System, method, and recording medium having recorded thereon program

Patent metadata

Field	Value
Publication number	US-12306619-B2
Application number	US-202217692115-A
Country	US
Kind code	B2
Filing date	Mar 10, 2022
Priority date	Sep 30, 2019
Publication date	May 20, 2025
Grant date	May 20, 2025

Abstract

Provided is a system including a planning section that generates a production plan for a production site, using a planning model; a simulating section that simulates operation of at least a portion of the production site, based on a simulation model of the at least a portion of the production site; a monitoring section that monitors actual operation of the at least a portion of the production site; a calibrating section that calibrates the simulation model, based on a difference between the simulated operation and the actual operation; and a control section that controls the at least a portion of the production site, based on a simulation result obtained by simulating the operation of the at least a portion of the production site in accordance with the production plan, using the simulation model that has been calibrated.

First claim

What is claimed is:

1. A control system for controlling a production site configured to produce one or more production site outputs selected from one or more of products, semi-finished products, and intermediates, the control system comprising:
at least a portion of the production site that includes at least one process unit; and
one or more computers executing one or more programs that cause the one or more computers to provide functioning sections comprising:
a planning section that generates a production plan for the production site and schedule information corresponding to the production plan, using a planning model;
an actual operation information acquiring section acquires actual operation information, obtained when the production site actually operates, via a network;
a simulating section that simulates operation of the at least a portion of the production site based on a simulation model of the at least a portion of the production site, the simulating section acquires site information relating to the production site and the schedule information corresponding to the production plan supplied by the planning section, the simulating section uses the site information to simulate the operation of the at least a portion of the production site occurring in a case where the operation of the at least a portion of the production site is performed according to the schedule information and generate a simulation result, and the simulating section outputs the simulation result for the at least a portion of the production site;
a monitoring section that monitors actual operation of the at least a portion of the production site using the actual operation information supplied by the actual operation information acquiring section;
a calibrating section that calibrates the simulation model, based on a difference between the simulated operation and the actual operation, to generate a simulation model that has been calibrated; and
a control section that controls the at least a portion of the production site based on the simulation result obtained from the simulating section,
wherein the simulation result outputted by the simulating section includes information such as targets for a production amount, stream properties, and optimal operating conditions for the at least a portion of the production site, wherein the one or more computers executing the one or more programs are configured to provide for the simulating section to supply the simulation result, which includes the targets for the production amount, the stream properties, and the optimal operating conditions for the at least a portion of the production site, to the monitoring section and the control section,
wherein the monitoring section is configured to compare the simulation result supplied from the simulating section and the actual operation information supplied from the actual operation information acquiring section, and if a difference between the simulation result and the actual operation information exceeds a predetermined threshold value, the monitoring section signals the calibrating section to calibrate the simulation model,
wherein the simulation model used by the simulating section to generate the simulation result is the simulation model that has been calibrated in a case where the calibrating section has generated the simulation model that has been calibrated, and
wherein the control section controls the at least a portion of the production site by using the simulation result to set one or more targets for the production amount, the stream properties and the optimal operating conditions for the at least a portion of the production site, which are used by the control section to automatically control the at least one process unit using one of feedback control and feedforward control.

2. The system according to claim 1 , wherein
the production site includes a refinery that produces a plurality of petroleum products by refining crude oil.

3. The system according to claim 2 , wherein
the at least a portion of the production site includes at least one of a crude distillation unit, vacuum distillation unit, naphtha hydrotreating unit, catalytic reforming unit, benzene extraction unit, kerosene hydrotreating unit, diesel desulfurization unit, heavy oil desulfurization unit, fluid catalytic cracking unit, FCC gasoline desulfurization unit, thermal cracking unit, hydrocracker unit, or asphalt production unit.

4. The system according to claim 3 , wherein
the control section controls at least one of a reactor temperature, distillation cut temperature, furnace outlet temperature, stripping steam ratio, reflux ratio, reboiler duty or pump around heat removal rate.

5. The system according to claim 1 , wherein
the at least a portion of the production site is one process unit at the production site.

6. The system according to claim 2 , wherein
the at least a portion of the production site is one process unit at the production site.

7. The system according to claim 3 , wherein
the at least a portion of the production site is one process unit at the production site.

8. The system according to claim 1 , wherein
the at least a portion of the production site is a group of a plurality of process units at the production site.

9. The system according to claim 2 , wherein
the at least a portion of the production site is a group of a plurality of process units at the production site.

10. The system according to claim 3 , wherein
the at least a portion of the production site is a group of a plurality of process units at the production site.

11. The system according to claim 8 , wherein
the control section selects a set of control parameters that realizes a simulation result that maximizes gross profit, from among a plurality of simulation results obtained by simulating operation of the at least a portion of the production site a plurality of times using different sets of control parameters.

12. The system according to claim 1 , wherein
the simulation model is a steady state model.

13. The system according to claim 2 , wherein
the simulation model is a steady state model.

14. The system according to claim 3 , wherein
the simulation model is a steady state model.

15. The system according to claim 1 , wherein
the planning model is a linear programming model.

16. The system according to claim 2 , wherein
the planning model is a linear programming model.

17. A method comprising:
generating a production plan for a production site and schedule information corresponding to the production plan, using a planning model, using one or more computers;
acquiring actual operation information, obtained when the production site actually operates, via a network;
simulating operation of at least a portion of the production site, based on a simulation model of the at least a portion of the production site, using the one or more computers, wherein simulating operation of at least a portion of the production site includes acquiring site information relating to the production site and the schedule information corresponding to the production plan, using the acquired site information to simulate the operation of the at least a portion of the production site occurring in a case where the operation of the at least a portion of the production site is performed according to the schedule information, generating a simulation result, and outputting the simulation result for the at least a portion of the production site;
monitoring actual operation of the at least a portion of the production site using the one or more computers and t

Assignees

• Yokogawa Electric Corp

Inventors

• Naito Takashi
• Kennedy Paul

Classifications

• G06Q50/04

  Manufacturing · CPC title

• G06Q10/0637

  Strategic management or analysis, e.g. setting a goal or target of an organisation; Planning actions based on goals; Analysis or evaluation of effectiveness of goals · CPC title

• G05B2219/32385

  What is simulated, manufacturing process and compare results with real process · CPC title

• C10G2400/02

  Gasoline · CPC title

• C10G45/72 Primary

  Controlling or regulating · CPC title