How much do you know about the applications of petrochemical simulation systems?

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Currently, the applications of the petrochemical simulation systems developed by Qinhuangdao Yuandao Technology Development Co., Ltd. are not limited to the skill training of operators; their scope of use includes skill training, skill assessment, safety analysis and accident simulation, as well as production guidance. 1. Skill training: (1) Training prior to the commissioning of new or upgraded facilities. The Yuan Dao Technology simulation system can accurately simulate the start-up, shutdown, normal operation, as well as various accident scenarios in a factory, including the related operations. Training on a simulation system allows operators to gain experience in just a few weeks that would otherwise take 2 to 5 years on-site. Therefore, training on the simulation system can reduce the commissioning time of new production units and save on commissioning costs. It also allows operators to become familiar in advance with the methods of operating the DCS, thereby ensuring a smooth commissioning and normal operation of the units. (2) Skill training for on-duty personnel: The skills of operators are essential requirements for the competence of staff in petrochemical enterprises, and skill training serves as a human resources foundation for the continuous development of such enterprises. In recent years, the operational pattern of petrochemical companies, characterized by long operation cycles and few accidents, is on one hand a positive development; yet it also poses significant risks. In the event of an emergency, staff will be caught off guard, as past experiences may have been forgotten, or even if they haven’t been forgotten, their skills may no longer be up to par. This could result in severe losses for the companies, as well as casualties. Therefore, it is very necessary and important to regularly train the on-duty operators in their skills. (3) Training of system operators: For each production facility, it is both a hope and a requirement for corporate development to train system operators who are proficient in one specific task but knowledgeable in multiple tasks. However, due to various factors, it is difficult to develop the skill of performing multiple tasks by one person in actual production processes. (4) Skill training for employees who change roles or those new to the company: Prior skill training before taking on a new position is key to enabling them to adapt to it successfully. Providing operational skills training for these individuals on a simulation system yields better results than simply conducting training on-site at the factory. 2. Skill assessment: Skill assessment is generally divided into two parts – what one should know and what one should be able to do; simulation serves as the main method for assessing the latter aspect. At present, the competency assessment for major units in petrochemical processes such as catalysis, atmospheric and vacuum distillation, hydrocracking, and reforming is mainly carried out through simulation exams. 3. Safety analysis and accident training: The Yuandao Technology petrochemical simulation system offers great flexibility for developing skills in handling accidents as well as for conducting assessments. It allows the difficulty of training and testing to be adjusted appropriately, thereby making the simulation system more reflective of real-world production conditions. Additionally, it has wireless expansion capabilities, which **extends the lifespan of the simulation system**. It requires trainees to have a thorough understanding of the processes and equipment in order to accurately determine the cause of an accident based on the observed symptoms, thereby enabling timely handling. It also provides production staff with simulated accident scenarios for conducting safety analysis and accident resolution. 4. Production Guidance (1) Testing and Optimization of Operation Schemes a. Testing and Optimization of Start-up and Shutdown Schemes The Yuandao Technology simulation system allows for the design and selection of different start-up and shutdown schemes, which can be tested within the simulation environment to identify the best options. This helps to save time, reduce energy consumption and raw material use, thereby maximizing economic benefits through the selection of the optimal start-up and shutdown schemes. b. Testing of ultimate processing capacity and production guidance: In the simulation system, production factors (such as processing load, raw material composition, performance parameters of various equipment, etc.) are deliberately changed, or different external disturbances are introduced. By adjusting the operating conditions, various tests are carried out to examine the device’s various \"ultimate processing capacities\" and identify the \"bottleneck\" points. It enables technicians and operators to fully understand the adaptability of the device and the coping methods under various influencing factors, while also providing a basis for feasible plans for the device’s further modification. c. Testing and optimization of energy utilization: On the simulation system, by adjusting relevant operational parameters, performance parameters of heat exchange equipment, or heat exchange processes, efforts are made to find better ways of utilizing energy while ensuring that the product meets quality standards. This helps to reduce the energy consumption of the equipment, especially under conditions that are not ideal or when certain production factors are suboptimal (such as unsuitable raw material composition, inadequate load, or other problematic production factors). The goal is to achieve lower energy consumption for the equipment. (2) Testing and optimization of control system schemes: On the Yuan Dao Technology simulation system, the local control system is redesigned or the original design scheme is modified for testing, in order to find better control schemes or to provide qualitative and quantitative basis for the advanced control of the device. It is also possible to tune and adjust the existing control system parameters, thereby making the device’s normal operation more stable and improving its resistance to interference. For particularly complex control algorithms or logical controls, simulation tests are conducted in a simulation system prior to the deployment of the device, in order to ensure the feasibility and safety of such complex control algorithms (such as advanced control algorithms) or logical controls. (3) Testing and optimization of the plant renovation plan: For the plant renovation plan, simulation tests can be conducted in a simulation system in advance to analyze its feasibility and effectiveness. This provides a suitable testing environment and conditions for the renovation of the plant, as well as scientific qualitative and quantitative criteria and viable methods for such renovation. (4) Conduct a thorough feasibility analysis to provide a testing environment for Advanced Process Control (APC) and On-line Process Optimization (OPT), ensuring the smooth and safe operation of the systems.