Challenge
beendet!

Deutsche Infineum GmbH & Co. KG

Introduction of a concept for advanced process control to increase production in a polymerisation plant

Detailed description of challenge

Current Plant Operation:

  • The EVA production involves a batch production process concerning the reaction step (polymerization) in the three high-pressure reactors.
  • The reaction is controlled via a predefined sequence chain in the control system.
  • The operator must synchronize all three process steps in time and occasionally manually control and optimize several control variables to minimize delays and waiting times of the reactions.

Target State:

  • A superior controller (Advanced Process Controller) is to take over the coordination of all control steps and control variables to ensure optimal plant operation and always maximize production utilization, i.e., to minimize waiting times.
  • This can be illustrated by assuming that the new Advanced Process Controller always represents and surpasses the best plant operator through immediate adjustments to control variables in real-time and the ability to simultaneously optimize multiple control variables and processes.
  • The overarching goal of the project is to maximize the number of batches per day and thereby increase production capacity using the Advanced Process Controller.

First initiatives within company

  • A first ideation initiative has been started.
  • Drafting of Business Case.
  • The working team has started to scout for APC-specialists with good fit to the project scope.

Need for support

  • Trigger and start feasibility study with the following scope:
    • Collection and evaluation of relevant historical process data for APC solution.
    • Evaluate a concept for pilot trials with experienced console operators at Infineum.
    • Start ideation & benchmarking for process optimization potentials (e.g. maximizing batch numbers, identifying the main controllers, major process variables)
    • Establish the basis for estimation feasibility study´s costs.
  • As follow-up project (not in scope of the ChemTelligence project):
    • Workshop with operators & feasibility study; workshop topics:
    • By how much will the value stream loss be reduced?
    • How much energy will be saved?
    • To which extend will the throughput be increased?

The challenge is over.

Applications are no longer possible.