Ethylene Fractionator Optimization
Enhance Ethylene Production with AI-Driven Optimization
Introducing the Ethylene Fractionator Column Optimization Solution—an AI/ML-powered platform designed to maximize ethylene product yield while minimizing ethylene slippage in the bottom ethane recycle stream. By leveraging real-time DCS data, it optimizes utility consumption and reduces ethylene vent rate. Tailored for process engineers and plant operators, this solution ensures your column runs at peak efficiency, helping you achieve higher ethylene yield, reduce losses, and unlock significant cost savings across your operations.
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Ethylene Fractionator Optimizer
Hybrid Model
Our model utilizes real-time ethane content data in ethylene and, based on the required on-spec ethylene product specifications, delivers precise operator set-points for optimizing key variables. These include:
- Column Top Pressure
- Reboiling stream flow rate
- Vent Rate
With these optimizations, the model increases ethylene product draw rates from the distillation column, ensuring consistent on-spec production while improving overall column efficiency and operational performance.
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Transform your Challenges into Opportunities
The Ethylene Fractionator 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 conversion rates. Experience increased conversion, real-time predictions of downstream Feed and product quality parameter values, and optimized hydrogen consumption, transforming your operations for enhanced efficiency and profitability!
Pain Point
Ethylene Product Loss & Heater Maintenance Issues
Benefit
Reduced Ethylene Slippage: Optimized reboiling and condensing operations push ethylene quality to spec limits, minimizing product loss.
Pain Point
Increased Operational Cost due to higher Vent and Recycle rates
Benefit
Lower Vent & Recycle Rates: Reduced ethylene venting and ethane recycle with minimal slippage.
Pain Point
Reduced Ethylene Recovery (Product-to-Feed Ratio)
Benefit
Maximized Ethylene Recovery: Optimized column operations leverage design specification margins to enhance ethylene product yield
Pain Point
High Refrigerant Consumption
Benefit
ptimized Refrigerant Use: Decreased refrigerant consumption and improved recovery through increased reboiling.
Performance Deviation Prediction
Takes the DCS and LIMS data with respect to the Ethylene Fractionator for further analysis and processing.
Key Parameter Monitoring
Checks the Ethylene Product Quality against the Design Specifications and checks for the Ethylene concentration on control Tray and Publishes an Alert run
Process and Efficiency Trends
He Alert checks if the unit is working fine (displays “Ethylene Product is on-spec”) or not and gives the necessary operator actions and upcoming events
Operational Benchmarking
Model runs and publishes the recommended values of the Operator Controlled Set points needed to achieve the lower vent rate, minimum ethylene slip and maximum on-spec Ethylene Product rates
Actionable Insights for Improvement
Comparison plot between “Current Operation” vs. “Optimized Operation“ is shown on the Dashboard
