Harnessing machine learning and data analytics for a real time predictive model for a FCC pre-treatment unit

Information

  • Patent Grant
  • 11676061
  • Patent Number
    11,676,061
  • Date Filed
    Wednesday, October 3, 2018
    5 years ago
  • Date Issued
    Tuesday, June 13, 2023
    11 months ago
Abstract
This disclosure provides an apparatus and method for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit. The method includes collecting operating parameters of a pre-treatment unit and fluid catalytic cracking (FCC) unit; evaluating an independent variable of the operating parameters; and adjusting an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit.
Description
TECHNICAL FIELD

This disclosure relates generally to industrial process control and automation systems and other systems using fluidized catalytic cracking (FCC) pre-treatment units. More specifically, this disclosure relates to an apparatus and method for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit.


BACKGROUND

Industrial process control and automation systems are often used to automate large and complex industrial processes. These types of control and automation systems routinely include process controllers and field devices like sensors and actuators. Some of the process controllers typically receive measurements from the sensors and generate control signals for the actuators.


Model-based industrial process controllers are one type of process controller routinely used to control the operations of industrial processes. Model-based process controllers typically use one or more models to mathematically represent how one or more properties within an industrial process respond to changes made to the industrial process. Model-based controllers typically depend on having accurate models of a process's behavior in order to perform well and effectively control the process. As conditions change in the process, a controller's models typically need to be updated.


SUMMARY

This disclosure provides an apparatus and method for harnessing machine learning and data analytics for a real-time predictive model for a fluidized catalytic cracking (FCC) pre-treatment unit.


In a first embodiment, a method provides for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit. The method includes collecting operating parameters of a pre-treatment unit and FCC unit; evaluating an independent variable of the operating parameters; and adjusting an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit.


In a second embodiment, an apparatus provides for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit. The apparatus includes at least one memory and at least one processor operatively coupled to the at least one memory. The at least one processor collects operating parameters of a pre-treatment unit and FCC unit; evaluates an independent variable of the operating parameters; and adjusts an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit.


In a third embodiment, a non-transitory computer readable medium provides for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit. The non-transitory machine-readable medium is encoded with executable instructions that, when executed, cause one or more processors to collect operating parameters of a pre-treatment unit and FCC unit; evaluate an independent variable of the operating parameters; and adjust an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit.


Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.





BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:



FIG. 1 illustrates an example industrial process control and automation system according to this disclosure;



FIG. 2 illustrates an example device for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit of model-based industrial process controllers according to this disclosure;



FIG. 3 illustrates an example schematic for a FCC pre-treatment unit of model-based industrial process controllers according to this disclosure; and



FIG. 4 illustrates an example process for a FCC pre-treatment unit of model-based industrial process controllers according to this disclosure.





DETAILED DESCRIPTION


FIGS. 1-4, discussed below, and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the invention may be implemented in any type of suitably arranged device or system.


Diesel and gasoline specifications require the reduction of sulfur to very low concentrations. The fluid catalytic cracking (FCC) unit is a major source of gasoline in a FCC refinery. A FCC feed pre-treatment operation, placed upstream of the FCC unit, improves the performance of the FCC unit and is an excellent way of meeting the required sulfur levels in gasoline. The degree of desulphurization in a FCC pre-treatment unit is observed by varying the temperature of the reactor, which is controlled by upstream heater firing. However, the FCC pre-treatment reactor temperature variation based on a downstream FCC unit gasoline product sulfur level is currently not available.


This disclosure applies a predictive model by harnessing data analytics and machine learning concepts with real time operating data to vary the pre-treatment reactor temperature with product sulfur level/specification. The disclosure describes controlling the FCC pre-treatment reactor temperature by using FCC gasoline product sulfur levels with the use of a real time algorithm, and not within the unit. This disclosure also describes predicting the FCC gasoline product sulfur level based on FCC pre-treatment feed sulfur levels by the use of a model algorithm built using real time data.



FIG. 1 illustrates an example industrial process control and automation system 100 according to this disclosure. As shown in FIG. 1, the system 100 includes various components that facilitate production or processing of at least one product or other material. For instance, the system 100 can be used to facilitate control over components in one or multiple industrial plants. Each plant represents one or more processing facilities (or one or more portions thereof), such as one or more manufacturing facilities for producing at least one product or other material. In general, each plant may implement one or more industrial processes and can individually or collectively be referred to as a process system. A process system generally represents any system or portion thereof configured to process one or more products or other materials in some manner.


In FIG. 1, the system 100 includes one or more sensors 102a and one or more actuators 102b. The sensors 102a and actuators 102b represent components in a process system that may perform any of a wide variety of functions. For example, the sensors 102a could measure a wide variety of characteristics in the process system, such as flow, pressure, or temperature. Also, the actuators 102b could alter a wide variety of characteristics in the process system, such as valve openings. Each of the sensors 102a includes any suitable structure for measuring one or more characteristics in a process system. Each of the actuators 102b includes any suitable structure for operating on or affecting one or more conditions in a process system.


