Project news: PetroChina releases results of polymer process optimization

12/05/2007


Offering a rare peek behind the operating curtain, PetroChina has published detailed results of implementing an Aspen Technology control solution. The specific plant involved in the study is the Mitsui high density polyethylene unit in Daqing, China. The improvements include a combination of increased capacity, higher product quality, and lower operating costs.

PetroChina implemented AspenTech’s aspenONE advanced process control for polymers solution on the HDPE unit, and reports that it has calculated annual savings of $640,000—equivalent to $8 per ton—through increased yield and reduced usage of reactor consumables. These savings, combined with a 28% decrease in off-specification material produced during grade transitions, have provided PetroChina with a rapid return-on-investment.

“We are delighted with the performance improvements achieved using the aspenONE advanced process control solution,” says Mr. Cao Jingliang, chief engineer of the PetroChina Daqing polyolefin plants. “AspenTech’s unique control technology coupled with the domain expertise of its polymers specialists were key contributors to the success of this project. Being able to automate even the most complex of transition strategies, such as a reactor configuration change, is a significant breakthrough and has enhanced our competitive position.”

Blair Wheeler, senior VP, AspenTech, adds, “China is now a major producer and consumer of polyolefins, and PetroChina is investing in innovative technology to maintain its position as a leading player in this highly competitive marketplace. With its ability to optimize even the most complex product transitions, the advanced process control for polymers solution is delivering significant operational benefits and a fast return on investment for a rapidly growing number of polymer producers worldwide.“

The aspenONE solution formed the basis of a comprehensive optimization strategy on the 80kt/yr HDPE unit. PetroChina set specific objectives for the project:

  • Maximize production yield and production rate;

  • Stabilize reactor operation;

  • Reduce catalyst consumption;

  • Minimize venting; and,

  • Reduce the amount of off-specification product manufactured during product grade transitions.

That last item was a key requirement due to the difficulty of automating and optimizing product transitions, which the company says are typical of the Mitsui HPDE process.

PetroChina reports the following results of the program:

  • Increased production capacity by 2.9%;

  • Reduced transition off-specification material by 28%;

  • Reduced catalyst consumption by 6%;

  • Reduced hydrogen consumption by 22%; and,

  • Reduced ethylene loss by 3 kg/tPE.

Read a recent article online from Control Engineering , “Effective Process Planning and Scheduling in the Olefins Industry.”

—Edited by Peter Welander, process industries editor, PWelander@cfemedia.com ,
Control Engineering Weekly News





No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Big plans for small nuclear reactors: Simpler, safer control designs; Smarter manufacturing; Industrial cloud; Mobile HMI; Controls convergence
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.