Köln, Germany
Köln, Germany

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Grant
Agency: Cordis | Branch: H2020 | Program: RIA | Phase: SPIRE-02-2016 | Award Amount: 6.54M | Year: 2016

The goal of CoPro is to develop and to demonstrate methods and tools for process monitoring and optimal dynamic planning, scheduling and control of plants, industrial sites and clusters under dynamic market conditions. CoPro will provide decision support to operators and managers and develop closed-loop solutions to achieve an optimally energy and resource efficient production. In most plants of the process industries, the energy and resource efficiency of the production depends critically on discrete decisions on the use of equipment, shutdowns, product changeovers and cleaning or regeneration of equipment. CoPro will consider these discrete decisions in plant-wide dynamic optimization and develop integrated scheduling and control solutions. Advanced online data analytics will be developed for plant health and product quality monitoring. The detection of anomalies will trigger fast re-scheduling and re-optimization. CoPro will demonstrate advanced plant-wide and site-wide coordination and control in five typical use cases that cover a wide range of sectors of the process industries, and the whole value chain: - Petrochemical production site - Base chemicals and polymer production site - Recycling system in cellulose production - Consumer product formulation and packaging plant - Food processing plant In addition,CoPro will develop methods for the coordination of plants in industrial parks that belong to different companies, thus providing a basis for future industrial symbiosis. CoPro pays special attention to the role of operators and managers in plant-wide control solutions and to the deployment of advanced solutions in industrial sites with a heterogeneous IT environment. As the effort required for the development and maintenance of accurate plant models is the bottleneck for the development and long-term operation of advanced control and scheduling solutions, CoPro will develop methods for efficient modelling and for model quality monitoring and model adaption


Grant
Agency: Cordis | Branch: FP7 | Program: CP | Phase: ICT-2013.3.4 | Award Amount: 3.43M | Year: 2013

The wellbeing of the citizens in Europe depends on the reliable and efficient functioning of large interconnected systems, such as electric power systems, air traffic control, railway systems, large industrial production plants, etc. Such large systems consist of many interacting components, e.g. generation plants, distribution systems, and large and small consumers. The subsystems are usually managed locally and independently, according to different policies and priorities. The dynamic interaction of the locally managed components gives rise to complex behaviour and can lead to largescale disruptions as e.g. black outs in the electric grid.\n\n\nLarge interconnected systems with autonomously acting subunits are called systems of systems. DYMASOS addresses systems of systems where the elements of the overall system are coupled by flows of physical quantities, e.g. electric power, steam or hot water, materials in a chemical plant, gas, potable water, etc. Within the project, new methods for the distributed management of large physically connected systems with local management and global coordination will be developed.\n\n\nThe approaches explored are:\n\n\tModelling and control of large systems analogously to the evolution of the behaviour of populations in biological systems;\n\tMarketlike mechanisms to coordinate independent systems with local optimisation functions;\n\tCoalition games where agents that control the subsystems dynamically group to pursue common goals.\n\n\nThe properties of the distributed management and control techniques for large systems of systems are investigated theoretically and validated in largescale simulations of case studies provided by industrial partners in the fields of electric grid management and industrial production management.\n\n\nFrom the experience gained in the case studies, conclusions will be drawn about the suitability of the proposed management and control mechanisms for certain classes of systems of systems.\n\n\nThe expected technical outcomes of the project are:\n \tInnovation in distributed management methods for complex interconnected systems\n \tProgress in methods for the rigorous analysis and validation of systems of systems;\n \tImprovements in the management of electric grids and of large production complexes;\n \tTools for the engineering of management systems for systems of systems;\n \tIdentification of technology gaps in advanced management and coordination methods.\n\n\nThe developed coordination methods will lead to improved system stability and lower resource consumption in industrial production, and in electricpower generation and distribution. This will result in a reduction of the CO2-emissions, higher competitiveness of the European industry and lower prices for the customers. Thus, DYMASOS will contribute to the goal of a greener and more competitive Europe.


Grant
Agency: Cordis | Branch: FP7 | Program: CP-FP | Phase: NMP.2013.3.0-1 | Award Amount: 3.92M | Year: 2013

In recent years, indicators for the environmental impact of products and production processes have been developed and are increasingly used in the communication of companies in the processing industries with the public as well as in the evaluation of alternative routes and for the decision on investments into new production facilities or revamp measures. In the MORE project, we will significantly extend the definition and the use of such indicators by Defining real-time resource efficiency indicators that can be efficiently used in daily operations and are computed based upon the processing of real-time data that is available in the monitoring and control systems and from innovative analytical measurements Taking the step from monitoring to improving resource efficiency by providing model-based real-time decision support to plant operators and plant managers. We will deal with resource efficiency as a multidimensional attribute with several indicators that measure different aspects of resource efficiency. The project is focused on large integrated chemical and petrochemical plants with many interconnected units. The real-time resource efficiency indicators and decision support tools will be developed exemplarily for this domain and will be adapted also to domains with similar production systems, e.g. sugar production, the pulp and paper industry, and metals production. Moreover the transferability to different sectors as e.g. the food industry will be investigated. The project will trigger standardization activities and input its result into the work of standardization bodies and disseminate the resource efficiency indicators and the real-time decision support methods to the whole process industry.


Minnich C.,S PACT GmbH | Hardy S.,S PACT GmbH | Hardy S.,BASF | Kramer S.,INEOS Cologne GmbH
Chemie-Ingenieur-Technik | Year: 2016

The different use of the classifiers inline, online, atline, and offline in the process analytical technology (PAT) and automation communities regularly induces unambiguity in communication. Therefore, the available definitions of the classifiers are summarized and merged. An updated nomenclature targeting the intended function of the analyzer rather than its features is suggested. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.