At least one network 104 is coupled to the sensors 102a and actuators 102b. The network 104 facilitates interaction with the sensors 102a and actuators 102b. For example, the network 104 could transport measurement data from the sensors 102a and provide control signals to the actuators 102b. The network 104 could represent any suitable network or combination of networks. As particular examples, the network 104 could represent at least one Ethernet network (such as one supporting a FOUNDATION FIELDBUS protocol), electrical signal network (such as a HART network), pneumatic control signal network, or any other or additional type(s) of network(s).


The system 100 also includes various controllers 106. The controllers 106 can be used in the system 100 to perform various functions in order to control one or more industrial processes. For example, a first set of controllers 106 may use measurements from one or more sensors 102a to control the operation of one or more actuators 102b. A second set of controllers 106 could be used to optimize the control logic or other operations performed by the first set of controllers. A third set of controllers 106 could be used to perform additional functions. The controllers 106 could therefore support a combination of approaches, such as regulatory control, advanced regulatory control, supervisory control, and advanced process control.


Each controller 106 includes any suitable structure for controlling one or more aspects of an industrial process. At least some of the controllers 106 could, for example, represent proportional-integral-derivative (PID) controllers or multivariable controllers, such as controllers implementing model predictive control (MPC) or other advanced predictive control (APC). As a particular example, each controller 106 could represent a computing device running a real-time operating system, a WINDOWS operating system, or other operating system.


At least one network 108 couples the controllers 106 and other devices in the system 100. The network 108 facilitates the transport of information between components. The network 108 could represent any suitable network or combination of networks. As particular examples, the network 108 could represent at least one Ethernet network.


Operator access to and interaction with the controllers 106 and other components of the system 100 can occur via various operator consoles 110. Each operator console 110 could be used to provide information to an operator and receive information from an operator. For example, each operator console 110 could provide information identifying a current state of an industrial process to the operator, such as values of various process variables and warnings, alarms, or other states associated with the industrial process. Each operator console 110 could also receive information affecting how the industrial process is controlled, such as by receiving setpoints or control modes for process variables controlled by the controllers 106 or other information that alters or affects how the controllers 106 control the industrial process. Each operator console 110 includes any suitable structure for displaying information to and interacting with an operator. For example, each operator console 110 could represent a computing device running a WINDOWS operating system or other operating system.


Multiple operator consoles 110 can be grouped together and used in one or more control rooms 112. Each control room 112 could include any number of operator consoles 110 in any suitable arrangement. In some embodiments, multiple control rooms 112 can be used to control an industrial plant, such as when each control room 112 contains operator consoles 110 used to manage a discrete part of the industrial plant.


The control and automation system 100 here also includes at least one historian 114 and one or more servers 116. The historian 114 represents a component that stores various information about the system 100. The historian 114 could, for instance, store information that is generated by the various controllers 106 during the control of one or more industrial processes. The historian 114 includes any suitable structure for storing and facilitating retrieval of information. Although shown as a single component here, the historian 114 could be located elsewhere in the system 100, or multiple historians could be distributed in different locations in the system 100.


Each server 116 denotes a computing device that executes applications for users of the operator consoles 110 or other applications. The applications could be used to support various functions for the operator consoles 110, the controllers 106, or other components of the system 100. Each server 116 could represent a computing device running a WINDOWS operating system or other operating system. Note that while shown as being local within the control and automation system 100, the functionality of the server 116 could be remote from the control and automation system 100. For instance, the functionality of the server 116 could be implemented in a computing cloud 118 or a remote server communicatively coupled to the control and automation system 100 via a gateway 120.


At least one component of the system 100 could support a mechanism for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit. For example, this functionality could be implemented in an operator console 110, a server 116, or a computing cloud 118 or remote server.


Although FIG. 1 illustrates one example of an industrial process control and automation system 100, various changes may be made to FIG. 1. For example, the system 100 could include any number of sensors, actuators, controllers, networks, operator consoles, control rooms, historians, servers, and other components. Also, the makeup and arrangement of the system 100 in FIG. 1 is for illustration only. Components could be added, omitted, combined, further subdivided, or placed in any other suitable configuration according to particular needs. Further, particular functions have been described as being performed by particular components of the system 100. This is for illustration only. In general, control and automation systems are highly configurable and can be configured in any suitable manner according to particular needs. In addition, FIG. 1 illustrates one example operational environment where harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit of model-based industrial process controllers can be used. This functionality can be used in any other suitable system.



FIG. 2 illustrates an example device 200 for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit of model-based industrial process controllers according to this disclosure. The device 200 could, for example, denote an operator console 110, server 116, or device used in the computing cloud 118 described above with respect to FIG. 1. However, the device 200 could be used in any other suitable system.


As shown in FIG. 2, the device 200 includes at least one processor 202, at least one storage device 204, at least one communications unit 206, and at least one input/output (I/O) unit 208. Each processor 202 can execute instructions, such as those that may be loaded into a memory 210. The instructions could harness machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit of model-based industrial process controllers. Each processor 202 denotes any suitable processing device, such as one or more microprocessors, microcontrollers, digital signal processors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or discrete circuitry.


