The Value of Model Predictive Control - Rockwell Automation · PDF fileThe Value of Model...

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The Value of Model Predictive ControlIndustrial Applications – CT505

Name – Maina MachariaTitle – Process Technical ConsultantDate – March 25/26,2015

PUBLIC CHICAGO PROCESS SOLUTIONS SUMMIT

MPC – Web Enabled

Composition Controller views

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Typical Project KPI – Monitor& Tracking

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MPC – Performance Metrics

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NGL Fractionation ROI Example

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Biofuel ROI Example

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Estimated Capital Investment Justification Calculations Margin Calculations (€/m3)year 0 year 1+ Selling Price of EtOH + DDGS 746.60$

Pavilion Project 1,096,190$ Budgeted Capacity 240,000 m3 per year Corn Cost 519.40$ Maint. Agreement 75,275$ Avg Ethanol Price 528$ /m3 Gas Cost 0.08$

PLC/DCS programming -$ Corn Price 186$ /MT Enzyme Cost 10.50$ Instrumentation -$ -$ DDGS MT/M Liters 0.90 MT/M Liters Electrical Cost 10.00$

PC Hardware/Comm. 7,000$ -$ DDGS $/Ton 243$ /MT Denaturant Cost 15.18$ Internal Engineering -$ Denaturant Costs 0.76$ /Liter Total Variable Cost 555.16$

Travel and Living 46,200$ -$ Denaturant Percentage 2.0% Gross Margin 191.44$ Total 1,149,390$ 75,275$ Enzyme Costs 10.5$ /kL

Capacity Increase Est Margin BTU/gallon 265003.0% 7,200 m3/Y 25% Kj/BTU 1.0550564.0% 9,600 m3/Y 191.442$ gallon/litre 0.2641721

Natural Gas 7385.983517 kJ/lit 7385.983517Natural Gas Costs 0.01040$ /MJ Increase Ethanol yield Base Yield (lit/kg)

Est. Annual Costs for natual gas 18,427,503$ per year 0.80% 1,014,421$ per year 0.35711.20% 1,521,631$ per year 2.800 kg/lit

Natural Gas Savings0.0% -$ per year0.0% -$ per year

Benchmark MetricsNew Plant Capital Investment 700€ per m3 0.0% -$ per year

APC Capital Investment 160€ per m3 0.0% -$ per yearAPC Benefits Metric 8€ per m3

Estimated Production Margin 951,020$ per yearEstimated Yield and Energy Savings 1,014,421$ per year

Expected Savings 1,965,440$ per year

Moisture Increase in DDGS yield

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Chemicals and PolymersProcess Types

– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants

CPG– Spray Dryers– Evaporators– Energy CentersProcess Types

– Milk Powder– Coffee– Laundry Detergent– Conc. juice

CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types

– Cement– Minerals– Fertilizer– Ammonia

Bio-fuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types

– Corn Ethanol– Cane Ethanol– Bio-diesel

Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction

Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction

Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction

Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase

Large Markets – Project Results

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Typical Project Payback: 3 to 9 months!

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Chemicals and PolymersProcess Types

– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants

CPG– Spray Dryers– Evaporators– Energy Centers– Crystallizers– French Fry MachinesProcess Types

– Milk Powder– Coffee– Laundry Detergent– Conc. Juice– French Frys– Sugar

CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types

– Cement– Minerals– Fertilizer– Ammonia

Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types

– Corn Ethanol– Cane Ethanol– Bio-diesel

Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction

Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction

Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase

Large Markets – Project Results

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Dryer Moisture Soft Sensor Results

Product In8-15% solids

Product Out45 -55% solids Cold Air

Hot Air

Hot Air

Powder Out

Solids In

Moisture Results = 49% Improvement

The Business Value isAchieved by

“raising the bar” with ConfidenceBefore MPC After MPC

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Dryer and Evaporator Balance – Value

Product In8-15% solids

Product Out45 -55% solids

Plant Obedience (reduced variability) enables:

Moisture – Lift moisture targets to Limit or revised uplift

Evaporator capacity – Optimize Solids to current UCL to reduce variability

Dryer capacity – Improve evaporation capability within proven heat envelope

Reduce Rework - Product & Cost

Reduce Energy – Dryer & Evaporation Balancing reduces the energy cost profile per tonne of product produced .

