UC-363
Catalyst Ageing & Reactor Yield Advisor
Tracks catalyst activity through the run, forecasts the end-of-run date at each severity, and recommends the yield set-point envelope.
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The Challenge
Reactor runs are ended on a calendar rather than on catalyst condition, giving away weeks of production or risking an unplanned trip. Activity is inferred from spot samples and one technologist's memory.
How It Works
- Reads reactor control tags, feed and product assays, supplier data and past run records.
- Models deactivation against feed quality and severity, and forecasts the end-of-run date.
- Gives the process engineer a weekly severity envelope and a dated end-of-run forecast.
What It Removes
- Manual weekly catalyst activity calculations
- Calendar-based end-of-run decisions
- Spot-sample guesswork on feed severity
Input Data RequirementsReactor and furnace historian tags, feed and product assays, catalyst supplier activity data, past run and regeneration records, yield accounting
Output FormatWeekly catalyst activity curve with a dated end-of-run forecast, a recommended severity and feed envelope, and a yield-at-risk figure per reactor
“We pull the catalyst on the calendar because nobody wants to be the one who let the reactor trip”