Operational Excellence with

Real-time Optimization

Rahul Bindlish
Aspentech Webinar
November 9, 2017
® TM The DOW Diamond is a Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
 Why We Need Optimization

Optimization
Changing Prices

Changing Equipment

Changing Environment
$
Plant

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 Types of Optimizers

Linear Optimizers
• LP (linear program), Simplex method
• These are often used for blending optimization, and require linear relationships
between the inputs and outputs
Nonlinear Optimizers
• Empirical
– Nonlinear algebraic equations
• Fundamental
– Nonlinear equations based on mass balance, thermodynamics, and kinetics
– Aspen Plus Optimizer is a fundamental equation-oriented optimizer

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Real-time Optimization

Site, Business,
Regional Envelope
Optimization Optimization

Site Balancing &

Scheduling

Real-time Optimization (RTO)

Model Predictive Control (MPC)

Advanced Regulatory Control (ARC)

Regulatory Control (PID loops, SIS, Automation, Sequencing)

Plant Instrumentation & Valves

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 Advanced Control & Optimization

Optimizer

Inferential Sensor
Model Pred. Controller
Model Pred. Controller

PID PID PID PID PID PID PID PID

DCS

Plant Instrumentation

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Processes Benefiting Most from Advanced Control &
Optimization (AC&O)

Process Characteristics MPC RTO

High production volume  
High profit margin  
High energy usage and integration  
Frequent disturbances, rate changes, etc. 
Frequently-changing constraint scenarios  
Ability to shift production of by-products and co-products 
Changing feed, product, and energy prices 
Multiple raw material sources (compositions)  
Under utilized flexibility 
• Setpoints that are rarely/never changed
• Operation by gut feel, intuition, or rules of thumb

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 Typical AC&O Benefits

• 1-5% capacity increase

• 1-5% energy savings
• ~1% yield improvement

Miscellaneous benefits
• Fewer alarms & operator setpoint changes
• Equipment performance monitoring using model parameters (fouling,
efficiencies, etc.)
• What-if-cases to identify appropriate plant debottlenecking projects
• Improved production planning including shutdowns

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 Real-time Optimization

• Rigorous equation-oriented (EO) Aspen Plus model accurately predicts

the actual behavior of the plant
• Real plant data is used to adjust model parameters
• Uses economic data (prices) to establish operating region
• Pushes the unit to economic optimum
• Takes constraints into account while calculating the optimum
• Makes the right trade-offs among feeds, products and energy based on
total operating profit ($)
• Runs every 5-240 minutes

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 Modeling for Real-time Optimization

• Rigorous steady-state fundamental model with approximately 50,000

– 100,000 equations that are solved simultaneously running as a
closed-loop optimizer
• Makes the right trade-offs among feeds, outputs and utilities to
maximize total operating profit (Φ)

max    (Output j  Cost j )   (Feed k  Cost j )   (Utility  Cost )

l l
DOF
j k l

Material and energy balances along with process constraints :

f ( x, u, d , b)  0, y  h( x, u, d , b)

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 Modeling for Optimization Versus Design

Model at equation-oriented level for optimization (as opposed to sequential

modular level for design)
• Need to use equation-oriented mode to solve robustly and reliably

Evaluate performance and tune models for optimization, as opposed to

calculating specifications for design
• Example: Calculate heat transfer coefficient based on area and temperature data during
optimization (instead of evaluating heat transfer area for design)

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 Why use equation-oriented models?

Process flowsheet for primary fractionator in an olefins plant

Equation-oriented (EO) model
of the Primary Fractionator
Q
Q Cracked Gas was used because the
Primary Fractionator has
HXFLUX
HXFLUX

recycle loops (Gasoline reflux,

MEASUREMENT
USER3

T
Q

HXFLUX
Quench oil reflux, Wash Oil
F T
Q

HXFLUX
MIXER

reflux), which make it very

FSPLIT MIXER
T
hard to converge the
F

RYIELD

Gasoline Reflux Gasoline Sequential Modular (SM)

model.
T

F
F

DP

SM: 203 iterations, 143.9 s

F F
T

MIXER
T
T
USER3
T

MIXER
T
T

EO: 4 iteration, 2.5 s

F
F
MIXER
DP

Fuel Oil
MIXER
P

MIXER

F
DP

From HYD
P F T
T T

FSPLIT
HEATER
F

FSPLIT

T T
T T

DP
DP DP

T
Quench Oil Reflux

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Typical Real-time Optimization cycle

