Refinery skyline under a grey sky, columns, stacks and a flare, in black and white
CHEMICALS

Real time optimisation of the cat cracker.

The best way to run a cat cracker moves with feed, catalyst and prices. EntroMetrix learns your unit from the historian and re optimises every set point in under a second, inside the limits.

KEY RESULTS
+2.3%
unit margin per barrel
+1.7%
gasoline yield
−3.2%
energy per barrel
−2.6%
dry gas make
−2.9%
carbon intensity
01 · THE PROBLEM

The optimum moves, and a fixed target lags behind.

The most profitable operating point shifts with feed quality, catalyst activity and the prices of gasoline, LPG and distillate, and it sits against several limits at once.

Operators hold targets chosen for a typical day and leave margin on the table to stay clear of the compressor, the air blower and product quality. A conventional optimiser solves on a slow cycle, so its advice arrives after the feed has moved.

01Margin against the moving optimum, and gasoline yield against conversion.
02 · WHAT IT COSTS YOU TODAY

Margin left on the table every hour.

Idle envelope: a fixed margin below the compressor and blower limits is capacity you own and never use.
Lagging advice: a slow optimisation cycle recommends a point the feed and catalyst have already drifted away from.
Yield given away: running below the conversion that pays sends gasoline value to dry gas, slurry and coke.
02Gasoline yield, energy, dry gas and carbon, before and after.
03 · WHAT ENTROMETRIX DOES

A model of your unit and an agent that keeps pace.

Reads the whole unit: feed preheat, riser, regenerator, fractionator and gas plant as one coupled system, from your own historian.
Checks itself first: the learned model is compared with the rigorous unit model before it is trusted to advise.
Trades the objectives: gasoline and LPG yield, margin, energy, coke and carbon in one decision, with the hard limits built in rather than penalised afterwards.
Keeps pace: re optimises every set point in under a second as feed, catalyst and prices drift, and offers a set of feasible points to choose from.
03Change in the product slate.
04 · HOW YOU STAY IN CONTROL

Advises, does not act.

Your limits: reactor temperature, pressure, catalyst to oil ratio and compressor load stay inside the limits your engineers set.
Your history: trained and tested on your own historian before it advises.
Your operators: every recommendation goes to the board with the yield, margin, energy and carbon it implies, and the operator decides.
Your control loop: offline first, with no closed loop step without your sign off.
Your feed changes: the model watches its own error, detects a feed change and refreshes without a full retrain.
04Compressor load against its limit over a run.
05 · WHAT YOU GAIN

Always at the moving optimum.

A Higher Value Slate

Gasoline and LPG rise while dry gas, slurry and coke fall.

The Envelope, Fully Used

The compressor runs closer to its limit because the limit is held by construction.

Margin Captured

Across feed and price conditions the agent captures most of the available margin, well ahead of a slow cycle.

05Cumulative margin uplift over a run.
CASE STUDIES

See what the model finds in your plant.

A short call with our engineering team, your process data stays on site.