(7c) Enhancing Ethylene Plant Operations through Generative, Predictive, and Prescriptive Applied AI Solutions

The integration of generative capabilities into predictive and prescriptive analytics within Applied AI solutions has significantly augmented the operational efficiency of a leading petrochemical manufacturer. This innovative approach resulted in a remarkable 134 KTA increase in production, 2,475 GBTU in energy savings, a reduction of 164 KTA in CO2 emissions, a 3% decrease in overall greenhouse gas emissions, and the prevention of unplanned shutdowns at least three times within the first year across various production units, including Olefins, LDPE, LLDPE, HDPE, EO-EG, Ammonia, and Methanol plants.

An effective Applied AI solution necessitates the meticulous orchestration of several key components:

• Selection of strategic use cases tailored to specific operational challenges
• Identification and integration of relevant data from sensors and advanced smart sensors, ensuring redundancy and capturing additional insights on unmeasured parameters
• Robust data handling and processing methodologies
• Application of advanced analytics leveraging appropriate algorithms to facilitate predictive, prescriptive, and generative analytics
• Comprehensive presentation of insights, recommendations, and forecasts, alongside descriptive analytics
• Capability for scenario analysis to support diagnostics and optimization efforts
• Seamless integration with existing or reengineered workflows
• Automation of action implementation through integration with advanced process controls (APCs) at the shop floor level
• Provision of remote access for experts to monitor and analyze data
• Utilization of collaboration software to enhance team communication and decision-making

This paper will delve into the necessity and functionality of each component outlined above, alongside the enabling technologies and challenges encountered during the implementation of these Applied AI-based digital solutions across diverse geographical settings. Insights drawn from practical experiences will illustrate how value is generated through this comprehensive approach, ultimately advancing the operational landscape of ethylene production.