SciDigital Edge®

SciDigital Connect® is a data monitoring and communication interface between clients and SD. The web-based online dashboard provides overview of data visualization with user defined settings, KPIs, performance comparison charts, etc. It allows for exploration of alerts, warnings, and advice generated by SD experts and acts as a communication platform between clients and SD. The cloud based digital portal keeps client data secured with end-to-end encryption, two factor authentication, access and 24/7 threat monitoring.

Operating costs of any EO/EG plant are driven by raw material efficiency which requires continuous optimization of EO reactor performance. The complexity of the EO reactor system cannot be adequately modeled by commercially available advanced process control (APC) software packages. A high degree of customization is necessary for optimization.

SD’s SciDigital RxTwin® , a hybrid model combining EO reactor kinetics and metaheuristic-based optimization, supports plant operators to maintain optimum catalyst performance throughout the EO catalyst lifecycle. The algorithm reviews current operating trends, predicts performance under actual conditions, and provides actionable recommendations to fine tune operating conditions which maximize catalyst performance within specific process constraints. The model drives raw material cost reduction and maximizes catalyst operating life.

Efficient operation of an EO Reactor system depends on maintaining optimum reactor feed conditions. To balance the competing effects of cost of purge streams, reactor performance, and recycle gas compression (which are difficult to determine in a dynamic environment) buildup of inert impurities from raw materials must be managed.

SD’s SciDigital YieldPro® optimizer extends the functionality of the SciDigital RxTwin® model to predict the impact of inert impurities on EO Reactor catalyst performance. An optimization routine then determines the lowest cost of production considering catalyst sensitivity, raw material losses, and recycle gas compressor power input. Raw material and energy intensity are optimized in real time to maximize overall profitability. The program can also be configured to provide a remote setpoint to the plant hardware or APC system.

In the EO/EG process, mono-, di-, and tri-ethylene glycols (MEG, DEG, TEG) are co-products of a hydration reaction generated in varying proportions based on reactor feed conditions. Glycol products operate in distinct and independent markets, therefore optimum overall product distribution will vary dependent on market conditions. Additionally, for production of higher glycols increased energy costs of recovery and recycling must be considered in the optimization calculation. Successfully balancing reactor conditions on a dynamic basis for the prevailing glycol market can improve plant operating margins.

Using market data, a hybrid model of glycol reactor kinetics and downstream recovery is deployed by SD’s SciDigital GlyPro® optimizer identifies optimum reactor conditions for the plant and provides feedback to the product planning group. The model is customized to operate within the plant’s specific design constraints, maximizing total plant operating margins in real time based on inventory and customer commitment.

Glycol drying is a critical step in the purification process when impurities harmful to MEG specifications are removed and purged in an aqueous waste stream. In the absence of the availability of an online analyzer, glycol breakthrough (in the case of overtreatment) or plant upset can go undetected by the plant operators, leading to high COD in the wastewater effluent and MEG product loss. To prevent such consequences the plant typically settles on operation at higher reflux rates in the column, resulting in higher energy consumption.

SD’s SciDigital DryOpt® is a multifunctional optimization tool. In Mitigation Mode, a soft sensor will detect glycol carryover in real time and advise of an optimum reflux rate. Such functionality can be utilized for plant upsets and upstream fluctuations. During stable operation, Preventive Mode will employ an advanced algorithm to perform a predictive optimization calculation based on upstream parameters to identify preventive measures against glycol carryover. In Optimization Mode, the algorithm will analyze the column operating data to conduct dynamic optimization of column steam consumption. The highly versatile model ensures stable product quality with no consequence to the plant’s effluent footprint or energy consumption.

“…we are proud to be the first SABIC affiliate to implement this revolutionary solution with the Licensor. As part of SK’s Advanced Solution initiative, this cutting-edge technology harnesses advanced algorithms to maximize the performance of our High Selectivity Catalyst, which will directly impact our profitability…There is immense untapped potential waiting to be realized as we continuously and efficiently utilize this system.”
Naser Al-Rashidi – Manager of Process Control

“This Model performs like an efficient Engineer, working 24 x 7 with advanced future prediction, Optimization, Chloride zone detection, and recommendation system.”
Naser Al-Rashidi – Manager of Process Control