Nonlinear APC Solution for Polypropylene Plants

Abstract

A Nonlinear Model Predictive Control Solution has been implemented on the two Polypropylene Lines at Saudi Polyolefins Company (TASNEE) complex in Jubail, Saudi Arabia. The project scope included both pre-audit and post audit study to evaluate the application performance before and after implementation of the solution.  The acceptance criteria for the project included both increased production and improved Cpk (product Quality improvements) for all four reactors.  The project was completed with great cooperative efforts between the client and APC solution provider team in seven month after the kick-off meeting and all performance criteria were achieved and mostly exceeded.  The ROI for this project was calculated at less than six month.

The installed APC solution has been on line for over 18 month and enjoys high acceptance by TASNEE operations team.  The average utilization is well over 90% and the solution is maintained so that it will continue to deliver the expected results.    Before implementation of this solution; TASNEE was focused to improve their lab QC performance and significant improvements was achieved.  Due to this effort and implementation of APC Solutions, client has been able to reduce extra lab samples required earlier to verify suspected results and improve production Quality Control at the same time.