Application of a Cooperative Control System to Residue Fluid Catalytic

Cracking Plant Using a Knowledge Based System and Model Predictive

Moltivariable Control
Kouicbi Nakane

Junzo Yamamoto

System Technology Development Center

Engineering & Technology Center,

Idemitsu Engineering Co., Ltd.,

37-24 Shinden-cho Chuo-ku, Chiba, JAPAN 260-0027

Idemitsu Kosan Co., Ltd.,

26 Anesaki-Kaigan, Ichihara, Chiba, JAPAN 299-0107

junzo@sie.idemitsu.cojp

nakane@sie.idemitsu.co.jp

Kouichi Takahashi

Tetsuji Tani

Hokkaido Refinery
ldemitsu Kosan Co., Ltd.,
25-1 Masuna-cho Tomakomai, Hokkaido, JAPAN 059-1392

System Technology Development Center

ldemitsu Kosan Co., Ltd.,
26 Anesaki-Kaigan, Ichihara, Chiba, JAPAN 299-0107

45006819@sie.idemitsu.co.jp

ttani@sie.idemitsu.co.jp

Takashi Inoue
Hokkaido Refinery
Idemitsu Kosan Co., Ltd.,
25-1 Masuna-cho Tomakomai, Hokkaido, JAPAN 059-1392
16oo9244@Sie.idemitsu.coJp

Abstract
This paper describes the implementation of coopel'ative
control system for Residue Fluid Catalytic Cracking
Plant in a refinery USing a knowledge based control
system and model predictive multivariable control system
(pMC system). PMC system is effective in the area of
time-delay and inteiference process. However, due to
their poor response to large time-delay and non-linearity.
it sometimes fails to control actual plants in a refinery.
On the other hand, expert operators control their plants
with large time-delay and nonlinearity fairly well by
manipulating the set points of regulatory controllers. The
proposed cooperative control system therefore combines
their advantages. The knowledge based control system is
used to determine set points of the reactor temperature,
feed flow rate and recycle flow rate with large time
delays and non-linearity using 'if then' type rules based
on expert operators' know-how. PMC sysm sets the
targets of PID controllers for other operation variables
and keeps the process within constraints to achieve
desired process conditions, which are difficult for
operators to control because of time-delay and
inteiference among those manipulated variables. The
implemented cooperative control system showed a
satisfactory peiformance in the actual plant.

0-7&03-6456-2/00/$10.00 2000 IEEE

1.

Introduction

From the early stages of its emergence, automatic

control schemes have been implemented

industry.

in

the refining

In most cases automatic control schemes, such

as PID controller

and

model predictive multivariable

control, have been relying on conventional regulatory

controllers because of their simplicity and reliability [1].
These control schemes
delay.

are

effective in the area

dead time and interference.

of time

However, due to their

poor response to large time-delay, non-linearity and

high-level noises, it has been very difficult to

realize

fully automatic control for all process units in a refinery.

Expert operators, working for refineries of the authors'
company, control their plant with large time-delay, long
dead-time,

and

high-level

noises

fairly

well

by

points of regulatory controllers.

company, by nature, wishes to utilize its

manipulating the set

Every refining

assets, no matter whether they are tangible or not, such

as

its control schemes, its

operators'

experience

and

expertise, in order to maximize profit [2]-[4]. In this

1056

Fuel Gas
Wet Gas Compressor
Gasoline. LPG

I To Gas Separation Plant!

M.RccycJe

Heavy Naphtha

Main
Distillation
Column

--=====:::-.L--+
:;

k-

___

H.Recycle

Light Cycle Oil

Residue
Heat Exchanger

Fig.l Process Flow Diagram of Residue Fluid Catalytic Cracking Plant

respect, the authors have devised a cooperative control

crude,

system using knowledge based control system and model

consists of a reactor, two catalyst regenerators, main

with less value into gasoline with higher value. It

predictive multivariable control system. The knowledge

distillation column and gas separation plant. Simplified

based control system manipulates the set points of

process flow

regulatory controller of the reactor temperature, feed

separation plant consists of many unit such as absorbers,

flow rate and recycle flow rate with large time-delays

strippers and distillation columns. Heavy oil fed to the

and non-linearity using 'if then' type rules based on

reactor is cracked at high temperature in the presence of

diagram is shown in Figure

1. Gas

expert operators' know-how. PMC system sets the

catalyst. The cracked oil mixture is fractionated by the

targets of PID controllers and keeps the process

within
constraints to achieve desired process conditions such as

main distillation column into gasoline, light cycle oil,

pressure differences between reactor and regenerators,

from the reactor is reactivated, coke combustion on

heavy cycle oil and residue. Deactivated catalyst

in

drawn

which are difficult for operators to control because of

catalyst,

time-delay and interference among those manipulated

sent back to the reactor. RFCCU is a complex and

the two catalyst regenerators in series and

difficult process to understand [5]. Complexity arises

variables.
This control system has been applied to the optimum

from the reaction kinetics, catalyst hydrodynamics, coke

control of reactor, two regenerators and main distillation

combustion on catalyst, process economics, operating

column of a residue fluid catalytic cracking plant. As a

constraints and process variable interactions that

result, it has become possible to stabilize the whole unit

dominated by the heat balances between reactor and two

at desirable process conditions regardless of whether the

regenerators.

