Integrated advanced chemical process control
View Patent ↗The application discloses a system for controlling a chemical manufacturing process having at least one piece of process limiting equipment in addition to a reactor. The system employs one or more multivariable predictive optimizer controllers for optimizing control of the chemical reactor and production limiting equipment located upstream or downstream of the reactor, to provide integrated process control of the reactor and the production limiting equipment.
1. A system for controlling a chemical manufacturing process having at least one chemical reactor and production-limiting factor located upstream or downstream from the reactor, comprising: a first multivariable predictive optimizer controller for optimizing control of the chemical reactor; and a second multivariable predictive optimizer controller operating hierarchically above the first controller and the production-limiting factor for providing integrated process control of the reactor and the production-limiting factor.
2. The system of claim 1 further including a third multivariable predictive optimizer controller operating hierarchically below the second controller for controlling the production-limiting factor.
3. The system of claim 1 wherein the production-limiting factor is production limiting equipment located downstream from the reactor.
4. The system of claim 3 wherein the production-limiting equipment and the reactor are close coupled.
5. The system of claim 1 wherein the multivariable predictive optimizer controller employs a mathematical technique selected from the group consisting of neural networks, partial least squares, principle component regression or first principles models to infer impending changes of reactor state variables.
6. The system of claim 1 wherein at least one of the multivariable predictive optimizer controllers is non-linear.
7. The system of claim 1 wherein the system is used to control a chemical manufacturing process comprising a polyolefin reactor and an extruder, wherein the extruder is located downstream of the reactor, and wherein the extruder is production-limiting equipment.
8. The system of claim 7 wherein the reactor and the extruder are close coupled.
9. The system of claim 7 wherein the polyolefin reactor is used to manufacture a polyolefin selected from the group consisting of polymers comprising at least fifty weight percent polypropylene and polymers comprising at least fifty weight percent polyethylene.
10. A system for controlling a chemical manufacturing process having at least one chemical reactor and production limiting factor located upstream or downstream from the reactor, comprising: a first multivariable predictive optimizer controller for optimizing control of the chemical reactor; and a second multivariable predictive optimizer controller operating hierarchically above the first controller and the production limiting factor for providing integrated process control of the reactor and the production limiting equipment.
11. The system of claim 10 further including a third multivariable predictive optimizer controller operating hierarchically below the second controller for controlling the production limiting factor.
12. The system of claim 10 wherein the production limiting factor is production limiting equipment located downstream from the reactor.
13. The system of claim 12 wherein the production limiting equipment and the reactor are close coupled.
14. The system of claim 10 wherein the multivariable predictive optimizer controller employs a mathematical technique selected from the group consisting of neural networks, partial least squares, principle, component regression or first principles models to infer impending changes of reactor stats variables.
15. The system of claim 10 wherein at least one of the multivariable predictive optimizer controllers is non-linear.