The memory 210 and a persistent storage 212 are examples of storage devices 204, which represent any structure(s) capable of storing and facilitating retrieval of information (such as data, program code, and/or other suitable information on a temporary or permanent basis). The memory 210 may represent a random access memory or any other suitable volatile or non-volatile storage device(s). The persistent storage 212 may contain one or more components or devices supporting longer-term storage of data, such as a read only memory, hard drive, Flash memory, or optical disc. The persistent storage 212 could store operating parameters 214, independent variables 216, real-time models 218, and specifications 220.


The communications unit 206 supports communications with other systems or devices. For example, the communications unit 206 could include a network interface card or a wireless transceiver facilitating communications over a wired or wireless network. The communications unit 206 may support communications through any suitable physical or wireless communication link(s).


The I/O unit 208 allows for input and output of data. For example, the I/O unit 208 may provide a connection for user input through a keyboard, mouse, keypad, touchscreen, or other suitable input device. The I/O unit 208 may also send output to a display, printer, or other suitable output device.


Although FIG. 2 illustrates one example of a device 200 for harnessing machine learning and data analytics for a real-time predictive model for a FCC pre-treatment unit of model-based industrial process controllers, various changes may be made to FIG. 2. For example, components could be added, omitted, combined, further subdivided, or placed in any other suitable configuration according to particular needs. Also, computing devices can come in a wide variety of configurations, and FIG. 2 does not limit this disclosure to any particular configuration of computing device.



FIG. 3 illustrates an example schematic for a FCC system 300 with a FCC pre-treatment unit 305 of model-based industrial process controllers according to this disclosure. The embodiment of the FCC system 300 illustrated in FIG. 3 is for illustration only. FIG. 3 does not limit the scope of this disclosure to any particular implementation of an FCC system.


The FCC system 300 receives feed 301 and furnace fuel 302 and outputs gasoline product 303. The FCC system 300 includes an FCC pre-treatment unit 305, an FCC unit 310, a sulfur sensor 315, an operating parameter controller 320, a real-time model algorithm controller 325, a split controller 330, a boiler 335, a boiler input valve 340, a heat exchanger 345, a heat exchanger bypass valve 350, a boiler temperature controller 355 and a reactor temperature controller 360. The FCC system 300 receives heavy hydrocarbons (feed 301) and through the cracking process produce lighter products that are more valuable (gasoline products 303). The controllers described herein can be implemented as processors.


The FCC pre-treatment unit 305 is upstream before the FCC unit 310 and after the boiler 335. The FCC pre-treatment unit 305 provides a level of desulphurization based on a input temperature of the feed 301 output from the boiler 335. The FCC pre-treatment unit can include a reactor or a fractionator.


The FCC unit 310 performs fluid catalytic cracking (FCC). In the FCC process, the feed 301 is heated to a high temperature and pressurized to a moderate pressure for the FCC unit 310 and brought into contact with a catalyst. Vapor is collected when the catalysts break down the long-chain molecules of the feed 301.


The sulfur sensor 315 is located downstream of the FCC unit 310. The sulfur sensor determines an amount or percentage of sulfur that is contained within the gasoline product 303. The sulfur sensor 315 transmits the sulfur level to the real-time model algorithm controller 325


The operating parameter controller 320 receives the operating parameters of the FCC pre-treatment unit 305. The operating parameter controller 320 uses the operating parameters to estimate a sulfur level of the gasoline product 303. The estimated sulfur level is then sent to the real-time model algorithm with the operating parameters of the FCC pre-treatment unit 305


The real-time model algorithm controller 325 receives the operating parameters and the estimated sulfur level from the operating parameter controller 320 and the actual sulfur level. The algorithm controller 325 processes the parameters, estimated sulfur level and actual sulfur level to determine the operating parameters of the boiler input valve 340, the heat exchanger bypass valve 350, the boiler temperature controller 355 and the reactor temperature controller 360. The algorithm controller 325 transmits the operating parameters to the split controller 330.


The split controller 330 operates the bypass valve 350, the boiler temperature controller 355, the boiler input valve 340, and the reactor temperature controller 360 according to the output of the real-time model algorithm controller 325. The split controller 330 receives the operating parameters from the algorithm controller 325 and determines which component of the FCC system is controlled by each operating parameter. The split controller 330 transmits the respective operating parameters to each of the bypass valve 350, the boiler temperature controller 355, the boiler input valve 340, and the reactor temperature controller 360.


The boiler 335 receives the feed 301 after the heat exchanger 345 and bypass valve 350 and receives oil fuel (FO) or gas fuel (FG) through the boiler input valve 340. The boiler 335 is controlled by the boiler temperature controller 355. The temperature is based on the algorithm controller 325 determining an optimal temperature or temperature adjustment for reducing the sulfur level in the gasoline product 303.


The boiler input valve 340 controls the amount of fuel 302 that is received by the boiler 335. The boiler input valve 340 is controlled by the operating parameters determined by the algorithm controller 325.


The heat exchanger 345 adjusts the temperature of the feed before the boiler 335. The heat exchanger 345 receives a portion of the feed 301. The portion could be an entire portion or no portion. The heat exchanger 345 outputs the treated feed 301 to the boiler 335.