unit is at steady state or transient state, such as switching

alters

feed stocks. This successful implementation of the

requirements.

cooperative control system resulted in a remarkable

instantaneously to the change, and some have long dead

reduction of cost and operators' burden, and increasing

time. The effects of most changes

the high valued product.

distillation column operations further compound the

2.
2.1

Process Overview
Operation

and

Problems

in

Process Overview

Residue Fluid Catalytic Cracking Unit (hereinafter

RFCCU) is a unit, which converts heavy oil, residue

others

Changing
because
Some

one
of

variable

are

the

variables

simultaneously

change

in

respond

are

energy
almost

nonlinear. Main

complexity of RFCCU. Input to the main distillation

column: feed rate, feed properties and heat content

are

not independently controlled, but are dependent on

upstream

reactor

and

two

regenerators

operations.

Changing main distillation column to maximize valuable

product flow rates and qualities is difficult because of the

1057

Knowledge Based System

Flow Rate
- RCO Recycle Flow Rate

Charge

- Reactor Temperature

30 Constraints
++- Reactor, Regenerators, Main
+- Gas Separation Plants

CVs

........

=:
L;;;J

DVs

23 Control Variables

+-

Feed Flow Rate

'-i-- Recycle Flow Rate
t-+-+-- Reactor Temp. .

Colmnn)

'"

PMC System

Total 7 DVs

MVs

CV: Control Variable

Reactor & Regenerators

MY: Manipulate Variable

5 MYs / 7DVs 123 CVs

DV:

Disturbance Variable

Reactor Press

No.1 Reg. Press

10 Control Variables

No.2 Reg. Press

No.1 Reg. Air
No.2 Reg. Air

Feed Flow Rate

rTemp.

HCORecycle

Main Distillation Column

Re

4 MVs ISDVs 110 CVs

Total.5 DVs

TPAP/ADUTY
MTC PIADUTY
RCOP/ADUTY
I----BTM PIADUTY

Fig. 1 Overall Configuration of Cooperative Control System

uncertainties and continuous variations in the input

stream to the

main distillation column. Downstream gas

5)

separation plant is also influenced. by operations of

reactor and two regenerators.

There are interferences among MVs. Therefore, the

magnitude of each interference and time-delay has to

be taken into account.

6)

The above mentioned responses show non-linearity.

Expert operators operate the unit based on their
experience and knowledge. They can handle some of the

2.2 Problems in Operation

Major constraints in the RFCCU are: reactor and two

non-linearity

and

large

dead-time

including

gas

regenerators metallurgical limits, product flow-rate and

separation

quality requirement, air blower capacity,

wet gas

control of reactor and regenerators for desired process

compressor capacity, slide valve differential pressure,

main distillation column overhead cooling, etc. Several

conditions has not always been done because there are

too many interference among MVs. In order to fully

difficulties in terms of controlling the reactor, two

utilize the experience and knowledge of expert operators

regenerators and the

as

while realizing the overall control of the reactor, two

follows:

regenerator and

1)

Because of a lot of constraints in RFCCU, it is

decided to combine a knowledge based system and PMC

main

distillation column

are

necessary to operate manipulate variables (hereinafter

system.

MYs) with monitoring all constraints conditions.

3.

2) Most of constraint change with time by floating with

ambient conditions, feed stock qualities, catalyst
3)

activity and process operations.

There are different time-delays in the responses of
controlled variables (hereinafter CV) versus

4)

MYs.

plants'

constraints. However, the

main

overall

distillation collllDll. the authors

Overview
of
Model
Predictive
Multivariable Control (PMC) System

PMC predicts the future behavior of process units in a

control envelope from the past moves ofMVs with using

Therefore, it is necessary to tal5:e the individual time

the dynamic models of the CVs versus MVs. It

delay into account.

determines the future moves of MVs in order that CVs

Especially, time-delays of gas separation plant

more

than eight hours.

are

will match the target values as close as possible in each

control cycle [6],[7]. The relationship among the CVs

1058

Knowledge Based System

Operation Target .
Operator

-- ------- --- ---,,

----[-----Kn--:--;--- ;::::= r
,
;
,
-- - -'
,
,
-----------:i
,- ,
I I
I
r-+j ------- ---t: -----------------I ;CVj)r--,-------;

@---------------

Operation Target
Operator

1--- -------------------- -

------

--

--

Process Data
:

nnint

Predictive
Control
(LP)
Optimum Target
: MV

Predictive

..

