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





The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Doubling down on digital manufacturing; Data driving predictive maintenance; Electric motors and generators; Rewarding operational improvement
2017 Lubrication Guide; Software tools; Microgrids and energy strategies; Use robots effectively
Prescriptive maintenance; Hannover Messe 2017 recap; Reduce welding errors
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Research team developing Tesla coil designs; Implementing wireless process sensing
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me