Steady-state? Wait
No
Yes
Parameter Case Error

Success
Optimization Case Error

Success
Implement Setpoints Error

Success

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 Success Stories

Real-time Optimization Success Story

Other benefits/uses of a detailed validated process model:
• Power Scheduling
• Process Debottlenecking

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 Process Flow Diagram

Product 1

Feed 1 Product 2
Solvent
Reactor Tank Dist 1
Feed 2 Removal

Dist 2
Steam Steam Steam

Steam Waste

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 Real-time Optimization

Oneway Analysis of DPG By Data

7000

6000

At same total production a more profitable 5000

product mix. 4000

$4MM EBIT generated in the first year.

DPG
3000

Oneway Analysis of M+DPG By Data

50000
2000

More profitable
1000

0-baseline 1-OD
Product 2 2-DMC 3-DMC+RTO All Pairs product mix
40000 Tukey-Kramer
Oneway Analysis of MPG By Data Data 0.05

44000Rows
Excluded 908
43000
Means Comparisons
42000
Comparisons for all pairs using Tukey-Kramer HSD
41000
q* Alpha
40000
2.56936 0.05
M+DPG

39000
Abs(Dif)-LSD
38000 3-DMC+RTO 1-OD 2-DMC 0-baseline
3-DMC+RTO
37000 -128.4 444.1 1076.6 1894.6
1-OD
36000 444.1 -137.9 493.6 1310.7
2-DMC 1076.6 493.6 -83.9 739.8
35000
0-baseline 1894.6 1310.7 739.8 -29.2
34000
30000 Positive
33000 values show pairs of means that are significantly different.
Level
32000 Mean
3-DMC+RTOA 6129.0187
31000
1-OD B 5551.7090

MPG
30000
2-DMC C 4943.9724
29000
0-baseline D 4141.3255
Levels
28000 not connected by same letter are significantly different.
27000
Level - Level Difference Lower CL Upper CL
3-DMC+RTO0-baseline 1987.693 1894.557
26000 2080.829

Same total
1-OD 0-baseline 1410.384 1310.740 1510.027
25000
3-DMC+RTO2-DMC 1185.046 1076.561 1293.532
24000
2-DMC 0-baseline 802.647 739.838 865.456
23000
1-OD 2-DMC 607.737 493.615 721.858
3-DMC+RTO1-OD
22000 577.310 444.069 710.550

20000
production 21000
20000
19000

0-baseline 1-OD 2-DMC 3-DMC+RTO All Pairs

18000
17000
16000
Product 1
All Pairs
Tukey-Kramer 0-baseline 1-OD 2-DMC 3-DMC+RTO
Tukey-Kramer
Data 0.05 Data 0.05

Excluded Rows 908

Excluded Row s 908 Means Comparisons

Means Comparisons Comparisons for all pairs using Tukey-Kramer HSD

q* Alpha
Comparisons for all pairs using Tukey-Kramer HSD 2.56936 0.05
Abs(Dif)-LSD
q* Alpha 2-DMC3-DMC+RTO 0-baseline 1-OD
2-DMC -416 576 9174 10811
2.56936 0.05 3-DMC+RTO 576 -637 7910 9602
0-baseline 9174 7910 -145 1397
Abs(Dif)-LSD
1-OD 10811 9602 1397 -683
3-DMC+RTO 2-DMC 0-baseline 1-OD
Positive values show pairs of means that are significantly different.
3-DMC+RTO -719 -536 9838 10095
Level Mean
2-DMC -536 -469 9937 10131 2-DMC A 42137.074
3-DMC+RTO B 41022.978
0-baseline 9838 9937 -163 -77
0-baseline C 32651.422
1-OD 10095 10131 -77 -771 1-OD D 30760.297
Levels not connected by same letter are significantly different.
Level - Level Difference Lower CL Upper CL
Positive values show pairs of means that are significantly different. 2-DMC 1-OD 11376.78 10811.18 11942.37
Level Mean 3-DMC+RTO1-OD 10262.68 9602.33 10923.03
2-DMC 0-baseline 9485.65 9174.36 9796.94
3-DMC+RTOA 47151.997
2-DMC A 47081.046 Aspentech Webinar 3-DMC+RTO0-baseline
0-baseline 1-OD
2-DMC
8371.56 7909.97
1891.13 1397.28
3-DMC+RTO 1114.10 576.43
8833.15
2384.97
1651.76
0-baseline B 36792.747
1-OD B 36312.006
Levels not connected by same letter are significantly different.
 Real-time Optimization