---

!". em

__________________ ___

DV

Reasoning

Model

L-------------s;---!

MV: Manipulate Variable

CV: Control Variable
DV: Disturbance Variable

Process Data

'

:---s;tp-t--------------.J

:_pb.Comro-crn----- 1 ProreiData i

I"___

...

...

_ut_r_-T-,-:-----------:- -:--------:-_:c________J
Outp
_.1i--'-i_
tput
_
r-_Ou
Reactor I Regenerators I Main Column

Plant

Gas Separation Plant

Fig. 3 Structure of Cooperative Control System

4.

andMVs is given below.

minimize:

4.1

f II J..;(yP (1+ k)- y;,J' + II'P,'..,(t+k)'

II

J='

P,

(II

1=1

+ I IJI,'(U;(I+M,}-u;w)'

1='

,If

",I

(1)

,,,,I

subject to

l''

.\1', (t--tJ..) Y/(t)

+

u, (I

11,(1: -lIlIll,(I+,,)+ ''(II,,(k+l)-a,'(II)III1,(t-I)

+ M,)

''I'Au, (I+ k)+u(t -1)

1-(1

(2)

(3)

where
A"qJ"t/f,
are weight coefficients of
objective function, Yp/ is the predicted value of CVs, y'",
is the target ofCVs, t.ui(t) is the move ofMVs at time
t, u;(t) is the value ofMVs at time t, u';" is the target of
MVs, Pj is the prediction horizon, M, is the control
horizon, n is the number of CVs, m is the number of
MVs, ap(k) is the step response coefficient, a;lk) aj,isj')
for all /(>Sj,'
The advantages of the PMC are as follows:
1) It easily handles multivariable problems with dead
time, time-delay and interference with constraints.
2) The step response model used in the controller is
familiar to engineers.
=

Cooperative Control System

Structure of Cooperative Control System

The coopemtive control system consists of two

components, namely knowledge based system and PMC.
PMC system consists of two systems. One is for reactor
and regenerators, the another is for main distillation
column. Overall configuration of cooperative system is
shown in Figure 2. Reactor and regenerators PMC
system has 5 MVs, 23 CVs, 7 Disturbance Variables
(DV). Main distillation column PMC system has 4 MVs,
10 CVs, 5DVs. The structure of cooperative system is
shown in Figure 3. The knowledge based system
determines the set points of the reactor temperature, feed
flow rate and recycle flow rate using 'if then' rules.
Those set points are transferred to the regulatory
controllers for them. PMC system calculates the target of
MVs within using predictive model, predictive controller
gives the set points to the regulatory. Output of
knowledge based system is DVs of PMC system, and
some MVs of reactor and regenerators PMC system is
DVs of main distillation column PMC system. As a
result, knowledge based system and two PMC system
can work cooperatively.

4.2

Knowledge Based System

The system monitors not only 21 constraint of reactor,

regenerators and main distillation column but also 9
constraints of gas separation plant. The constraints of gas

1059

separation plant are difficult for PMC systems to monitor

For example, in case there are not any CVs violating its

MY,

feed flow rate. In cas e

due to large time delay and non-linearity. The system

limit, then increase

monitors whether the process values are violating the

there is at least one CV violating its limit, then decrease

constraints

MY.

or

not and,

in

case they are ,not bound by

constraints, it searches optitfium conditions of the-reactor

such

as

The structure of knowledge i"ule is shown in

Figure 4.

temperature, feed flow rate and recycle flow rate. The

typical constraint rules is shown in Table I.

4.3

Advantage of Cooperative Control System

The knowledge based system covers MYs, which are

Table 1
Upper
Limit
Lower
Limit

difficult for PMC systems to handle due to a large-time

Constraint Rule for CVi and MV

PV

H <PVSH,

H,<PVSH

PV>H"

PS

ZE

NS

Nl3

PV2L

L >PV2L,

L;>PV2L

PV<L,J

ZE

ZE

ZE

ZE

also covers MYs, which change slowly, while PMC

handles MYs which have to be modified more frequently
for the purpose of obtaining stable behavior of cv. The

PV: Present Value of CV;

Ld: 1st Lower limit ofCVi

Hi,: IstUpperlimitofCVi,

delay and non-linearity. The knowledge based system

H;,: 2nd Upper limit ofCV"

L,,: 2nd Lower limitofCV;

H;3: 3rd Upper limit ofCV,

L;3: 3rd Lower limit of CV;

PS: Positive Small Output,

NS: Negative Small Output

PB: Positive Big Output,

NO: Negative Big Output

ZE: Zero Output

control cycle for PMC

from the result of

from CVi constraint rule is PS.

constant value, for instance

tlUii

output

of

MVj

PS is positive small

+ 10 [kIId) of feed flow rate.

