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List of Illustrations

1 Chapter 1Figure 1.1 Various constraints or limits of chemical processes Figure 1.2 Optimum operating point versus operator comfort zone
2 Chapter 2Figure 2.1 Developing stages of the chemical industry Figure 2.2 Three major ways digital transformation will impact the chemical ...Figure 2.3 Three major impact areas where advance analytic tools will help t...Figure 2.4 Different components of the insights value chain Figure 2.5 Overview of the insights value chain upstream processes (A–B) and...Figure 2.6 Data science is an iterative process that leverages both human do...
3 Chapter 3Figure 3.1 Different steps in profit maximization project (PMP) implementati...
4 Chapter 4Figure 4.1 Different ways to maximize the operating profit of chemical plant...Figure 4.2 Schematic diagram of a glycol plant Figure 4.3 Steps to map the whole plant in monetary terms and to gain insigh...Figure 4.4 Representing the whole plant as a black box Figure 4.5 Mapping the whole plant in monetary terms Figure 4.6 Break‐up of the total cost of production Figure 4.7 Cost of raw material Figure 4.8 Cost of different utilities (USD/h)Figure 4.9 Cost of different chemicals (USD/h)Figure 4.10 Variations of profit margin (USD/h) throughout the yearFigure 4.11 Variations of profit margin (USD/MT of product) throughout the y...Figure 4.12 Variations of production cost (USD/MT) throughout the yearFigure 4.13 Variations of MEG production (MT/h) throughout the year
5 Chapter 5Figure 5.1 Five‐step process of a key parameter identificationFigure 5.2 Queries normally asked to perform a process analysis and economic...Figure 5.3 Major six categories of limitations in a plant to increase profit...Figure 5.4 Some examples of process limitationsFigure 5.5 Some examples of equipment limitationsFigure 5.6 Examples of instrument limitationsFigure 5.7 Guideline questionnaires to initiate the discussion with plant pe...Figure 5.8 Various causes of catalyst selectivity increase
6 Chapter 6Figure 6.1 Comparison of daily actual profit (sorted) versus best achieved p...Figure 6.2 Daily opportunity loss in million US$ for one year of operationFigure 6.3 Cumulative opportunity loss in million US$ for one year of operat...
7 Chapter 7Figure 7.1 Advantage and disadvantage of the first principle‐based modelFigure 7.2 Advantages and disadvantages of data‐driven modelsFigure 7.3 Advantages and disadvantages of the grey modeling techniqueFigure 7.4 Advantages and disadvantages of the hybrid modeling techniqueFigure 7.5 Typical pseudo code of a back‐propagation algorithmFigure 7.6 Architecture of a feed‐forward network with one hidden layer (Lah...Figure 7.7 Steps followed in data collection and data inspectionFigure 7.8 Task performed in the data pre‐processing and data conditioning s...Figure 7.9 Two main univariate approaches to detect outliersFigure 7.10 Guidelines for selection of the relevant input output variables...Figure 7.11 Relation between catalyst selectivity and promoter concentration...Figure 7.12 Actual selectivity versus ANN model predicted selectivityFigure 7.13 Prediction error percent between actual selectivity and predicte...Figure 7.14 Plot of actual selectivity versus predicted selectivity for test...Figure 7.15 ANN model performance for testing and training dataFigure 7.16 Different ANN algorithms developed by different scientists in th...Figure 7.17 Different activation functions used in an ANN
8 Chapter 8Figure 8.1 Different minimum values of a function depending on different sta...Figure 8.2 Principle features possessed by a genetic algorithmFigure 8.3 Foundation of the genetic algorithmFigure 8.4 Five main phases of a genetic algorithmFigure 8.5 Mechanism of crossoverFigure 8.6 Calculations steps performed in DE (Babu, 2004)Figure 8.7 Schematic diagram of DEFigure 8.8 Calculation sequence of a simulated annealing algorithm
9 Chapter 9Figure 9.1 Cause and effect relationship of a steam increase in the distilla...Figure 9.2 KPI‐based process monitoringFigure 9.3 Projection of a three‐dimensional object on a two‐dimensional pla...Figure 9.4 Projection of a three‐dimensional object on a two‐dimensional pri...Figure 9.5 Projection of data towards a maximum variance planeFigure 9.6 Steps to calculating the principal componentsFigure 9.7 Normal and abnormal operating zones are clearly different when pl...Figure 9.8 Trends of the first principal componentFigure 9.9 Variance explained by the first few principal componentsFigure 9.10 Front end to detect abnormality in the reciprocating compressor...Figure 9.11 Normal and abnormal data projected onto the first two and first ...