The heat exchanger bypass valve 350 controls the amount of the feed 301 that passes through the heat exchanger 345. The bypass valve 350 can allow a remaining portion of the feed to flow to the boiler 335 without passing through the heat exchanger 345. The output of the bypass valve 350 can be combined with the output of the heat exchanger 345 before being input to the boiler 335, or separately input to the boiler 335 and combined in the boiler 335 itself.


The boiler temperature controller 355 adjusts the temperature in the boiler 335. The boiler temperature can be constantly adjusted in real-time according to the results of the algorithm controller 325. The temperature of the boiler 335 in combination with the FCC pre-treatment unit 305 affects the sulfur level of the gasoline product 303.


The reactor temperature controller 360 adjust the temperature of the FCC pre-treatment unit 305. The reactor or fractionation temperatures can both be constantly and independently adjusted in real-time according to the results of the algorithm controller 325. The temperature of the FCC pre-treatment unit 305 in combination with the boiler 335 affects the sulfur level of the gasoline product 303.



FIG. 4 illustrates an example process 400 for a FCC pre-treatment unit of model-based industrial process controllers according to this disclosure. For example, the process depicted in FIG. 4 may be performed by the device 200 in FIG. 2. The process may also be implemented by the system 300 in FIG. 3.


In operation 405, device 200 collects operating parameters of a pre-treatment unit and a fluid catalytic cracking (FCC) unit.


In operation 410, device 200 evaluates an independent variable of the operating parameters. The independent variable can be evaluated for being within a range of specifications. The specifications require


A real-time model can be developed to evaluate the independent variable. The real-time model can be developed using data analytics to develop a correlation between a change of the input and the independent variable. The real-time model can be updated with the operating parameters in real-time. The input can be adjusted using a machine learning capability based on the real-time model.


In certain embodiments, the independent variable is a concentration of sulfur in FCC gasoline.


An estimated sulfur level can be determined from the operating parameters. The estimated sulfur level can also be determined based on the following equation:

Ln(Sg)=0.905*Ln(Sf)−2.5

where Sg is an estimated sulfur level by weight percentage in a gasoline product and Sf is a sulfur level measured by weight percentage in a feed.


In operation 415, device 200 adjusts an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit. The input can include a percentage of feed flow diverted from the heat exchanger, a temperature adjustment in the boiler, a fuel flow adjustment to the boiler, a temperature adjustment for the pre-treatment unit, etc. The adjustments to the input affect the level of sulfur that is output from the FCC unit.


The input can include a pre-treatment reactor temperature. The temperature is adjusted by varying an inlet exchanger bypass valve and a heater fuel gas valve.


Although FIG. 4 illustrates an example process 400 for a FCC pre-treatment unit of model-based industrial process controllers, various changes could be made to FIG. 4. For example, while shown as a series of steps, various steps in each figured could overlap, occur in parallel, occur in a different order, or occur multiple times.


In some embodiments, various functions described in this patent document are implemented or supported by a computer program that is formed from computer readable program code and that is embodied in a computer readable medium. The phrase “computer readable program code” includes any type of computer code, including source code, object code, and executable code. The phrase “computer readable medium” includes any type of medium capable of being accessed by a computer, such as read only memory (ROM), random access memory (RAM), a hard disk drive, a compact disc (CD), a digital video disc (DVD), or any other type of memory. A “non-transitory” computer readable medium excludes wired, wireless, optical, or other communication links that transport transitory electrical or other signals. A non-transitory computer readable medium includes media where data can be permanently stored and media where data can be stored and later overwritten, such as a rewritable optical disc or an erasable storage device.


It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “application” and “program” refer to one or more computer programs, software components, sets of instructions, procedures, functions, objects, classes, instances, related data, or a portion thereof adapted for implementation in a suitable computer code (including source code, object code, or executable code). The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.


The description in the present application should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function. Use of terms such as (but not limited to) “mechanism,” “module,” “device,” “unit,” “component,” “element,” “member,” “apparatus,” “machine,” “system,” “processor,” or “controller” within a claim is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 U.S.C. § 112(f).


