Caramel Extract Production Improvement

Caramel Extract Production Improvement

Juice Concentration Plant – Control Loops Tuning

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Juice Concentration Plant – Control Loops Tuning

Fuel Gas HDS Plant – Control Loops Tuning

Fuel Gas HDS Plant – Control Loops Tuning

The Fuel Gas HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Benefits:
Significant improvements were observed in the Standard Deviation of the control loops (>12 fold) and in the control valve travel (>175 fold!).

Economic indexes were not calculated.

Kerosene HDS Plant – Control Loops Tuning

Kerosene HDS Plant – Control Loops Tuning

The Kerosene HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Among other things:

  • Top Reflux valve was identified as “Sticky” and had been mended.
  • Instrumentation ranges changed to give true and effective ranges of operation.
  • Change logic of Reflux operation to “Reflux Ratio” to better follow changes in plants throughput.

Gasoline HDS Plant – Control Loops Tuning

Gasoline HDS Plant – Control Loops Tuning

The Gasoline HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Economical Benefits:
The improvement of temperature control in the column TOP TEMP only, brought savings of nearly 1 Million $/Year by reducing product RVP and savings in steam due to better temperature control and reduction in the reflux.

Project Documentation

Gasoline HDS Plant – Control Loops Tuning

Gasoline HDS Tuning Report

Methanol – Fuel Oil Blending System

Methanol – Fuel Oil Blending System

Design of the system to enable Fuel Oil users switch to more environmental friendly and more economical energy source.
Number of approached were offered.

Client decided to abort project due to high cost of implementation.

Blending device was designed by Mr. David Livschitz.

Steam Saving in a Turbo Compressor Operation

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Steam Saving in a Turbo Compressor Operation

In the process of performance checking for a refinery we came across a turbo compressor that, apparently, operated in a very un economically way.

Careful checking was needed to assure our first observation until the decision was taken to change the machine setting which was made when the plant was commissioned by the vendor rep. some years before.

Keeping the same rate of production, the steam consumption dropped to less than 3/4 from is previous one and the machine speed dropped more than 5%.

The immediate savings from steam only, at the project time, estimated in more than 1.5 MM$/Year.

Sulphuric Acid Process and Process Control Improvements

Sulphuric Acid Process and Process Control Improvements

Customer is operating a Sulphuric Acid plant.

Instability in the waste heat recovery – Steam production  brought the need to stabilize the process and let the system operate more efficiently.

Using the existing process instrumentation, changing some of the configurations (Adding some cascade levels and feed forward compensations) made the plant manager happy.

 

 

Stabilize Cooling Water Make-Up

Stabilize Cooling Water Make-Up

Customer is operating a steam generation plant.

Instability in the make-up water streams reduces the overall plant throughput.

Based on the existing instrumentation, addition of one controller – the performance of the existing controllers was orchestrated to give smooth operation to the whole steam production operation.

 

 

Reduce Steam Blow Off

Reduce Steam Blow Off

Customer is operating a complex where some of its plants produce HP steam. The steam is used in the other complex’ plants and the excess is used to generate electricity with the option to use the steam down to condensation.

The control system was not designed to properly deal with surplus steam and the pressure at the “users” distribution spider exceeded the safety set. Large quantities of steam were blown off to protect the system which was also accompanied by noise nuisance.

Taking into considerations the actual pressure at the “Users”, Controlling the condensing stage of the turbines – reduced the actual blowing off to cases where “real” problems accrue.

Effluent Treatment Plant Stage 1

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Effluent Treatment Plant Stage 1

Client has multi sources of effluents some extremely Acidic while others very Basic.

Environmental permission strict the pH range and the solids content (Turbidity) of the effluent stream to local water body

Together with the client engineers we were able to bring stage 1 of the effluent treatment plant to perform according to the requirements.

Green Phosphoric Acid – Process and Process Control

Green Phosphoric Acid – Process and Process Control

Our main contribution to the plant Process and Process Control were around the concentration process.

Thorough analysis of the process and the dynamics involved led to the development of “Operations Envelop”. The acid concentration has a cycle influenced by the constant fouling of all units with heavy deposits of gypsum which changes the system dynamics continuously. Innovative implementation of the “Operations Envelop” concept enabled significant improvement in plant performance in terms of Continuous operation, Rate of Production, Energy Efficiency.

Polpan / Merpan Process Stabilizing

Polpan / Merpan Process Stabilizing

Unit 80 is a plant with set chemistry and well defined actions to be taken. After studying the process we were able to offer automation of these while maintaining the ability of the operators to override all decisions.

