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Raissa Maria Cotta Ferreira da Silva, Petrleo Brasileiro S.A, Brazil; Luciano Villanova de Oliveira, Petrleo Brasileiro S.A., Brazil; Joyce Stone de Souza Aires, Petrleo Brasileiro S.A., Brazil. Abstract. Neural Network technology is an approach for describing process data behavior, using mathematical algorithms and statistical techniques. The use of neural network for modeling process is increasing in several kinds of chemical industries. This paper makes comments about successful critical factors, advantages and disadvantages of this methodology. Moreover, it presents some applications in Hydrotreating process of the petroleum refining industry. In feedstock Hydrotreating, the knowledge about characteristics of process regarding product property estimation, hydrogen chemical consumption and removal of contaminants (sulfur, nitrogen, aromatics), is very important to process optimization, product quality control and environment protection. The Neural Network technique has been used to model the behavior of the hydrogen chemical consumption, generation of light gas, the conversions of the hydrogenation of aromatic hydrocarbons (HDA), hydrodesulfurization (HDS) and hydrodenitrogenation (HDN) reactions and product physical properties. Operation conditions and some relevant feedstock properties were selected as input variables. In addition, Neural Networks have been built to predict the cetane number and stability of feedstock and hydrogenated products. The models were developed with experimental data, which were obtained in hydrogenation pilot plants from PETROBRAS. This paper presents a comparison between pilot plant data and estimated data. 1. Introduction
The neural network technology is used to describe the behavior of systems, through mathematical algorithms and statistical techniques, which try to mimic the human brain. The purpose of developing a neural network is to produce a tool that captures essential relationships in data. Artificial neural networks are computing tools composed of many interconnected elements called processing elements or neurons. A neuron performs a weighted summation of its input array and the application of a non-linear transfer function to this summation to give an output. The output of a neuron can be connected to input of other processing elements through weighted connections. Learning is the process of modifying the connection weights, i.e., it is the fitting of parameters in the modeling. These weights are obtained through an optimization process with the objective of minimizing the differences between the predicted and the observed outputs. The trained network can be used to estimate unknown output data; giving to the trained network the input data of the sample not included in the data set, the network calculates corresponding output data. Although a large variety of architectures exist, the feed-forward architectures, where data propagates in only the forward direction, are more useful for steady-state modeling. At present, there is the predominance in the literature of the supervised multi layer feed-forward architecture trained by Backpropagation[1]. Rarely, supervised multi layer feed-forward networks with an alternative approach are considered, such as cascade correlation architecture. The cascade correlation algorithm[2] is an option that attempts to reduce the complexity in the net construction process by simultaneous training and design of the network. The procedure begins with a minimal network that has some inputs and one or more output nodes but no hidden nodes. The hidden neurons are added to the network one by one, thereby obtaining a multi layer structure. Each new hidden neuron receives a connection from each of the input nodes and also from each preexisting hidden neuron; in other words this mode of construction entails adding hidden units one at a time, and always connecting all the previous units to the current unit. The procedure of adding new hidden neurons is continued in the manner described until satisfactory performance is attained. In the refining sector, there is growing pressure to produce higher quality and cleaner products at lower cost. Thus, refinery processes must maintain great flexibility in their manufacturing operations due to tighter environment requirements. In this sense, modeling, simulation and optimization are increasingly viewed as essential activities and a significant competitive differentiation among the refining industries to achieve these challenges.
There are a variety of tools to build a model, using both on-line data sets, by collecting real time plant data, or off-line data sets, by using data from carefully conducted pilot plant tests. Regarding the required ending use, modeling approaches can vary extensively; they range from detailed representations of the unit based on first-principles to empirical procedures. Normally, these models have associated optimizers, which are capable of predicting the most economic operating mode, attempting to force technical and commercial constraints. An important prerequisite for process optimization is the availability of a representative mathematical model. Process models based on first-principles are developed from fundamental laws of conservation of mass, energy, momentum, and other chemical engineering principles. However, this approach often leads to highly complicated nonlinear models that require simplifying assumptions for their solution. In many practical industrial situations, fundamental models are difficult to obtain for being computationally time-consuming and for lack of sufficient understanding about the process under consideration. For optimization purposes, which involve quite a high number of simulations, the model has to be able to describe the system accurately and, at the same time, has to run fast. In this case, neural network offers one of the most promising tools for modeling.
Neural networks have to be first trained with a set of data and then tested using another set of data different from that used in the training, in order to assess the prediction capability. If the neural network is overtrained, the results from the test data will likely be unacceptable, leading to the conclusion that the neural network will not work adequately. A typical approach when developing a neural network is to keep an unused data set for final validation. The purpose is to provide an independent test of the neural network performance. Once the neural network has been trained and tested, if the results have not been satisfactory, the developer may make some changes to the neural network topology, then retrain and test it again. The same data sets may be used for training and testing or the data may be split into different random sets. In either case, the test data will be used to modify the neural network architecture. Nevertheless, it is necessary to spare a third data set not used during the development process[4]. The topology of the model has a significant effect on the training efficiency and the estimation accuracy. There is no rule to decide on the numbers of processing elements, and they are usually determined empirically through preliminary trial and error experimentation. However, it is recommended to use as few hidden units and training passes as possible through the data. The greater the number of neurons, the greater the amount of input/output training patterns, which must be used and the longer it takes to train the network. Generally, the use of only one hidden layer for backpropagation neural networks gives suitable results.
was determined by liquid chromatography (LC) and gas chromatography-mass spectrometry (GC-MS). In addition, Leeuwen et al. [16] applied neural networks to the results of gas chromatographic analysis of 824 gasolines, each separated in 89 PIANO groups (paraffines, iso-paraffines, aromatics, naphthenes, olefins), in order to model the relation between PIANO groups and the octane number of gasoline.
