

MVPC
MVPC
Controller
Controller

DV History

MV Setpoint

Amine System Revisited


Process
Gas
Outlet

CO2

CV

CV
CV

Reboiler

CV

MV

Stripper
Absorber

Process
Gas
Inlet
DV

Heat
Exchanger

CV
CV
MV

How do these guys interact?


MVs

Stripper Reboiler

Amine Recirc

Total CO2 Flow

Stripper Ovhd Temp

CO2 Slip

Rich Liquid Loading

Stripper Top DP

Stripper Bottom DP

Absorber DP

CVs

Next came the tough part


Test & collect process
reaction curves
Import to Excel &
Matlab
Fit First Order plus
Time Delay models

Example Step Response

(0.5)

G = 0.5
= 4.5
= 3.0

(3.0)

(7.5)

Now we Know
CVs

MVs

Stripper Reboiler

Stripper Ovhd Temp

Modeled

CO2 Slip

Modeled

Rich Liquid Loading

Amine Recirc

Total CO2 Flow

Modeled

Modeled

Modeled

Modeled

Stripper Top DP

Modeled

Modeled

Stripper Bottom DP

Modeled

Modeled

Absorber DP

Modeled

Modeled

Inserting Models into MVPC

Overall Results
235F

Corrision Temperature
235F

230F

230F
225F

225F

Post Implementation

220F

215F

220F

Reduced average temperature by 5F (225F to 220F)


215F
Decreased
deviation by
T standard
= 225 10F
T 60%
= 220 (10F
4Fto 4F)
avg

avg

Miscellaneous
Project Updates
Tools used
Tasks performed

Conclusions
Important Factors:
ENTIRE team
We reduced the risk of corrosion!
Projects success is leading to further MVPC
around the plants reformer

Thanks!
Questions?

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