While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Claims
  • 1. A method comprising: collecting operating parameters of a pre-treatment unit and fluid catalytic cracking (FCC) unit;developing a real-time model to evaluate an independent variable of the operating parameters;adjusting an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit,wherein the real-time model is developed using data analytics to develop a correlation between a change of the input and the independent variable;the real-time model is updated with the operating parameters in real-time; andthe input is adjusted using a machine learning capability based on the real-time model.
  • 2. The method of claim 1, wherein the independent variable is a concentration of sulfur in FCC gasoline.
  • 3. The method of claim 2, wherein: an estimated sulfur level is determined from the operating parameters, andthe estimated sulfur level is determined by the following equation: Ln(Sg)=0.905*Ln(Sf)−2.5,where Sg is an estimated sulfur level by weight percentage in a gasoline product and Sf is a sulfur level measured by weight percentage in a feed.
  • 4. The method of claim 1, wherein: the input includes a pre-treatment reactor temperature; andthe pre-treatment reactor temperature is adjusted by varying an inlet exchanger bypass valve and a heater fuel gas valve.
  • 5. An apparatus comprising: at least one memory; andat least one processor operatively coupled to the at least one memory, the at least one processor configured to: collect operating parameters of a pre-treatment unit and fluid catalytic cracking (FCC) unit;develop a real-time model to evaluate an independent variable of the operating parameters;adjust an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit,wherein the real-time model is developed using data analytics to develop a correlation between a change of the input and the independent variable;the real-time model is updated with the operating parameters in real-time; andthe input is adjusted using a machine learning capability based on the real-time model.
  • 6. The apparatus of claim 5, wherein the independent variable is a concentration of sulfur in FCC gasoline.
  • 7. The apparatus of claim 6, wherein: an estimated sulfur level is determined from the operating parameters, andthe estimated sulfur level is determined by the following equation: Ln(Sg)=0.905*Ln(Sf)−2.5,where Sg is an estimated sulfur level by weight percentage in a gasoline product and Sf is a sulfur level measured by weight percentage in a feed.
  • 8. The apparatus of claim 5, wherein: the input includes a pre-treatment reactor temperature; andthe pre-treatment reactor temperature is adjusted by varying an inlet exchanger bypass valve and a heater fuel gas valve.
  • 9. A non-transitory computer readable medium containing instructions that, when executed by at least one processing device, cause the at least one processing device to: collect operating parameters of a pre-treatment unit and fluid catalytic cracking (FCC) unit;a real-time model to evaluate an independent variable of the operating parameters;adjust an input to the pre-treatment unit to control the independent variable within specifications in an output of the FCC unit,wherein the real-time model is developed using data analytics to develop a correlation between a change of the input and the independent variable;the real-time model is updated with the operating parameters in real-time; andthe input is adjusted using a machine learning capability based on the real-time model.
  • 10. The non-transitory computer readable medium of claim 9, wherein the independent variable is a concentration of sulfur in FCC gasoline.
  • 11. The non-transitory computer readable medium of claim 10, wherein: an estimated sulfur level is determined from the operating parameters, andthe estimated sulfur level is determined by the following equation: Ln(Sg)=0.905*Ln(Sf)−2.5,where Sg is an estimated sulfur level by weight percentage in a gasoline product and Sf is a sulfur level measured by weight percentage in a feed.
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 62/568,746 filed on Oct. 5, 2017. This provisional application is hereby incorporated by reference in its entirety.

