Online Crude Column Relief Load EstimationShell (Canada)
Implementation of a model-based relief load estimator for a crude column. Online estimation of combined feed composition changes allowed maximum feed diet flexibility while ensuring continued safe operation.
Online Heat Exchanger Fouling and Cleaning Benefit EstimationShell (Canada)
System to estimate heat exchanger fouling rates, flow maldistribution, bypass rates, and online/offline status of site heat exchangers. Economic analysis produced one-shot and aggregate cleaning benefits.
Online Safeguarding of a Fired HeaterShell (Canada)
Development of an adaptive crude furnace model to improve firing limit prediction. The system ensured safe on-going operation while maximizing product yields.
Optimal Heat Exchanger Bypass using Hydraulic ModelsShell (Canada)
Addition of network hydraulics to an existing online process model to support generation of optimal heat exchanger bypass flow targets. The system resulted in significant increases in feed preheat and reduced energy costs.
A&V Unit Real Time Optimization SystemShell (Canada)
Design and implementation of a real time optimization (RTO) system for a 155,000 bbl/d Upgrader A&V unit. Generated 36 advanced control (APC) targets with tools to monitor target utilization and constraint relaxation economic opportunities.
Energy Optimization SystemDow (USA)
Online optimization of a steam-power system using HYSYS.RTO. System included equipment selection/line-up optimization and offline what-if cases.
Refinery Steam Real Time Optimization SystemRepsol (Spain)
Real time optimization system for a refinery steam/power facility. Operating targets included changes to boiler status and drive selections.
Hydrocracker Unit Real Time Optimization SystemPetrochemia Plock (Poland)
Real time optimization system for a new hydrocracker unit (HCU) at a 200,000 bpd refinery. Delivered as part of an advanced control and automation project.
Energy Management SystemSamsung Chemicals (South Korea)
Real time optimization system for the steam/power facility at a large petrochemical complex.
Energy Optimization Feasibility StudyDow-Bayer-NOVA (Canada)
Study of the potential economic benefits of a multi-site steam/power optimization system.
Nickel Smelter Dynamic ModelFalconbridge (Canada)
Dynamic model of a 45MW electric furnace to predict matte, slag, and off-gas compositions. Used to investigate alternative operating conditions and evaluate process design changes.
Water Reservoir Management StudySA Water (Australia)
Water reservoir process model and case study to determine the feasibility of developing a real time inventory management system.
Refinery Steam System Dynamic ModelExxon (USA)
Dynamic fired boiler process model with advanced steam drum controls. Used to evaluate process modifications and control designs to improve disturbance rejection.
Correction and Compensation of Orifice Meter FlowsShell (Canada)
Tool to improve the accuracy of measured vent gas flows used in greenhouse gas (GHG) emissions reporting.
Reconciled Flow Measurements for Emissions ReportingShell (Canada)
Incorporation of flow meter health and reconciled measurements for Refinery greenhouse gas (GHG) reporting.
Model-Based Control of Diluent ProductionShell (Canada)
Development of a non-linear control method to produce high quality C5-C6 diluent with existing advanced control (APC) and optimization (RTO) applications.
Batch Control of Kraft Pulp DigestorsDomtar (Canada)
Enhancement of a large-scale batch digester advanced control program. Resulted in reduced cycle time and improved product quality.
Advanced Control of a Utility BoilerDomtar (Canada)
Performance analysis, modification, and tuning of the advanced control system for a 230 tph utility boiler to improve load disturbance rejection.
Mixed Integer Nonlinear Programming (MINLP) AlgorithmAspen Technology (Canada)
Development of an object-oriented mixed integer optimization algorithm (MINLP) for HYSYS.RTO. The algorithm was required to support selection optimization in a steam/power real time optimization (RTO) project.
Dynamic Process Model Interface for SimulinkOpen Models (Canada)
Development of a real-time interface between MASSBAL dynamic process models and Simulink for use in control design and operator training (OTS) projects.
Open Equation Kinetic Reactor Models for RefiningHoneywell (Canada)
Creation of equation-based refinery reactor kinetic models from closed-form versions. Hydrotreating/hydrocracking (HTR/HCR), Fluid Catalytic Cracking (FCC), and HF-Alkylation reactors were required for real time optimization (RTO) projects.
Online Process Modeling SystemHoneywell (Canada)
Development of the OPTIMIZER platform for use in online process monitoring and optimization systems. Components included online executive, real-time data interfaces, steady-state detection, and data screening.
Equation-based Process Simulator Hydrocarbon ProcessesHoneywell (Canada)
Modification of the MASSBAL process simulator to support hydrocarbon process models, data reconciliation and gross error detection, and optimization. Developed distillation models, physical property packages, real time process data interfaces, and solution algorithms.
Refinery-wide Data Reconciliation SystemShell (Canada)
Implementation of a Refinery-wide data reconciliation system for 430+ flow measurements and 120+ mass balances across 21 operating units. Reconcilied flows adopted by Business, Technical, and Environment groups for reporting and analysis.
Plant-wide Data Reconciliation SystemShell (Canada)
Implementation of a multi-Upgrader data reconciliation and mass balance system for 560+ flow measurements and 150+ mass balances across 16 operating units. System used daily to determine flow meter health and mass balance troubleshooting.
Pricing Method for Intermediate Process StreamsShell (Canada)
System to estimate intermediate stream prices for use in real time optimization (RTO) systems. Method utilized linear programming (LP) volumetric yields, variable unit production costs, and fence-line product prices to produce back-blended break-even values.
Web-Based Client RolloutShell (Canada)
Managed PI-Vision rollout for a site of 400+ PI users. Developed standards, site-wide navigation pages, and conversion of existing displays (10,000+).
Archive Performance AssessmentShell (Canada)
Evaluation of archive read performance for a new regional PI system. Developed test cases using standard clients and custom applications. Poor performance results led to system architecture changes.
Calculated Point Platform MigrationShell (Canada)
Conversion of 8000+ PI performance equations to PI-AF Analytics. Project methodology developed was subsequently used for sites world-wide.