Physics Meets AI: Hybrid Models for Optimization.
CDU/VDU Optimization ensures your unit runs at peak efficiency, boosting side stream yields, reducing losses, and unlocking significant cost savings across your operations. Our hybrid AI modelling running at the core of this optimizer is designed to maximize the flow rates of Side Stream 1, Side Stream 2, and SPVGO by optimizing the movement of the Vacuum Tower Bottom (VTB) product into the middle section of the column. By leveraging real-time DCS data, it ensures that viscosity, flash point, and VTB penetration number remain within specification limits.
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CDU & VDU Predictor and Optimizer
Hybrid Model
Our model leverages real-time, high-frequency predictions of viscosity, flash point, and VTB pen test values to deliver precise operator set-points for optimizing key variables. These include:
- Stripping steam flow rate
- Pump around flow rates and temperatures
- Reflux flows
- Draw rates with information on draw temperatures
Additionally, it provides optimized values for viscosity, flash point, and VTB pen test, ensuring consistent on-spec product quality while improving overall column efficiency and performance.
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Transform your Challenges into Opportunities
The CDU/VDU Optimization Model aims to achieve maximum conversion by utilizing DCS and Feed Quality data in real time. The AI/ML platform delivers essential DCS set points and recommendations for plant operators and process engineers, facilitating the achievement of desired product rates.
Experience increased recovery, real-time predictions of downstream product quality parameter values, transforming your operations for enhanced efficiency and profitability!
Pain Point
Crude Blend Uncertainty
Benefit
Crude Mix Clarity: Our crude mix model accurately determines the processed blend by integrating analyzer API values with user-provided crude mix data.
Pain Point
Unstable Operation During Crude Changeovers
Benefit
Dynamic Crude Optimization: The model adapts to varying crude blends, providing optimized set points for each combination, ensuring smooth operations and stability.
Pain Point
Loss of High-Value Streams
Benefit
Maximized Product Value: The model optimizes VTB blending with higher-value middle streams, keeping all quality parameters within spec limits to maximize profitability.
Pain Point
Low Frequency Sampling of side streams and Vacuum Tower Bottom
Benefit
Real-Time Quality Predictions: Our model delivers high-frequency, real-time predictions of key quality metrics, enabling faster, more accurate control.
Performance Metrics
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Performance Deviation Prediction
Operator enters the estimated crude mix on dashboard and presses run
Key Parameter Monitoring
The Crude Mix model calculates the correct crude mix and displays the results on the dashboard
Process and Efficiency Trends
Every 2 hours, the prediction model runs to predict the Viscosity, Flash point and VTB Pen test values at operating conditions
Operational Benchmarking
Using the Corrected Crude mix and the predicted Product Quality parameters, the Optimizer model runs and gives out the table of actual and optimized / recommended values is populated
Actionable Insights for Improvement
Comparison plot between “Current Operation” vs. “Optimized Operation“ is shown on the Dashboard