US Referenced Citations (192)
Number Name Date Kind
4380146 Yannone Apr 1983 A
4775460 Reno Oct 1988 A
4795545 Schmidt Jan 1989 A
5077252 Owen et al. Dec 1991 A
5605435 Haugen Feb 1997 A
5666297 Britt et al. Sep 1997 A
5817517 Perry et al. Oct 1998 A
6038540 Krist et al. Mar 2000 A
6392114 Shields et al. May 2002 B1
6760716 Ganesamoorthi et al. Jul 2004 B1
6772044 Mathur et al. Aug 2004 B1
6795798 Eryurek et al. Sep 2004 B2
7006889 Mathur et al. Feb 2006 B2
7067333 Pasadyn et al. Jun 2006 B1
7133807 Karasawa Nov 2006 B2
7151966 Baier et al. Dec 2006 B1
7246039 Moorhouse Jul 2007 B2
7313447 Hsuing et al. Dec 2007 B2
7415357 Stluka et al. Aug 2008 B1
7567887 Emigholz et al. Jul 2009 B2
7742833 Herbst et al. Jun 2010 B1
7877596 Foo Kune et al. Jan 2011 B2
7925979 Forney et al. Apr 2011 B2
7936878 Kune et al. May 2011 B2
7979192 Morrison et al. Jul 2011 B2
7995526 Liu et al. Aug 2011 B2
8050889 Fluegge et al. Nov 2011 B2
8055371 Sanford et al. Nov 2011 B2
8111619 Liu et al. Feb 2012 B2
8204717 McLaughlin et al. Jun 2012 B2
8244384 Pachner et al. Aug 2012 B2
8280057 Budampati et al. Oct 2012 B2
8352049 Hsiung et al. Jan 2013 B2
8385436 Holm et al. Feb 2013 B2
8428067 Budampati et al. Apr 2013 B2
8458778 Budampati et al. Jun 2013 B2
8571064 Kore et al. Oct 2013 B2
8644192 Budampati et al. Feb 2014 B2
8811231 Budampati et al. Aug 2014 B2
8923882 Gandhi et al. Dec 2014 B2
9134717 Trnka Sep 2015 B2
9166667 Thanikachalam Oct 2015 B2
9176498 Baramov Nov 2015 B2
9751817 Jani et al. Sep 2017 B2
9864823 Horn et al. Jan 2018 B2
9968899 Gellaboina et al. May 2018 B1
10095200 Horn et al. Oct 2018 B2
10107295 Brecheisen Oct 2018 B1
10180680 Horn et al. Jan 2019 B2
10183266 Victor et al. Jan 2019 B2
10222787 Romatier et al. Mar 2019 B2
10328408 Victor et al. Jun 2019 B2
20020123864 Eryurek et al. Sep 2002 A1
20020179495 Heyse et al. Dec 2002 A1
20030147351 Greenlee Aug 2003 A1
20040079392 Kuechler Apr 2004 A1
20040099572 Evans May 2004 A1
20040109788 Li et al. Jun 2004 A1
20040204775 Keyes Oct 2004 A1
20040220689 Mathur et al. Nov 2004 A1
20040220778 Imai et al. Nov 2004 A1
20050027721 Saenz Feb 2005 A1
20050009033 Mallavarapu et al. May 2005 A1
20050216209 Evans Sep 2005 A1
20060020423 Sharpe, Jr. Jan 2006 A1
20060133412 Callaghan Jun 2006 A1
20060259163 Hsiung et al. Nov 2006 A1
20070020154 Evans Jan 2007 A1
20070059159 Hjerpe Mar 2007 A1
20070059838 Morrison et al. Mar 2007 A1
20070091824 Budampati et al. Apr 2007 A1
20070091825 Budampati et al. Apr 2007 A1
20070185664 Tanaka Aug 2007 A1
20070192078 Nasle et al. Aug 2007 A1
20070212790 Welch et al. Sep 2007 A1
20070250292 Alagappan et al. Oct 2007 A1
20070271452 Foo Kune et al. Nov 2007 A1
20080078693 Sexton Apr 2008 A1
20080086322 Wallace Apr 2008 A1
20080130902 Foo Kune et al. Jun 2008 A1
20080217005 Stluka et al. Sep 2008 A1
20080282606 Plaza et al. Nov 2008 A1
20090059786 Budampati et al. Mar 2009 A1
20090060192 Budampati et al. Mar 2009 A1
20090064295 Budampati et al. Mar 2009 A1
20090201899 Liu et al. Aug 2009 A1
20090245286 Kore et al. Oct 2009 A1
20090268674 Liu et al. Oct 2009 A1
20100014599 Holm et al. Jan 2010 A1
20100108567 Medoff May 2010 A1
20100125347 Martin et al. May 2010 A1
20100158764 Hedrick Jun 2010 A1
20100230324 Al-Alloush et al. Sep 2010 A1
20100262900 Romatier et al. Oct 2010 A1
20110112659 Pachner et al. May 2011 A1
20110152590 Sadler et al. Jun 2011 A1
20110152591 Sadler et al. Jun 2011 A1
20110311014 Hottovy et al. Dec 2011 A1
20120029966 Cheewakriengkrai et al. Feb 2012 A1
20120083933 Subbu et al. Apr 2012 A1
20120095808 Kattapuram et al. Apr 2012 A1
20120104295 Do et al. May 2012 A1
20120121376 Huis in Het Veld May 2012 A1
20120123583 Hazen et al. May 2012 A1
20120197616 Trnka Aug 2012 A1
20120232870 Devereux Sep 2012 A1
20120259583 Noboa et al. Oct 2012 A1
20130029587 Gandhi et al. Jan 2013 A1
20130079899 Baramov Mar 2013 A1
20130090088 Chevsky et al. Apr 2013 A1
20130094422 Thanikachalam Apr 2013 A1
20130253898 Meagher et al. Sep 2013 A1
20130270157 Ferrara Oct 2013 A1
20130311437 Stluka et al. Nov 2013 A1
20140026598 Trawicki Jan 2014 A1
20140074273 Mohideen et al. Mar 2014 A1
20140114039 Benham et al. Apr 2014 A1
20140131027 Chir May 2014 A1
20140163275 Yanagawa et al. Jun 2014 A1
20140179968 Yanagawa et al. Jun 2014 A1
20140212978 Sharpe, Jr. et al. Jul 2014 A1
20140294683 Siedler Oct 2014 A1
20140294684 Siedler Oct 2014 A1
20140296058 Sechrist et al. Oct 2014 A1
20140309756 Trygstad Oct 2014 A1
20140337256 Varadi et al. Nov 2014 A1
20150059714 Bernards Mar 2015 A1
20150077263 Ali et al. Mar 2015 A1
20150078970 Iddir et al. Mar 2015 A1
20150098862 Lok et al. Apr 2015 A1
20150158789 Keusenkothen Jun 2015 A1
20150185716 Wichmann et al. Jul 2015 A1
20150276208 Maturana et al. Oct 2015 A1
20150330571 Beuneken Nov 2015 A1
