Industrial implementation of a real-time optimization strategy for maximizing production of LPG in a FCC unit

Abstract This paper describes the implementation of a new non-conventional real-time optimization strategy applied to the maximization of LPG production in a fluid catalytic cracking (FCC) converter in the refinery of Sao Jose dos Campos in Brazil. Focus is given on the difficulties of integrating optimization to existing controllers. The first commissioning tests are described in detail. They show that the benefits from optimization are not restricted to economic values. Implementation of the strategy gives directions on how to change the operating mentality of the plant operators. The implemented optimization strategy is shown to be able to maintain control of the plant even in the loss of several manipulated variables and in the presence of strong disturbances. Furthermore, we show that the optimization strategy is able to drive the process to new operational points.