A Real-Time Optimization Strategy for Small-Scale Facilities and Implementation in a Gas Processing Unit

The rise of new digital technologies and their applications in several areas pushes the process industry to update its methodologies with more intensive use of mathematical models—commonly denoted as digital twins—and artificial intelligence (AI) approaches to continuously enhance operational efficiency. In this context, Real-time Optimization (RTO) is a strategy that is able to maximize an economic function while respecting the existing constraints, which enables keeping the operation at its optimum point even though the plant is subjected to nonlinear behavior and frequent disturbances. However, the investment related to the project of commercial RTOs may make its application infeasible for small-scale facilities. In this work, an in-house, small-scale RTO is presented and its successful application in a real industrial case—a Natural Gas Processing Unit—is shown. Besides that, a new method for enhancing the efficiency of using sequential-modular simulator inside an optimization framework and a new method to account for the economic return of optimization-based tools are proposed and described. The application of RTO in the industrial case showed an enhancement in the stability of the main variables and an increase in profit of 0.64% when compared to the operation of the regulatory control layer alone