20160033941 T et al. Feb 2016 A1
20160098037 Zornio et al. Apr 2016 A1
20160147204 Wichmann et al. May 2016 A1
20160237910 Saito Aug 2016 A1
20160260041 Horn et al. Sep 2016 A1
20160291584 Horn et al. Oct 2016 A1
20160292188 Horn et al. Oct 2016 A1
20160292325 Horn et al. Oct 2016 A1
20170009932 Oh Jan 2017 A1
20170058213 Oprins Mar 2017 A1
20170082320 Wang Mar 2017 A1
20170284410 Sharpe, Jr. Oct 2017 A1
20170315543 Horn et al. Nov 2017 A1
20170323038 Horn et al. Nov 2017 A1
20170352899 Asai Dec 2017 A1
20180046155 Horn et al. Feb 2018 A1
20180081344 Romatier et al. Mar 2018 A1
20180082569 Horn et al. Mar 2018 A1
20180121581 Horn et al. May 2018 A1
20180122021 Horn et al. May 2018 A1
20180155638 Al-Ghamdi Jun 2018 A1
20180155642 Al-Ghamdi et al. Jun 2018 A1
20180197350 Kim Jul 2018 A1
20180275690 Lattanzio et al. Sep 2018 A1
20180275691 Lattanzio et al. Sep 2018 A1
20180275692 Lattanzio et al. Sep 2018 A1
20180280914 Victor et al. Oct 2018 A1
20180280917 Victor et al. Oct 2018 A1
20180282633 Van de Cotte et al. Oct 2018 A1
20180282634 Van de Cotte et al. Oct 2018 A1
20180282635 Van de Cotte et al. Oct 2018 A1
20180283368 Van de Cotte et al. Oct 2018 A1
20180283392 Van de Cotte et al. Oct 2018 A1
20180283404 Van de Cotte et al. Oct 2018 A1
20180283811 Victor et al. Oct 2018 A1
20180283812 Victor et al. Oct 2018 A1
20180283813 Victor et al. Oct 2018 A1
20180283815 Victor et al. Oct 2018 A1
20180283816 Victor et al. Oct 2018 A1
20180283818 Victor et al. Oct 2018 A1
20180284705 Van de Cotte et al. Oct 2018 A1
20180286141 Van de Cotte et al. Oct 2018 A1
20180311609 McCool et al. Nov 2018 A1
20180362862 Gellaboina et al. Dec 2018 A1
20180363914 Faiella et al. Dec 2018 A1
20180364747 Charr et al. Dec 2018 A1
20190002318 Thakkar et al. Jan 2019 A1
20190003978 Shi et al. Jan 2019 A1
20190015806 Gellaboina et al. Jan 2019 A1
20190041813 Horn et al. Feb 2019 A1
20190083920 Bjorklund et al. Mar 2019 A1
20190101336 Victor et al. Apr 2019 A1
20190101342 Victor et al. Apr 2019 A1
20190101907 Charr et al. Apr 2019 A1
20190108454 Baneijee et al. Apr 2019 A1
20190120810 Kumar Kn et al. Apr 2019 A1
20190151814 Victor et al. May 2019 A1
20190155259 Romatier et al. May 2019 A1
Foreign Referenced Citations (7)
Number Date Country
2746884 Jun 2014 EP
2801937 Nov 2014 EP
WO 2001060951 Aug 2001 WO
WO 2009046095 Apr 2009 WO
WO 2014042508 Mar 2014 WO
WO 2014123993 Aug 2014 WO
WO 2016141128 Sep 2016 WO
Non-Patent Literature Citations (43)
Entry
International Preliminary Report on Patentability for PCT/US2018/054607, dated Apr. 8, 2020.
U.S. Appl. No. 15/058,658, filed Mar. 3, 2015, Ian G. Horn Zak Alzein Paul Kowalczyk Christophe Romatier, System and Method for Managing Web-Based Refinery Performance Optimization Using Secure Cloud Computing.
U.S. Appl. No. 15/640,120, filed Mar. 30, 2015, Ian G. Horn Zak Alzein Paul Kowalczyk Christophe Romatier, Evaluating Petrochemical Plant Errors to Determine Equipment Changes for Optimized.
U.S. Appl. No. 15/851,207, filed Mar. 27, 2017, Louis A. Lattanzio Alex Green Ian G. Horn Matthew R. Wojtowicz, Operating Slide Valves in Petrochemical Plants or Refineries.
U.S. Appl. No. 15/851,343, filed Dec. 21, 2017, Louis A. Lattanzio Alex Green Ian G. Horn Matthew R. Wojtowicz, Early Prediction and Detection of Slide Valve Sticking in Petrochemical Plants or Refineries.
U.S. Appl. No. 15/851,360, filed Mar. 27, 2017, Louis A. Lattanzio Alex Green Ian G. Horn Matthew R. Wojtowicz, Measuring and Determining Hot Spots in Slide Valves for Petrochemical Plants or Refineries.
U.S. Appl. No. 15/853,689, filed Mar. 30, 2015, Ian G. Horn Zak Alzein Paul Kowalczyk Christophe Romatier, Cleansing System for a Feed Composition Based on Environmental Factors.
U.S. Appl. No. 15/858,767, filed Dec. 28, 2017, Ian G. Horn Zak Alzein Paul Kowalczyk Christophe Romatier, Chemical Refinery Performance Optimization.
U.S. Appl. No. 15/899,967, filed Feb. 20, 2018, Joel Kaye, Developing Linear Process Models Using Reactor Kinetic Equations.
U.S. Appl. No. 15/935,827, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,847, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,872, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, 3744early Surge Detection of Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,898, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Reactor Loop Fouling Monitor for Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,920, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Sensor Location for Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,935, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Determining Quality of Gas for Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,950, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Determining