Improve Quality & Consistency Optimize Evaporator & Dryer Efficiency

Squeeze more value from the existing asset

Produce more product with the same operating profile

Reduce Variable Cost Sell more free water Enable product mix flexibility to gain

more higher value products

Cold Air

Hot Air

Hot Air

Powder Out

Solids In

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Dairy spray dryer• Inlet temp controlled with gas valve• Exhaust temp controlled with feed pump speed• Feed is pumped through nozzles and the backpressure from the nozzles is a key

constraint• Inlet temp sp to valve output, response of pid algorithm• Inlet temp to nozzle press, response of exhaust temp pid algorithm rejecting

disturbance from inlet temp change. • Exhaust temp to nozzle press, response of exhaust temp pid algorithm. As with Inlet

temp, omitting the overshoot will cause cycling and possibly trip the dryer.

Spray Dryer

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Chemicals and PolymersProcess Types

– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants

CPG– Spray Dryers– Evaporators– Energy CentersProcess Types

– Milk Powder– Coffee– Laundry Detergent– Conc. juice

CMM– Crushing/Grinding– Preprocessing– Kilns & Drying– Stockpile BlendingProcess Types

– Cement– Minerals– Fertilizer– Ammonia

Bio-fuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types

– Corn Ethanol– Cane Ethanol– Bio-diesel

Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction

Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction

Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase

Large Markets – Project Results

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Rotary Cement Kiln Typical LayoutRaw Material Feed Stream

Fuel Addition

Fuel Addition

Fuel Addition

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Production Rate 4 Months Before/ After MPC

With Pyroprocessing MPC Solution

Without Pyroprocessing MPC Solution

220 tph

220 tph

190 tph

220 tph=+14 %

Multiple Slowdowns

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Chemicals and PolymersProcess Types

– Polymers– PE, PP, PS,

PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants

CPG– Spray Dryers– Evaporators– Energy CentersProcess Types

– Milk Powder– Coffee– Laundry Detergent– Conc. juice

CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types

– Cement– Minerals– Fertilizer– Ammonia

Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types

– Corn Ethanol– Cane Ethanol– Bio-diesel

Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction

Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction

Typical Benefits– 4 to12% ethanol production capacity increase – 2 to 5% ethanol yield increase– 3 to 6% energy use/gallon reduction– 1 to 2% DDGS yield increase

Large Markets – Project Results

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Before & After APC Comparison

variables(PV-SP)

Before APC STD After APC STD APC Improvement

AIC201 12.23 4.48 63%AIC202 148.5 46.03 69%DIC241 2.540 1.29 49%DIC251 2.402 1.58 34%PIC402 0.01739 0.0032 82%AIC402 0.00254 0.000296 88%AIC403 0.00535 0.002977 44%

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AIC201/AIC202）H2 concentration in Loop 1&2 reactor

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Transition:V30GZ30S, APC OFFtime: 7.5 hours

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Transition: V30GZ30S, APC ONtime: 3.3 hours

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Chemicals and PolymersProcess Types

– PE, PP, PS, PC– Ethylene Plants– Styrene Plants– Crude Refining– Gas Plants

CPG– Spray Dryers– Evaporators– Energy CentersProcess Types

– Milk Powder– Coffee– Laundry Detergent– Conc. juice

CMM– Crushing/Grinding– Kilns & Drying– Stockpile BlendingProcess Types

– Cement– Minerals– Fertilizer– Ammonia

Biofuels– DDGS Evap/Dryer– Water Balance– Fermentation– DistillationProcess Types

– Corn Ethanol– Cane Ethanol– Bio-diesel

Typical Benefits– 5 to 8% production increase– 30 to 60 % moisture variability reduction– 20 to 50% off-spec product reduction– 5 to 10% energy consumption reduction

