Plant-wide hierarchical optimization and control of an industrial hydrocracking process

Hydrocracking is a crucial refinery process in which heavy hydrocarbons are converted to more valuable, low-molecular weight products. Hydrocracking plants operate with large throughputs and varying feedstocks. In addition the product specifications change due to varying economic and market conditions. In such a dynamic operating environment, the potential gains of real-time optimization (RTO) and control are quite high. At the same time, real-time optimization of hydrocracking plants is a challenging task. A complex network of reactions, which are difficult to characterize, takes place in the hydrocracker. The reactor effluent affects the operation of the fractionator downstream and the properties of the final products. In this paper, a lumped first-principles reactor model and an empirical fractionation model are used to predict the product distribution and properties on-line. Both models have been built and validated using industrial data. A cascaded model predictive control (MPC) structure is developed in order to operate both the reactor and fractionation column at maximum profit. In this cascade structure, reactor and fractionation units are controlled by local decentralized MPC controllers whose set-points are manipulated by a supervisory MPC controller. The coordinating action of the supervisory MPC controller accomplishes the transition between different optimum operating conditions and helps to reject disturbances without violating any constraints. Simulations illustrate the applicability of the proposed method on the industrial process. (C) 2013 Elsevier Ltd. All rights reserved.