Real-Time Optimization of Refinery FCC

Problem

Optimizing plant performance is crucial to maximize output and achieve optimum profit, yield, production, and energy consumption without significant capital investments. However, many plants operate based on outdated design conditions and set points, leading to suboptimal performance. Additionally, the implementation of Advanced Process Control (APC) does not always result in true optimization as its primary function is process control, not maximizing performance. To address these challenges, a more effective and dynamic approach to optimize the Refinery Fluid Catalytic Cracking (FCC) process is required.

Approach

To achieve real-time optimization for the Refinery FCC process, Algo8’s solution employs the following approach:

• Plant Model and AI Optimizer: The Real-Time Optimization (RTO) system consists of a hybrid plant model that incorporates both first principles and data science. This model replicates the plant behavior and response accurately. The system also includes an AI optimizer that works with the plant model to optimize its objective function (e.g., production, yield, or profit). 
• Autotraining Capability: The hybrid plant model has autotraining capabilities, enabling it to adapt and learn from real-time plant behavior and conditions. This ensures accurate predictions and optimal performance even as the plant’s behavior and feedstock conditions change over time. 
• Manipulation of Independent Variables: The AI optimizer manipulates the independent variables within the plant model towards the boundaries to push the plant’s operation closer to its optimal limits. It identifies the best possible operating conditions to achieve the desired objectives while adhering to constraints and limitations. 
• Frequency of Optimization: The RTO system runs on a regular frequency (e.g., every 4 hours) or whenever significant changes in feed or operating conditions occur. It provides optimal target set points for the manipulated variables either as advisory inputs to DCS engineers (open loop) or directly communicates these values to the Advanced Process Control (APC) system for implementation in DCS (close loop). 

Benefit

The implementation of Algo8’s Real-Time Optimization (RTO) solution for Refinery FCC brings substantial benefits:

• Increased Profit: The RTO system helps achieve a 2% increase in profit by optimizing the product mix (e.g., propylene vs gasoline), optimizing catalyst consumption, and gaining higher total liquid production. 
• Energy Consumption Reduction: The RTO system leads to a significant reduction in energy consumption, resulting in 7-10% energy savings.

Impact

By adopting Algo8’s RTO solution, a refinery operating a 105kbpd FCC experienced substantial financial benefits:

The RTO solution added $8-9 million in annual benefits, primarily driven by improved profit and energy savings. The optimized FCC process resulted in enhanced plant performance, increased profitability, and reduced energy costs, making the refinery more competitive and efficient.