Constraint rule of each CV is decided individually using

operator's knowledge.

From

6u!;

of CVi,

final

output ofMVj at time t is calculated. Calculation logic is

as follows:

was

determined as one minute

response test. The knowledge

based system passes the set point of each MY to the

regulatory flow rate controller every four hours.
Advantages of the combined control system are as
follows:

1) The system is

familiar to expert operators since their

operation know-how is embedded in the knowledge

For example, using Table I, if PV of CVi is lower than

1st Upper limit of CVi, then,

step

rules in the knowledge based system.

2) The PMC part of the system covers the area which

operators cannot achieve satisfactory control due to its

3)

interference.
The knowledge based system covers the area which
is difficult for PMC system to handle satisfactorily

. due to its large-time delay.

4)

The knowledge based system covers the area which

is difficult for PMC system to control satisfactorily
due to its non-linearity.

The function of min means that it selects the most

safety output.

S.

Result
The control system has been capable of

maximizing

profits by keeping the CVs at desired conditions. The

result of the performance of the cooperative control
Output
Olcull!l'ion

Lngic

r------. feed Aow Rate

f--+ RcC\de flow Rate
RtatorTemp.

system for three months is summarized in Figure 5.

It is shown that the coke burn ratio of two regenerators

and the

cyclone

air

velocity of reactor are close at

limit value, and the pressure of reactor is kept

as

their

low

as

possible.
I:. uq : Output Vallie of Hh manipul1k vonbabk's xt pl.)Jnl L"3\culatcd by .i-th constraint rult'

Fig.4

Structure of Knowledge Rule

The performance of control after the implementation is

summarized as Table 2.

1060

Fig. 5 Results after Implementation of the System

Ailer

Implem'. on

+2.5

30

60

90

I:)

ii"'

120

!%J

150

180

[days)

After Implementation

stable operation of RFCCU. The knowledge based

system enables the full utilization of expert operators'
know-how and PMC system enables the stable control of
the reactor, regenerators and main distillation column,
which ordinary regulatory control could not handle
nicely. This system achieved: (1) the stable control of
reactor, regenerators and main column distillation, (2)
increasing high valued products, (3) the energy saving,
and (4) the reduction of operators' burden regardless
whether the unit is operated at steady state or transient
state. The authors are planning to implement this
cooperative control system in similar process unit in the
future.

30

60

90
[days]

120

150

180

After Implementation

-''i;-\._-,

- (1.03 [kgicm2]
60

Table 2

90
[days]

120

ISO

180

Improvement Summery

Operation Variables
Coke Burn Ratio
Cyclone Inlet Velocity
Press. of Reactor
Diff. Press. of Slide Valve
Oxygen of Flue Gas

-:rn}piovement

+ 2.5 [%]
+ 0.3 [mls]
- 0.03 fkelcm2]
- 0.04 fkelcm2J
-0.2
['Vo]

After the implementation of the cooperative control

system, all CVs are successfully improved. The overall
economical merit from this implementation is
approximately over one million US dollar per year
because of increasing high valued products and energy
saving. Moreover the 1,000 hour/year reduction of
operators' burden has been achieved
6.

Conclusion

References

[1] K. Hirai: Concepts of Automatic Control and the

Basics of PID Control Technology, Instrumentation
and Control Engineering, Vo1.33, No.9, pp.91-96,
1990
[2] W. H. Bare, R. J. Mulholland and S. S. Sofer: Design
of a Self-tuning Expert Controller for a Gasoline
Refinery Catalytic Reformer, Proc. American Control
Conf.,VoU pp 247-253, 1988
[3] T. Tani, S. Murakoshi, M.Umano: Neuro-Fuzzy
Hybrid Control System of Tank Level in Petroleum
Plant, mEE Tran. on FUZZY SYSTEM, Vol.4 no.3
pp360-368,1996
[4] Y. Iritsuki, K. Suzuki, S. Murata, H. Uno and T. Tam:
Design of Combined Control System Incorporating
Knowledge Based System and, Model Predictive
Multivariable Control System and its Application to
Refining Plant, Proc. ofKES'98, pp26-34, 1998
[5] T.D.V. Lin: FCCU Advanced Control and
Optimization, Hydrocarbon Process, April pp.107114,1993
[6] Cutler and Remaker: Dynamic Matrix Control - A
Computer Control Algorithm, AlChE Meeting,
Houston, TX (1979)
[7] Van Hoof, Cutler and Finlayson: Application of a
Consttaint Multivariable Controller to a Hydrogen
Plant, American Control Conference, Pittsburgh, PA,
June pp.21-23, 1989

In this paper, the authors demonstrated the effectiveness

of the cooperative control system, which enables the

1061