10 Chapter 10Figure 10.1 New business challenges versus improve performanceFigure 10.2 Pyramid of a process monitoring systemFigure 10.3 Fault diagnosis systemFigure 10.4 Characteristics of an automated real–time process monitoring sys...Figure 10.5 Concerns when building an effective fault diagnosis systemFigure 10.6 Different requirements of different stakeholders from fault diag...Figure 10.7 Summary of user perspective and challenges to build an effective...Figure 10.8 Principal component plotFigure 10.9 Schematic of an ethylene oxide reactor and its associated unitFigure 10.10 EO reactor process parameters along with a schematicFigure 10.11 Various challenges to develop an EO reactor fault diagnosisFigure 10.12 Chloride versus catalyst selectivity plotFigure 10.13 PCA scores plot, T ² plot, and residual plotFigure 10.14 Interface between a data historian and a dedicated PC loaded wi...Figure 10.15 Contribution plots of 15 variablesFigure 10.16 Dynamic movement of the reactor status from the normal zone to ...Figure 10.17 Steps to build a PCA‐based fault diagnosis systemFigure 10.18 Actual versus ANN model predicted selectivity and equivalent et...Figure 10.19 Integrated robust fault diagnosis system
11 Chapter 11Figure 11.1 Effect of tower loading on the tray efficiency valve versus siev...Figure 11.2 Capacity diagram or feasible operating window diagramFigure 11.3 Vapor liquid flow pattern on the tray (Zhu, 2013)Figure 11.4 Froth regime versus spray regime operationFigure 11.5 Jet flooding and its impact on entrainment and tray efficiencyFigure 11.6 Downcomer chokingFigure 11.7 Vapor recycle increases the vapor loadFigure 11.8 Downcomer fillingFigure 11.9 Effect of weeping on efficiencyFigure 11.10 Operational guide for deriving the operating windowFigure 11.11 Capacity diagram of the case study
12 Chapter 12Figure 12.1 Operating limits of a distillation column trayFigure 12.2 Various constraints need to be satisfied during a distillation c...Figure 12.3 Various downcomer‐related constraints need to be satisfied durin...Figure 12.4 Various process constraints need to be satisfied during distilla...
13 Chapter 13Figure 13.1 Some chemical engineering applications of genetic programming (G...Figure 13.2 Five major preparatory steps for the basic version of genetic pr...Figure 13.3 Flow chart of genetic programmingFigure 13.4 A typical individual that returns 5(x + 7)Figure 13.5 Two‐offspring crossover genetic operationFigure 13.6 Example of sub‐tree mutationFigure 13.7 Initial population of four randomly created individuals of gener...Figure 13.8 Fitness of the evolved functions from generation 0Figure 13.9 Population of generation 1 (after one reproduction, one mutation...
14 Chapter 14Figure 14.1 Different ways to increase plant throughputFigure 14.2 Schematic diagram of strategy 2 of the maximum capacity test run...Figure 14.3 Schematic diagram of strategy 3 of the maximum capacity test run...Figure 14.4 Schematic diagram of strategy 4 of the maximum capacity test run...
15 Chapter 15Figure 15.1 Different low grade heat recovery options
16 Chapter 16Figure 16.1 Flow scheme of a simple cracking furnace using an advance proces...Figure 16.2 Hierarchy of the plant‐wide control frameworkFigure 16.3 Features of potential plants for APC implementationFigure 16.4 Capital investment versus benefits for different levels of contr...Figure 16.5 Typical benefits of APCFigure 16.6 APC stabilization effect can increase plant capacity closer to i...Figure 16.7 Reduced variability allows operation closer to constraints by sh...Figure 16.8 Operating zone limited by multiple constraintsFigure 16.9 Typical intangible benefits of APCFigure 16.10 Typical payback period of APCFigure 16.11 Typical benefits of APC implementation in CPIFigure 16.12 Advance control implementations by oneof the major APC vendors...Figure 16.13 Spread of APC application across the whole spectrum of the chem...Figure 16.14 Different steps in the APC implementation projectFigure 16.15 Steps in the functional design stage

Profit Maximization Techniques for Operating Chemical Plants

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