Optimized the operation and decoking cycle of the ethylene cracking furnace. Achieved an annual revenue improvement of 50 million dollars!
"gOLEFINS" is an online monitor that accurately estimates the operational state of the furnace by acquiring information such as the outlet temperature of the reaction tube in the cracking furnace using a highly reliable model. It allows for the understanding of increased pressure loss due to coke accumulation and decreased heat transfer rates, enabling operational adjustments based on highly accurate predictions. This optimization of the operational conditions and decoking cycles of the cracking furnace has led to real examples of annual revenue increases of tens of millions of dollars. [Benefits] ■ Optimization of decoking through accurate end-of-run predictions ■ Optimization of operational margins for each cracking furnace ■ Continuous updates to the cracking furnace model through dynamic optimization of the entire cracking furnace *For more details, please refer to the materials. Feel free to contact us with any inquiries.
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basic information
<Mechanism of the Cracking Monitor> By combining PSE's dynamic state estimation technology with a reliable mathematical model, we adjust plant data and model predictions. This allows us not only to monitor the amount of coke that accumulates over time in the length direction of the coil but also to calculate accurate real-time operating values. <Advantages> The use of the gOLEFINS cracking monitor provides timely and appropriate information, such as the outlet temperature of the reaction tubes in the cracking furnace, enabling much more efficient operation of the cracking furnace compared to conventional methods. ◎ Just the improvement in ethylene yield can lead to a revenue increase of $1 million to $3 million per month for large-scale plants. *For more details, please refer to the materials. Feel free to contact us as well.
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Applications/Examples of results
For large-scale ethylene plants, the overall benefits are estimated to be between $25 million and $50 million per year.
Detailed information
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Estimated Coke Deposition Amount This is an estimate of the coke deposition amount. It allows for an accurate estimation of the distribution of deposition along the length of the reaction tube. By accurately tracking the increase in pressure loss and decrease in heat transfer rate associated with coke accumulation, it enables precise and optimal operational adjustments and planning based on high-accuracy predictions.
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Awarded the Automation & Modeling Prize for "Virtual Multi-Sensor" Our company received the Automation & Modeling Prize for "Virtual Multi-Sensor" at the International Refining and Petrochemical Conference held in Vienna, Austria in June 2017, thanks to this cracking monitor and virtual multi-sensor technology.
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Decomposition furnace yield (ethylene) The red line shows the predictions using the g┃OLEFINS cracking monitor against the plant data (black line). The predictions are close to the plant measurements.
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Maximum temperature of the reaction tube The estimated value is close to the actual value (point).
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Company information
Founded in 1997 by the gPROMS development team at Imperial College London, PSE became part of the Siemens Group in 2019 and has been providing products and services in Japan as Siemens Corporation since 2023. gPROMS features a powerful equation-based computation engine that differs from traditional simulators, allowing for seamless handling of both steady-state and dynamic simulations. This enables the effective scaling up of models adjusted with experimental data from batch processing for the design and operational optimization of continuous processing plants. With gPROMS's excellent capabilities in custom modeling, parameter estimation, and optimization, it is possible to quickly build optimal manufacturing processes, resolve issues, and achieve optimization.