energy intensitiy
energy intensitiy

production rate

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 Typical Cogeneration Power Plant

LP Steam
IP Extraction Steam to Process
HP Steam
LP Extraction Steam To Process
Fuel Gas
Fuel Gas
GT Exhaust DB’s

STACK HP IP LP Turbine Generator

HRU’s
STEAM
Compressor Turbine Generator TURBINE

GAS TURBINES Polished

Water

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 Scheduler and Real-time Optimization

Steady-state? Wait
No
Yes
Error Success Model Validation Error
Scheduler Cases Case
Succes Success
s offer
Power schedule Optimization Case Error
Day-ahead (3 minutes)
Real-time
Offer (daily) Success
Offer (hourly) Implement Setpoints Error
MISO Power using MPC (15 seconds)
Day-ahead Market Dispatch
Success
dispatch
Schedule

Bindlish, R. (2016). Power scheduling and real-time optimization of industrial cogeneration plants,
Computers & Chem. Eng., 87, 257-266

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 Power Scheduling

• Power scheduling calculations are done for the scheduling

interval of each hour by solving multiple optimization cases
using the validated process model
• Offer curve for the power schedule includes exported
power and incremental heat rate
• Incremental Heat rate is the common measure of system
performance in a cogeneration power plant
Fuel input
Incremental Heat rate 
Output power

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 Power Scheduling

12.8 percent improvement in power sales margin

compared to selling power without scheduling

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 Process debottlenecking

waste Good match between measured data

and model prediction
Product
Feed

Column 1

Column 2

Recycle

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 Process debottlenecking

Vary feed location in both columns

Column 1 Column 2
Feed location reflux rate / Feed location reflux rate /
normalized normalized
bottom 3.42 top 2.23

between bed 4 and 5 0.95 between bed 1 and 2 0.97

between bed 3 and 4 0.83 between bed 2 and 3 1

between bed 2 and 3 1 between bed 3 and 4 1.19

Moving the feed location down one bed in column 1 and up one bed in
column 2 gives the desired higher recovery at the same hydraulic load
and separaton efficiency
Minimal costs involved in doing these changes

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 Process debottlenecking

Good match between measured data and model

waste prediction, also for flows and compositions
Product
Feed
New New
Feed Feed
location location

Column 1

Column 2

Recycle

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 Real-time Optimization model support

Support strategy is important to maintain the model and sustain the gains
Support Description Emphasis Generally Time Scope
Level Provided By: Commitments

1st Provides day to day oversight and Mechanics of Plant or Daily Plant or
review of the DMC controllers and implementation, Business Site
Optimizer online models. uptime

2nd Providing advice, mentoring and Process Business Daily-Weekly Business

support for the First Level Support Technology, Technology
function. sustainability, Center
planning

3rd Provide advanced advice, Tools and Engineering As needed Global

mentoring, training and Methodology, Solutions
troubleshooting on the use of the AC&O Technology
AC&O applications and systems.

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 Conclusions

Real-time Optimization increases plant profitability

• Uses fundamental nonlinear model with details of control strategies and
equipment design curves
• Accounts for ambient temperature and equipment contingency
• On-line model validation
• Optimizer results are implemented using model predictive controller
Real-time optimization model has additional benefits
• A well maintained process model is available for other studies, e.g.
debottlenecking or improvement idea evaluation studies
• Helps in production and shutdown planning

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Thank
You
Q&A

Rahul Bindlish
RBindlish@dow.com

Jack Zhang
Jack.zhang@aspentech.com

David LeGrand
David.Legrand@aspentech.com

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