model-based operator support for improved energy efficiency in … · 2018-11-08 · 3 na2so4...
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Model-based operator support for improved energy efficiency in viscose production
Christian Jasch, LENZING Group
Frankfurt, 18.10.2018
Results from the CoPro Lenzing use case
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- World market leader in man made cellulose fibers
- Sales: EUR 2.26 bn
- Fiber sales volumes: 1 Mio tons
- Employees: 6488
The Lenzing Group 2017
Digitized Operations Workshop Frankfurt 2018
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Na2SO4
Spinning
Recovery
Heat Recovery
Bottom tank Degassing
FilterEvaporation
ZnSO4
CS2
H2S
H2SO4
H2O
Calcination
Na2SO4*10H2O
H2O
Fiber Viscose (NaOH+CS2+Cell)
Crystallization
To maintain a certain spinbath composition and to extract the co-product Na2SO4
Digitized Operations Workshop Frankfurt 2018
The Spinbath Recovery Cycle
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The challenge with the evaporator network
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A single evaporator at Lenzing
Digitized Operations Workshop Frankfurt 2018
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EV2EV1 EV4EV3
Cycle 1
Cycle 2
Target output
2020
4242Cycle 3
1515
EV6EV5
t/h
t/h
t/h
Evaporators
⁞
…EV5
The Lenzing evaporator network- 29 different evaporators- 9 different product cycles- Target evaporation output per cycle is fixed
allocation
allocation
Digitized Operations Workshop Frankfurt 2018
The challenge with the evaporator network
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EV2EV1 EV4EV3
Cycle 1
Cycle 2
Target output
2020
4242Cycle 3
1515
EV6EV5
t/h
t/h
t/h
Evaporators
…EV5
Production constraints- Only specific combinations are possible- Each evaporator can only serve one cycle per time - Cleaning and maintenance reduce the network availability
Cleaning / Maintenance
Digitized Operations Workshop Frankfurt 2018
The challenge with the evaporator network
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EV2EV1 EV4EV3
Cycle 1
Cycle 2
Target output
2020
4242Cycle 3
1515
EV6EV5
t/h
t/h
t/h
Evaporators
…EV5
Optimization potential - Manual load allocation by operator based on experience is
complicated and time consuming - Not shifting load to more efficient evaporators can cost energy- Hundreds of various combinations possible
Goal: operation at minimum overall energy consumption
Cleaning / Maintenance
Digitized Operations Workshop Frankfurt 2018
The challenge with the evaporator network
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For our operators in the control room to find the most energy efficient load allocation for our evaporator network
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The Solution: Model-based Decision Support System (DSS)
DSS Key Features:1. Multiple data-based
evaporator regression models
2. Optimization algorithm with live connection to process data in matlab
3. HMI for Visualization and settings in OSIsoft PI
Digitized Operations Workshop Frankfurt 2018
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Evaporator modelling
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Capacity and efficiency depends on:- Cycle flowrate F- Flow temperature T
- Condenser temperature TK
- Fouling
multi-stageevaporatormulti-stageevaporator
TT
FF
Spin bath TK
Fouling
Concentrate
Data-based modelling approach- Evaporation capacity
- Specific steam consumption
- Absolute steam consumption
Data-based modelling approach- Evaporation capacity
- Specific steam consumption
- Absolute steam consumption
Digitized Operations Workshop Frankfurt 2018
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Optimization task and constraints
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Simplified formulation as MIQP:
Information and constraints from live process data- Target EC - State of every evaporator
Current load and allocation Fouling and steady state Max. EC
Information and constraints from live process data- Target EC - State of every evaporator
Current load and allocation Fouling and steady state Max. EC
Digitized Operations Workshop Frankfurt 2018
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Modelling and network optimization
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Data historian/ Process data
Decision Support Interface
Data treatment
Process information
Least-Squares Optimization
Modelstructure
Plant state
Optimization
Results
Model parameters
Fouling state
Constraints
Single run
Online analysis
Digitized Operations Workshop Frankfurt 2018
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HMI for the operators in control
Digitized Operations Workshop Frankfurt 2018
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Results so far
Advanced DSS implemented in control room August 2018
1.8 % more efficient operation
Steam savings around 1200 t/month
≈250.000 €/year savings
v2.0 update with semi automatic control currently under development
Digitized Operations Workshop Frankfurt 2018
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Thanks for your attention
Digitized Operations Workshop Frankfurt 2018
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The projects leading to this application have received funding from theEuropean Union’s Horizon 2020 research and innovation program
Christian Jasch
CoPro – LENZING Group
www.copro-project.euwww.lenzing.com