Module 06 · Real-Time Optimization
Continuous Real-Time Optimization
Continuous nonlinear economic optimization against the live digital twin. Refinium RTO delivers optimal APC setpoints every few minutes — extracting maximum margin within all operating constraints, automatically and without operator intervention.
06.1 · Overview
Refinium RTO
Refinium RTO is the real-time optimization module. It continuously solves the nonlinear economic optimization problem using the live, calibrated digital twin and current commodity prices — delivering updated APC setpoints every few minutes. Where Plan answers "what should we make this month," RTO answers "what setpoints maximize margin right now."
06.2 · Why It Matters
Key Capabilities at a Glance
01
Margin Captured Continuously
Every few minutes, RTO solves for the setpoints that maximize margin against the current model and current prices — and delivers them straight to the APC layer.
02
Nonlinear Optimization
Unlike linear approximations, RTO uses the rigorous nonlinear process model. Yields, energy, hydrogen, and quality are all solved correctly — not approximated.
03
Live Commodity Prices
The economic objective updates continuously with live crude, product, and utility prices through Refinium Finance.
04
Constraint Shadow Prices
Every binding constraint reports its shadow price, telling operations and engineering exactly which constraint is most valuable to relieve.
05
Direct APC Integration
Optimal setpoints flow directly to APC controllers. Operators see the recommendations and the economic justification together.
06
No Stale Models
RTO runs against the live, calibrated model that Refinium Twin maintains — so optimization is always grounded in current plant reality.
06.3 · Technical Depth
Full Capability Set
Every capability included in Refinium RTO.
Nonlinear Optimization Engine
Successive quadratic programmingInterior point methodsTrust region methodsMulti-start solvingActive set strategyInequality constraintsEquality constraintsBound constraintsSolution stabilityInfeasibility recovery
Economic Objective & Pricing
Live commodity prices via FinanceCrude differentialsProduct netbacksUtility costsCatalyst & chemicalsQuality premiumsPenalty functionsMulti-product marginMulti-period objectiveDiscounting
Constraint Management
Equipment ratingsHydrogen network limitsFCC capacityHydrotreater capacityColumn flooding marginWet gas compressor limitsSulfur emissionsSpecification constraintsActive constraint reportingShadow price calculation
APC Layer Integration
Optimal setpoint deliverySetpoint move limitsRate-of-change limitsOperator approval workflowOverride handlingWatchdog timersHeartbeat monitoringFailover behaviorAPC-friendly trajectoriesDisturbance rejection
Operator & Engineering Workflow
Recommended action displayMargin attribution dashboardConstraint margin displayWhat-if scenario solveManual override modeApproval queueAudit trailPerformance reportsMargin realization trackingTuning interface
06.4 · Use Cases
Refinium RTO in Action
Scenario
What operating changes maximize today’s margin?
RTO continuously solves the nonlinear economic optimization using the live digital twin and current commodity prices — delivering updated APC setpoints every few minutes to extract maximum margin within all operating constraints.
Scenario
Optimize FCC APC setpoints for maximum conversion
The APC engineer uses RTO and the calibrated process model to identify optimal riser temperature, cat-to-oil ratio, and feed preheat — maximizing FCC conversion and gasoline yield while respecting regenerator temperature, wet gas compressor limits, and hydrogen constraints.
Scenario
Quantify the value of relieving a binding constraint
When wet gas compressor capacity becomes the binding constraint, RTO reports the shadow price — telling engineering exactly how much margin/day a debottleneck would unlock.
06.5 · Integrated Platform
How Refinium RTO Connects
Refinium RTO is part of the integrated Refinium platform. Every module shares the same continuously calibrated refinery model.
Refinium Twin
RTO solves against the live calibrated model that Twin maintains.
Refinium Finance
Finance supplies live commodity prices and computes margin for the objective function.
Refinium Process
The rigorous Process model is the basis for the nonlinear optimization.
Refinium Plan
RTO drives the plant toward the daily target Plan establishes.
See Refinium RTO on Your Refinery
Request a personalized demo. We will walk through Refinium RTO on your refinery's actual configuration.
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