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Development & analysis of an IT based system to monitor the performance of a multi-product batch lubricant blending

Development & analysis of an IT based system to monitor the performance of a multi-product batch lubricant blending plant. Abdulla Mohammed Al-Shehhi Adel Mohamed Al-Hajri Ahmed Obaid Al-Falahi Mohamed Abdalla M.Salim. Acknowledgments:.

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Development & analysis of an IT based system to monitor the performance of a multi-product batch lubricant blending

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  1. Development & analysis of an IT based system to monitor the performance of a multi-product batch lubricant blending plant Abdulla Mohammed Al-Shehhi Adel Mohamed Al-Hajri Ahmed Obaid Al-Falahi Mohamed Abdalla M.Salim

  2. Acknowledgments: • We would like to convey our deep appreciation and gratitude to: • our academic supervisorDr. Farid BENYAHIA • Dr. Ali Guidoum & Mr. Arman Asghar (our external co-advisors from ADNOC Distribution Company). • Dr. Mohamad Abdel-Hafez (our coordinator from Electrical Eng. Department).

  3. Content of Presentation: • Define the problem. • Um Ennar real plant. • Solution tool. • Simulation of Um Ennar Plant using SPD. • Scheduling approach • Sample tasks and results. • Conclusions. • Difficulties. • Future work and Recommendations.

  4. Define the problem: • ADNOC Distribution is facing a severe scheduling problem despite a recent partial automation of the plant. • It is a real industrial problem from practical life. • Objective is to design an IT based system that can improve operation scheduling and plant productivity.

  5. Solution tool: Super-Pro Designer simulation tool: • SPD is a superset of BatchPro, EnviroPro, and BioPro Designer. • Used in batch and continuous processes simulation. • More suitable for chemical and biochemical systems. • It facilitates modeling, evaluation and optimization of integrated processes in a wide range of industries.

  6. ADT Tank Pump BO Tank Pump Heat Exchanger Heat Exchanger Blending Kettle Holding Tank Cans Truck Ship Extract from Um Ennar real plant:

  7. Simulation Model of Um Ennar Plant using SPD:

  8. Some tasks: Studying effect of process variable Effect of some variables on the simulation: Flow rate (transfer in & out) effect. Clean in place (CIP) time effect. Holding timeeffect.

  9. Some tasks: A sample order was studied to: • See if the delivery time can be respected • Check product quality an revenue

  10. Conclusions: • The objectives of this project were successfully fulfilled and the system developed can be applied to the scheduling problem at ADNOC. • The method developed in this work can be extended to the full range of products using more sophisticated tools (full version of software). • With a series of "what-if" scenarios it is possible to arrive at an optimum situation. This can be done quickly with a software.

  11. Difficulties: • Scheduling batch blending of multiple products is a complex operation. • Defining real life problems is very difficult and requires a great deal of work and experience. We have appreciated this in the project. • It is impossible to predict demand and plan for a long period of time, because there are so many uncertainties and there are too many constraints.

  12. Future work and Recommendations : • This work can be extended further in a new Graduation Project using full plant data and full software version. • We recommend to use a full range of plant data from the field in order to compare the results achieved theoretically with the one obtained practically. For this, the full version of the software (Super-Pro Designer) must be used. • We recommend to the university to give more industry based projects to the engineering students and help them appreciate real problems.

  13. Thanks for listening

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