Main topics of the project:

  • Automate the process of starting the process.
  • Enabling the operator to keep the process exactly where it should be.
  • Operator can overrule the system.
  • Can accommodate higher levels of control with no changes.

Deaerator Process Control

Deaerator Process Control

Client was unable to operate the DeAerator to get low enough dissolved Oxygen content.

System analysis revealed:

  • Errors in the mechanical design (Barometric Leg)
  • Physical controller placement in wrong locations.

After fixing these, an unique “rescue” procedure was designed and implemented.

System has been working since – No Problems.

Drying Furnaces Temperature control improvements

Drying Furnaces Temperature control improvements

Drying furnaces has special features that has to be taken when coming to deal with its performaces in general and specifically with its thermal, Fuel and product quality (dryness).

We participated in few of this kind for different customers:

Advanced Temperature Control of fertilizers granulation plant – fuel oil firing.

Product (fertilizer) dryer temperature and load control, changing from fuel oil to Natural Gas firing

Related Projects

Potash Filtering

Potash Filtering

The Potash Filtering section is dealing with very large quantities of slurry and the quality of this section operation has significant impact on the economics of the whole production.
This comes to light in the production rate, quality of product as well as the rate of breakdowns in the process.

Conducting careful process analysis, together with the client engineers and the production team brought number of improvements such as using unusual means to control process parameters, as well as some inovative process control techniques implementations.

Results:

  • Better stability in the filtering process by reducing variability in cake thickness.
  • Higher production per filter unit.
  • Significant saving in water and electricity consumptions.
  • Reduce number of filter units in operation.

Color Dosing in Potash Granulation Plant

Color Dosing in Potash Granulation Plant

Potash fertilizers are expected to be red to help the user to make out these.

The dosing of color onto the product was not accurate enough which caused the product not to confirm with the spec, Different types of red showed up, customer unsatisfaction, over usage of expensive coloring material.

Following our work – with the customer:

  • The control of the dye improved and is done automatic in RATIO to the quantity of material (Potash) in processs, rather then manually as it used to be.
  • Control system was improved and was tuned to the proper range of action.
  • Inherent mechanical problems were identified and were addressed by maintenance.

pH Control

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pH Control

pH control is considered by the majority of Process Control Experts as the most difficult one topic control job.

Careful study the unique situation in each project together with cautious implementation of advance process control techniques brings excellent results to the full satisfaction of the projects’ goals.

pH control is found in Processes, in effluent treatment plants in scrubbers and more.

Wet Scrubber Process Control

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Wet Scrubber Process Control

Wet Scrubbing plays important role in Gas Cleaning operations.

As such it is widely used where gases that are released to the atmosphere have to meet the environment standards.

In the DSW case we had to take care of the brine collected at the system bottom to meet the required pH values as well to be suitable to be released to the sewage.

In refining projects, sour gases were treated to reduce the sulfur content down to acceptable levels.

Cristalizers Density Control stabilysing

Cristalizers Density Control stabilysing

In the process of Potash (KCl) production Carnallite [KMgCl3·6(H2O)] and water are fed into crystallizers. Instability in the Carnallite rate of feed requires the water to follow and maintain the proper ratio between these two streams.

Examining the system and instrumentation we found some mistakes in the control strategy implementation.

We redesigned the control strategy.

Number of readings outside the required values dropped dramatically.

Stage II of this project brought significant savings in water consumption and reduced the Potash lost considerably.

Process Control Improvement in Potash Granulation Unit

Process Control Improvement in Potash Granulation Unit

To unify the granulation process product it was required to balance the feed rate from all raw material sources.

The plant was not designed to allow direct controlling of these streams. With the aid of the plant staff it was made possible.

Significant improvements were observed.

 

Potash Hot Extraction Stabilizing

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Potash Hot extraction stabilizing

Instability in “Hot Extraction” operation cause (among other things):

  • Instability in all Tanks Levels and hence reduction of production rate.
  • Bottle Necks: production means are not equally loaded which causes production losses even with no mechanical failures.

With the expected new Drying Furnace and new Sivanite Filters situation is expected to worsen.

Checking all parts of the process enabled us to improve the control performance and as a result to that – the stability both in feed rates and in tanks level.

Feed Rate to section E
Before and After adjusting and tuning.

604E Level
Before and After adjusting and tuning.

(Click Trends to enlarge)

Solvents Recovery & Azeotropic Distillation

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Solvents Recovery & Azeotropic Distillation

Client is operating multi purpose set of Distillation columns in continues and batch modes, according to the needs and the changing conditions.

To make out the reasons for unsatisfactory results we carried out a survey that reveals the points needed attention.

Following the survey, a workshop in DISTILLATION was given to the operating crew which brought the understanding and the willingness of the team to new higher level.