Polymer production intelligent control system Process calculation based solution
Category:
Smart Factory Integrated Solution
Better Your Technology
Our goal:The output is increased by 3%-10%, the defective rate is reduced by 30%--50%, and the switching time of the grade is reduced by 25%-50%.
Current Situation, Problem
At present, the polymer industry is developing rapidly, with broad development prospects, and market demand is increasing year by year. In order to meet the needs of the market, it is necessary to improve product quality, reduce waste, and increase the capacity of the device. However, current polymer control methods have the following problems:
In the production control process of the polymer, the operating parameters of each grade are different, the grades are inconsistently switched, and the length of the switching is different, resulting in an increase in production waste.
In addition to the brand switching, in the normal production process, due to the instability of control, it will also cause quality problems and even waste.
Due to some limitations of the production unit itself, operators generally adopt conservative operation methods, resulting in failure to maximize production capacity.
When developing a new grade, it takes a long time to explore the control conditions of the new grade. Delayed the development time of high-grade brands, lost a good opportunity to occupy the market, and affected the economic benefits of enterprises.
The introduction of advanced process control based on process calculation can effectively solve the problems in the polymer production process.
In the production control process of the polymer, the operating parameters of each grade are different, the grades are inconsistently switched, and the length of the switching is different, resulting in an increase in production waste.
In addition to the brand switching, in the normal production process, due to the instability of control, it will also cause quality problems and even waste.
Due to some limitations of the production unit itself, operators generally adopt conservative operation methods, resulting in failure to maximize production capacity.
When developing a new grade, it takes a long time to explore the control conditions of the new grade. Delayed the development time of high-grade brands, lost a good opportunity to occupy the market, and affected the economic benefits of enterprises.
The introduction of advanced process control based on process calculation can effectively solve the problems in the polymer production process.
Bangye Technology Polymer Solutions
Advanced process control based on process calculation is currently the world's leading nonlinear model prediction technology, which can directly embed process calculation into model predictive control. The formula is the model. Modeling in this way makes the modeling process clear and easy for engineers to participate. Our solution model is highly scalable, and the new model does not require long-term exploration and can be extended directly. When the conditions change, our solution model is automatically adjusted and very easy to maintain.
Ttraditional craft
The traditional advanced polymer control method uses historical data and neural network algorithms to build mathematical models. The specific process is shown in Figure 1. The neural network model adopts black box modeling, and the historical data is directly input to obtain the model, which requires a lot of good data to generate a good model. This modeling method is time consuming and laborious, and it is difficult for factory engineers to verify the quality of the model. When the factory adds new grades or changes in working conditions, it needs to re-collect long-term data, and even need to conduct factory testing to build new models, which increases the difficulty of maintenance.
Process calculation
Advanced process control based on process calculation is currently the world's leading nonlinear model prediction technology, which can directly embed process calculation into model predictive control. The formula is the model. The so-called process calculation model uses the language of the chemical engineer (such as mass balance, heat balance, phase balance, mechanism model, dynamic model or empirical formula) to build the model. It is easy for chemical engineers to understand the principle of the model and facilitate its participation. Modeling in this way seems to face a transparent box, and the process of modeling can be seen clearly.
Typical Case
Zhejiang Bangye Technology Co., Ltd. successfully applied advanced process control technology based on process calculation to Zhenhai refining and chemical polypropylene plant, and achieved very significant results. After the Zhenhai Refining and Chemical Propylene Control Project was put into operation, the control effect is shown in the following figure: Figure 3 is the comparison of the effect of the hydrogen concentration in the ring of Zhenhai Refining and Chemical Plant before and after the application. The standard deviation after the application decreased by 62% and 66%.
Figure 3 Comparison of the effect of the hydrogen concentration of the loop before and after the application
Figure 4 shows the comparison between the gas-phase hydrogen-to-ethylene ratio of Zhenhai refining and polypropylene and the gas pressure before and after the application. The standard deviation after the application decreased by 88% and 82%, respectively.
Figure 4 Comparison of gas-phase hydrogen-to-ethylene ratio (top) and gas phase pressure (bottom) before and after application
Figure 5 is a comparison of CPK effects before and after the melt index of three grades of Zhenhai Refining & Chemical. The CPK (Complex Process Capability Index, CPK<1 is required for improvement, 1≦CPK<1.33 is standard, 1.33≦CPK) A large increase in goodness, the increase in CPK represents a decrease in the fluctuation of the melt index, while the average value of the melt index is closer to the target value of the product.
Address：19F, Building S3, HeRui Science and Technology Park, No.475, Changhe Road, BInjiang District, Hangzhou, Zhejiang, China