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 rates. 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 setpoints 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.
Transform your Challenges into Opportunities
The Ethylene Fractionator Optimization Model is designed to maximize conversion by leveraging real-time DCS and feed quality data. This AI/ML-powered platform delivers essential DCS setpoints and actionable recommendations for plant operators and process engineers, enabling the achievement of target conversion rates.
Experience increased conversion, real-time predictions of downstream feed and product quality parameters, and optimized hydrogen consumption—transforming your operations for greater 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
Optimized 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. Checks for the Ethylene concentration on the Control Tray and publishes an Alert Run
Process and Efficiency Trends
The alert indicates if the unit is operating normally (displays “Ethylene Product is on-spec”) or not, and provides recommended operator actions and upcoming event forecasts.
Operational Benchmarking
The model runs and publishes recommended values for operator-controlled setpoints to achieve lower vent rates, minimize ethylene slip, and maximize on-spec ethylene product rates.
Actionable Insights for Improvement
Displays a comparison plot of Current Operation vs. Optimized Operation on the dashboard to highlight potential areas for improvement.