Quality of Gas for Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/935,957, filed Mar. 28, 2017, Michael R. Van de Cotte Ian G. Horn, Using Molecular Weight and Invariant Mapping to Determine Performance of Rotating Equipment in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/937,484, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Detecting and Correcting Maldistribution in Heat Exchangers in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/937,499, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Detecting and Correcting Cross-Leakage in Heat Exchangers in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/937,517, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Strain Gauges and Detecting Pre-Leakage in Heat Exchangers in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/937,535, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Detecting and Correcting Thermal Stresses in Heat Exchangers in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/937,588, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Detecting and Correcting Problems in Liquid Lifting in Heat Exchangers.
U.S. Appl. No. 15/937,602, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Air-Cooled Heat Exchangers.
U.S. Appl. No. 15/937,614, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Wet-Cooled Heat Exchanger.
U.S. Appl. No. 15/937,624, filed Mar. 28, 2017, Sanford A. Victor Phillip F. Daly Ian G. Horn, Heat Exchangers in a Petrochemical Plant or Refinery.
U.S. Appl. No. 15/963,840, filed Apr. 28, 2017, Ryan McCool Chad E. Bjorklund Jorge Charr Luk Verhulst, Remote Monitoring of Adsorber Process Units.
U.S. Appl. No. 15/972,974, filed Jun. 20, 2017, Jorge Charr Kevin Carnes Ralph Davis Donald A. Eizenga Christina L. Haasser James W. Harris Raul A. Ohaco Daliah Papoutsis, Incipient Temperature Excursion Mitigation and Control.
U.S. Appl. No. 15/979,421, filed May 14, 2018, Mahesh K. Gellaboina Louis A. Lattanzio, Catalyst Transfer Pipe Plug Detection.
U.S. Appl. No. 16/007,669, filed Jun. 28, 2017, Yili Shi Daliah Papoutsis Jonathan Andrew Tertel, Process and Apparatus to Detect Mercaptans in a Caustic Stream.
U.S. Appl. No. 16/011,600, filed Jun. 19, 2017, Theodore Peter Faiella Colin J. Deller Raul A. Ohaco, Remote Monitoring of Fired Heaters.
U.S. Appl. No. 16/011,614, filed Jun. 19, 2017, Mahesh K. Gellaboina Michael Terry Seth Huber Danielle Schindlbeck, Catalyst Cycle Length Prediction Using Eigen Analysis.
U.S. Appl. No. 16/015,579, filed Jun. 28, 2017, Killol H. Thakkar Robert W. Brafford Eric C. Tompkins, Process and Apparatus for Dosing Nutrients to a Bioreactor.
U.S. Appl. No. 16/133,623, filed Sep. 18, 2017, Chad E. Bjorklund Jeffrey Guenther Stephen Kelley Ryan McCool, Remote Monitoring of Pressure Swing Adsorption Units.
U.S. Appl. No. 16/140,770, filed Oct. 20, 2017, Dinesh Kumar KN Soumendra Mohan Banerjee, System and Method to Optimize Crude Oil Distillation or Other Processing by Inline Analysis of Crude Oil Properties.
U.S. Appl. No. 16/148,763, filed Oct. 2, 2017, Jorge Chan Bryan J. Egolf Dean E. Rende Mary Wier Guy B. Woodle Carol Zhu, Remote Monitoring of Chloride Treaters Using a Process Simulator Based Chloride Distribution Estimate.
U.S. Appl. No. 16/151,086, filed Oct. 5, 2017, Soumendra Mohan Banerjee Deepak Bisht Priyesh Jayendrakumar Jarti Krishna Mani Gautam Pandey, Harnessing Machine Learning & Data Analytics for a Real Time Predictive Model for a Fcc Pre-Treatment Unit.
U.S. Appl. No. 16/154,138, filed Oct. 8, 2018, Raul A. Ohaco Jorge Charr, High Purity Distillation Process Control With Multivariable and Model Predictive Control (Mpc) and Fast Response Analyzer.
U.S. Appl. No. 16/154,141, filed Oct. 8, 2018, Ian G. Horn Zak Alzein Paul Kowalczyk Christophe Romatier, System and Method for Improving Performance of a Plant With a Furnace.
U.S. Appl. No. 16/215,101, filed Dec. 10, 2018, Louis A. Lattanzio Christopher Schindlbeck, Delta Temperature Control of Catalytic Dehydrogenation Process Reactors.
U.S. Appl. No. 16/252,021, filed Sep. 16, 2016, Christophe Romatier Zak Alzein Ian G. Horn Paul Kowalczyk David Rondeau, Petrochemical Plant Diagnostic System and Method for Chemical Process Model Analysis.
U.S. Appl. No. 16/253,181, filed Mar. 28, 2017, Ian G. Horn Phillip F. Daly Sanford A. Victor, Detecting and Correcting Vibration in Heat Exchangers.
U.S. Appl. No. 16/363,406, filed Mar. 30, 2018, Louis A. Lattanzio Abhishek Pednekar, Catalytic Dehydrogenation Reactor Performance Index.
WO App. PCT/US2018/054607: International Search Report and Written Opinion (dated Jan. 31, 2019).
Related Publications (1)
Number Date Country
20190108454 A1 Apr 2019 US
Provisional Applications (1)
Number Date Country
62568746 Oct 2017 US