Trends in Advanced Process Control in the polyolefin industry Nordic Process Control Workshop, 29-30 January 2009, Telemark by Bjørn Glemmestad, Borealis Thanks to colleagues: Ketil S. Andersen Staffan Haugwitz Øivind Moen

Outline Purpose of presentation Polyolefin industry, Borealis and a typical polyolefin plant What is meant by APC (Advanced Process Control) in this presentation Status and trends MPC Real Time Optimization (RTO) Transition management Planning and scheduling Summary and suggested focus areas for further research February 16, 2019 Presentation title

Purpose of presentation Background Different industries develop differently with respect to Advanced Process Control Purpose Present status, trends and to suggest research needs within APC in the polyolefin industry In addition: Recruitment February 16, 2019 Presentation title

Polymer (polyolefins) Polyolefin chain Monomer (olefins) Polymer (polyolefins) Ethylene or propylene Polyethylene or polypropylene February 16, 2019 Presentation title

Providing solutions in Polyolefins infrastructure We focus on three specific market sectors: Infrastructure – that’s pipes for utilities such as water, gas and sewage and for oil transport as well as power and communication cables Automotive components that enhance safety and bring light- weight energy saving and corrosion-proof solutions Advanced packaging –niche and specialised applications in rigid moulded and flexible film packaging as well as highly advanced medical applications We are confident that our choice to focus on these strategic markets will continue to lead to profitable growth. automotive advanced packaging Copyright © 2008 Borealis AG February 16, 2019 Presentation title

Borealis: where we are Borealis locations Borouge locations Production Plants: Austria, Belgium, Brazil, Finland, Germany, Italy, Sweden, United States Innovation Centres: Austria, Finland, Sweden Customer Service Centres: Austria, Belgium, Finland, Germany, Italy, Singapore, Sweden, Turkey, United States Head Office: Austria Borouge locations Production Plant: Ruwais (UAE) Customer Service Centres: Abu Dhabi (UAE), China, India, Singapore Sales Offices: Abu Dhabi (UAE), Australia, China, Lebanon, New Zealand, Saudi Arabia Head Offices: Abu Dhabi (UAE), Singapore Together with Borouge, we operate production plants, innovation centres, customer service centres and sales offices all over the world. We are present in 20 countries and have customers in more than 120 countries from Brazil to New Zealand. Copyright © 2008 Borealis AG February 16, 2019 Presentation title

Investment in innovation capability Expansion at our International Innovation Centre in Linz, Austria New facilities at the Innovation Centre in Porvoo, Finland Borstar® PP pilot plant in Schwechat, Austria Investment in a new Innovation Centre in Abu Dhabi, United Arab Emirates Continue to leverage capacities at our Innovation Centre Stenungsund, Sweden This is underpinned by the ongoing development of our Innovation Centres and our desire to maximise the speed of bringing advanced solutions to market. Borealis is currently investing substantially: Over the next few years, we will invest EUR 25-30 million into our International Innovation Centre in Linz, Austria where we develop solutions for automotive, film & fibre, moulding, base chemicals and polymer research, We are currently investing EUR 9 million in new facilities and laboratories to create a single Innovation Centre building at our centre in Porvoo, Finland. We are on the way to completing a PP Borstar® pilot plant in Schwechat, Austria that will help speed up the delivery of new products to the market Our European innovation centres, which also includes an Innovation Centre in Stenungsund Sweden for wire & cable and pipe, will be complemented on a global scale by Borouge’s planned innovation centre in Abu Dhabi which is planned to open in 2009. In order to provide further impetus to our step change innovation programme we announced the creation of a new Science and Technology Advisory Board in February which comprises well respected experts in the fields of plastics. They will further stimulate and challenge our own thinking so that we can go beyond the level of innovation we have today. Copyright © 2008 Borealis AG February 16, 2019 Presentation title

Example of a polyolefin plant 2nd Gas phase reactor Loop reactor 1st Gas phase reactor Ethylene feed Hydrogen feed Propylene feed Catalyst feed Prepolymerisation reactor To dry-end part of plant C2 feed H2 feed C3 feed Monomer Polymer February 16, 2019 Presentation title

What is meant by APC in this presentation Plant Regulatory control Supervisory control Real Time Optimization Planning/scheduling MPC RTO Transition management Planning and scheduling February 16, 2019 Presentation title

Status and trends within MPC (PO industry) Linear MPC only in limited use (and fading out?) Nonlinear MPC used (50%?) Control of production rate, reactor conditions and partly product quality Mainly commercial MPC. Borealis use in-house technology Trends Increased use of nonlinear MPC in reactor area APC/MPC in recovery area? Challenges Robust nonlinear MPC Understanding product quality control February 16, 2019 Presentation title

Status and trends within RTO What could it be? Minimize production cost Status Practically not used, but probably some scarce tests Trends Hopefully some projects during the next 5-10 years Possible that ‘simplified’ methods will be developed Challenges More complex modeling compared to MPC Modeling of constraints and understanding of quality aspects Recovery section Gas losses Feed Product Cost of monomer loss Cost Purge Total variable cost Catalyst cost February 16, 2019 Presentation title

Status and trends within transition management Product B Status Commercial products for automated transitions exists. (Semi-) commercial products to find optimal transition off-line exists. Some industrial implementations, but not very common Incentive to reduce transition costs, but this can be done in many ways H2 Intermediate product Product A Hours Trends Possible that specific systems for transition management get common Challenges To develop systems that are profitable February 16, 2019 Presentation title

Status and trends within planning and scheduling E.g. production cycle optimization Trends Lot of general academic research Little specific products for the PO industry Challenges Develop useful systems Planning and APC in totally different organizations 4-6 weeks H2 Status Little real optimization Focus is to meet customer demands February 16, 2019 Presentation title

Summary (APC in polyolefin industry) Nonlinear MPC has become common during the last decade RTO, transition management and planning/scheduling: Commercial products and applications are much more scarce and development is needed Further research to support improved operation in this industry can be: Very robust nonlinear MPC and better understanding of quality control Development of efficient methods for economic optimization of operation Develop useful tools to optimize scheduling and planning February 16, 2019 Presentation title

We have one or more vacant positions for the right persons… Thanks for your attention! February 16, 2019 Presentation title

End of presentation Presenter Name(s) Date The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis extends no warranties and makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors. February 16, 2019 Presentation title