CIMdata PLM Industry Summary Online Archive
30 October 2007
Implementation Investments
aspenONE Advanced Process Control for Polymers Solution Delivers Major Performance Improvements at PetroChina Polyethylene Plant
Aspen Technology, Inc . announced that PetroChina has achieved significant financial and operational benefits from implementing AspenTech's aspenONE Advanced Process Control for Polymers solution on its Mitsui high density polyethylene (HDPE) unit in Daqing, China. The solution has delivered annual savings of $640,000 - equivalent to $8 per tonne - through increased yield and reduced usage of key reactor consumables. These savings, combined with a 28 percent 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," said 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."
The aspenONE solution formed the basis of a comprehensive optimization strategy on the 80kt/yr HDPE unit. PetroChina's project objectives were to maximize production yield and production rate, stabilize the reactor operation, reduce catalyst consumption, minimize venting and reduce the amount of off-specification product manufactured during product grade transitions. A key requirement was to automate and optimize the challenging product transitions which are typical of the Mitsui HPDE process.
The solution was implemented by advanced process control consultants from AspenTech's Professional Services group. Following completion of the project, PetroChina Daqing has realized significant performance benefits including successfully optimizing transitions involving a parallel-to-series reactor configuration change. The measured benefits include:
• Increased production capacity by 2.9 percent
• Reduced transition off-specification material by 28 percent
• Reduced catalyst consumption by 6 percent
• Reduced hydrogen consumption by 22 percent
• Reduced ethylene loss by 3kg/tPE
"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," said Blair Wheeler, Senior Vice President at AspenTech. "With its unique ability to optimize even the most complex product transitions, the aspenONE 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."
PetroChina deployed AspenTech's aspenONE for Polymers advanced process control suite which includes a full nonlinear model predictive controller, comprehensive recipe management and full process sequencing capability. The controller remains on-line at all times, delivering fully automated and optimized product transitions.
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