Kramer S.,INEOS Cologne GmbH | Dunnebier G.,Bayer AG | Kahrs O.,BASF | Luft H.,Evonik Industries
Chemie-Ingenieur-Technik | Year: 2011

Continuous processes show dynamics during load changes, start-up and shutdowns whereas batch processes exhibit inherent dynamics. In the past, the major concern of automating these dynamics states of process operation were safe and reproducible operation, however, today modern methods of process operation allow for the economic optimization at the same time. The automation and optimization of batch processes pose challenges in several areas: Mastering the high complexity, connecting heterogeneous components by automation, and combining extensive knowledge from both process engineering and automation during project execution. This contribution describes approaches from industrial practice and punctually academic research, which solutions for the challenges are readily available and how to implement these. Copyright © 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.


Ebrahim T.,TU Dortmund | Hernandez R.,TU Dortmund | Subramanian S.,TU Dortmund | Kalliski M.,TU Dortmund | And 2 more authors.
IFAC-PapersOnLine | Year: 2016

Measurement-based optimization schemes can be used to counteract the effect of uncertainty and to drive the process to optimality. Necessary Conditions of Optimality Tracking (NCO-tracking) is a promising scheme which uses the process measurements to update the inputs directly. The limiting assumption for the application of the NCO-tracking scheme is that the set of active constraints does not change from its nominal value under the influence of the uncertainties. This paper presents a scheme that extends the NCO-tracking approach to handle parametric uncertainties that change the set of active constraints. Several solution structures are implemented to cover the whole range of the uncertain parameters. Based on the identification of the region of the uncertain parameters, the correct solution model is determined and applied to the process. The applicability of the methodology is shown for the benchmark Williams-Otto semi-batch reactor. © 2016


Stojanovski G.,TU Dortmund | Maxeiner L.,TU Dortmund | Kramer S.,INEOS Cologne GmbH | Engell S.,TU Dortmund
2015 European Control Conference, ECC 2015 | Year: 2015

The efficient real-time plant-wide coordination of petrochemical production sites is a challenging and yet not fully resolved problem and its solution can substantially improve the productivity and the efficiency of such complex petrochemical plants. While a site-wide integrated optimization might be feasible in principle, the size of the problem, the unavailability of data and the management structures of the plants favour a distributed solution, where the global coordination has to be achieved by suitable mechanisms. In this paper we propose price based coordination in a moving horizon setting to achieve plant-wide real-time coordination of the utilization of shared resources without communication of detailed knowledge of the structure of the subsystems. The shared resources are considered as market commodities that are traded between the units and global coordination is achieved by real-time adjustment of their market prices. We provide results of different price coordination methods for a model of an integrated petrochemical site. The results clearly show that market mechanisms can be applied for the coordination of large sites in the petrochemical industry. © 2015 EUCA.


Wenzel S.,TU Dortmund | Paulen R.,TU Dortmund | Stojanovski G.,Ss. Cyril and Methodius University of Skopje | Kramer S.,INEOS Cologne GmbH | And 2 more authors.
At-Automatisierungstechnik | Year: 2016

We address the distributed hierarchical optimization of industrial production complexes where the individual plants exchange resources via networks. Due to the site-wide couplings a centralized or a distributed hierarchical optimization is needed to achieve the best overall performance of the site and to balance the networks of the shared resources. We discuss market-like algorithms that set prices of the shared resources in order to influence the individual optimizers so that the overall operation converges to the site-wide optimum. A novel algorithm for price adjustment based on the quadratic approximation of the responses of the individual optimizers is presented. It shows convergence to the site-wide optimum with significantly less iterations in comparison to the standard subgradient-based method for a set of case studies, including a petrochemical complex. © 2016 Walter de Gruyter.


Roth T.,TU Dortmund | Hoffmann A.,TU Dortmund | Kreis P.,TU Dortmund | Lauterbach S.,Ineos Cologne GmbH
Chemie-Ingenieur-Technik | Year: 2011

The combination between reaction and pervaporation has been investigated using the example of a heterogeneous catalysed esterification reaction. The process model parameters have been determined based on experimental investigations and a scale-up has been performed to the pilot scale. A detailed process analysis leads to optimal operating as well as structural variables and two separation sequences have been suggested. © 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.


Kalliski M.,TU Dortmund | Krahe D.,TU Dortmund | Beisheim B.,INEOS Cologne GmbH | Kramer S.,INEOS Cologne GmbH | Engell S.,TU Dortmund
Computer Aided Chemical Engineering | Year: 2015

Operational decisions in the day-to-day business of chemical production plants can have a significant impact on the resource efficiency, but this is usually not transparent to managers and operators because of complex interactions in the plants and the lack of real-time resource efficiency indicators (RTREI). As a first step towards real-time decision support to improve resource efficiency, this contribution presents principles for the definition of resource efficiency indicators that capture the performance of a plant on shorter time scales. Guided by these principles, individual RTREI for a specific plant can be chosen. To assess the indicators, an evaluation framework was developed that helps to identify which indicators are capable of reflecting the total resource efficiency best. To demonstrate the approach, indicators for an ethylene oxide production unit that is operated at INEOS in Cologne are presented and compared to the currently used energy efficiency indicator (EnPI), showing that the new indicators are better suited to capture the operational efficiency of the plant. © 2015 Elsevier B.V.

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