Table I Summary of Used Main Procedures for Process and Product Neural Networks Used Main Procedures Division of data set Commercial Transformation Selection of Training Test Software Package of variables variables data set data set Professional/II Plus fix random data fix random data No No sets, 80% of all sets, 20% of all NeuralSim Yes Yes different random data sets, 70% of all Different random data sets, 20% of all
The predictive capacity of the neural networks for a new feedstock depends strongly on similarity between the new one and data set used in the neural network modeling. Hierarchical clustering method[17] was applied to the feedstock, using the city-block (Manhattan) distance as similarity measure and unweighted pair-group average linkage rule, in order to evaluate the level of security in the neural model prediction. In most practical applications of cluster analysis, the investigator has to know enough about the problem to select an appropriated final configuration. In this work, the input variables of the trained neural networks were used as the input variables of cluster analysis. In fact, the input variables of nets have different weights in the estimation of the output variables. Thus, the variables in the cluster analysis were used in the non-weighted form, because it is difficult to stipulate their weights.
Table III Performance Measures for Cascade Correlation Neural Networks (NeuralSim package) Viscosity Viscosity H2 C1 C2 C3 C4 HDS HDN HDA Cons. @ 20oC @ 50oC Intercept -44.3 -3.9 -4.2 -1.9 -3.7 -0.44 0,003 0,001 0,004 0,006 Slope 1.43 1.04 1.03 0.95 1.33 1.08 0,99 0,96 0,89 0,88 R2 0.71 0.60 0.75 0.97 0.86 0.94 0,96 0,95 0,96 0,94
Density
Intercept Slope R2
D-2887 T10
D-2887 T30
D-2887 T50
D-2887 T70
D-2887 T90
Table IV Comparison between Pilot Plant Results and Process Neural Network Results Conditions and Properties FEED 1 Product 1_1 FEED 2 Product 2_1 PPH2, bar --46.8 --62 WABT, oC --379.7 --350.5 LHSV, h-1 --2.0 --1.0 EXP. EXP. NET1 NET2 EXP. EXP. NET1 NET2 Density 20/4oC 0.8854 0.8730 0.8726 0.8731 0.9132 0.8934 0.8949 0.8922 Viscosity @ 20oC, cSt 13.93 10.95 10.17 11.01 17.93 14.59 12.19 15.67 Viscosity @ 50oC, cSt 5.39 4.70 4.21 4.67 6.240 5.50 5.02 5.60 T ASTM D2887, oC 10 w % 249.0 234.0 239.5 236.5 247 234.0 234.8 234.8 30 w % 297.0 287.0 287.6 290.4 298 283.0 285.5 288.0 50 w% 327.0 319.0 323.8 321.1 350 341.0 340.7 342.2 70 w % 361.0 353.0 356.1 356.2 383 377.0 374.7 377.1 90 w % 418.0 408.0 410.6 410.5 421 416.0 414.8 416.1 HDA conversion, w % --22.3 21.1 23.1 --35.2 27.3 26.7 HDN conversion, w % --81.2 73.9 78.2 --77.9 66.4 72.1 HDS conversion, w % --99.9 97.6 97.7 --98.1 95.1 96.6 --46 39 45 --100 82 89 H2 Consumption, Nl/l Stability Unstable Stable Stable --Unstable Stable Stable --Cetane Number 40.8 43.5 --43.4 33.8 39.1 --37.4
80 60 40 20 F_11 F_10 F_9 F_8 F_13 F_12 F_5 FEED 1 F_4 F_3 F_2 F_17 F_16 F_15 F_14 F_7 F_6 F_1 0
(a)
(b) Fig. 1. Tree clustering diagram for the 17 feedstock together with (a) FEED 1 and (b) FEED 2
F_11 F_10 F_9 F_8 F_13 F_12 F_5 FEED 2 F_4 F_3 F_2 F_17 F_16 F_15 F_14 F_7 F_6 F_1
7. Conclusions
Neural network technology is a reliable tool in product and process modeling. It can be successful applied in Hydrotreating Process for predicting the behavior of the hydrogen chemical consumption, generation of light gas and the conversions of the HDA, HDS and HDN reactions. Another important application is related to the product physical properties (density, viscosity, simulated distillation temperatures), as well as the cetane number and stability of feedstock and hydrogenated products. The models have been used in process simulator and optimizer designed with friendly user interface. The network models can be used to properly plan the operation of a refinery according to fluctuating demand and to determine the blend of feedstock appropriate for getting a pre-specified product quality. In addition, the neural networks can be applied in research project and unit design, reducing the number of pilot plant tests used in such applications. One important key element able to increase benefits in the area of process modeling and optimization is to choose a reduced number of feedstock properties that can be easily measured in the industrial plant. The neural network models performance depends strongly on similarity of new feedstock related to feedstock data bank. In this way, the cluster analysis can be used to increase the reliability of model predictions.
References
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