Typical Benefits– 2 to 5% production increase– 2 to 5% energy consumption reduction– 20 to 40% product variability reduction– 10 to 30% off-spec product reduction

Typical Benefits– 4 to 8% prime product yield increase– 35 to 75% product variability reduction– 20-40% transition time reduction– 3 to 7% feed stock wastage reduction

Large Markets – Project Results

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BioEthanol Process Overview

Distillation/Sieves MPC

Fermentation MPC

Waterbalance MPC

Dryers/Evap & TO MPC

MPC Objectives:• Optimize plant throughput • Maximize ethanol and DDGS yield• Minimize energy/gallon ethanol

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The Challenge: Cascading Dryers

22Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Natural gas Dryers A, B

Natural gas to Dryers C, D

Optimize NG energy in drying – 2 lines, 2 dryers/line, 2 parallel

lines

Dryer A Dryer B

Dryer C Dryer D

Wet Cake

DDGSProduct

Dryer Amoisture

Dryer Dmoisture

Dryer Cmoisture

Dryer Bmoisture

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Dryer Operations Snap-shot

Inlet Dryers Outlet Dryers

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The Challenge: Cascading Dryers

24Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Dryer A Dryer B

Dryer C Dryer D

Wet Cake

DDGSProduct

Dryer Amoisture

Dryer Dmoisture

Dryer Cmoisture

Dryer Bmoisture

0.0201 MMBTU/lb

0.0275 MMBTU/lb

0.0221 MMBTU/lb

0.0354 MMBTU/lb

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The Solution: Natural gas Dryer Optimization

Task MPC Operator

Minimize the Natural gas use

Automatically computes dryer loading to minimize Natural gas

Not done because it was too complex

Controlling moisture targets of each dryer

Targets incorporate current moisture levels and are proactively adjusted

Targets set at installation and reactively changed once out‐of‐spec

Dryer constraint handling Uses models of the process to proactivelymanage constraints

Only reactively changes moisture if equipment alarms are triggered

Recording of moisture levels

Once per minute Every 2 hours

Frequency of Natural gas target  change

Once per minute Depends on the operators judgment

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Actual plant Results: Reduced Variability & Increased Stability

Plant Key Performance IndicatorsMean Value

ChangeSTD Value

Change

Abs Rel Abs Rel

• Plant Production Rate

Total Corn Grain Feed [lbs/min] +15.30% -34.71%

200 Proof Flow [gpm] +17.61% -41.99%

• Specific Energy Consumption

Total Gas [BTU/gal-EtOH] -11.70% -44.16%

Natural gas for Dryers [lbs/gal-EtOH] -3.73% -38.56%

Total Natural gas [lbs/gal-EtOH] -8.53% -46.50%

• Ethanol Yield

Gallons of Ethanol per Bushel of Grain +0.59% -48.49%

Significant reduction in

standard deviation of all variables

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Fermenter Data – Reduced Residual Sugars (USA)

Fermenter MPC online

Without Fermenter MPC

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Fermenter data – Increased Ethanol Conc.

Fermenter MPC onlineWithout Fermenter MPC

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Who is Windsor Utilities?

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Pressure Locations

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Drinking Water -System Overview

• Total daily supply capacity: 349 ML (92MGD)

• Reservoir storage capacity: 118 ML (31MG)

• Number of treatment plants: 2• Number of pumping stations: 3• Number of Elevated Storage Tanks: 2• Length of water main: 1,100 km

(690 Miles)• The Albert H. Weeks Water Treatment

Plant supplies an average of 140 ML (37 MG) of water to City residents per day.

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The Opportunity

• 238 Main Breaks per year (average)

• 44 average age of distribution water main (one of the oldest in Ontario/Canada)

• Increasing Electricity costs• Inconsistent system

pressures during peak/low demand periods

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APC Faceplate in FTView

VSD

VSD

P = Pressure ControlM= Manual Control

R = RunningS = Stopped

O = OptimizedM = Manual

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Before MPC

Pump start/stop cyclesPump start/stop cycles

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Results – After with MPC

When were the pumps started?When were the pumps started?

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