Post on 06-Mar-2018
© ABB Group November 14, 2014 | Slide 1
Overview of hydrocarbon petroleum industryFourier transform infrared in refineries
Dr. Michael B. Simpson, ABB Quebec, BU Measurement Products, PG Analytical Measurements
What Is Process FT-NIR
• Applicable, in general, to most refinery hydrocarbon streams– Final product blending: Gasoline and diesel – Naphtha conversion units: CCR, HDT, HDS, ISOM, etc.– HF alkylation: HF, iC4, olefins– Crude oil, crude distillation units, and base oils
• It provides:– Real-time data for Process Unit Optimization– Real-time, multi-property physical and chemical analyses
• E.g., RON, cetane, D86, T95, E70, E100, cloud point, freeze point, aromatics, benzene, KV40, PIONA, etc.
– Multiple physical streams per analyzer– An ideal link to APC (low noise, validate-able, fast)
Process hydrocarbon stream analytics using FT-NIR
ABB Process FT-NIR Classical Applications
ABB BU Measurement Products, Analytical Measurements, Quebec, Canada
© ABB Group November 14, 2014 | Slide 5
Applications - Refining
Blending SolutionsGasoline, Diesel, Kero, Crude, Fuel Oil
In-line release
Conversion Unit / Distillation SolutionsCrude Assay
CDU Rundown – LN, HN, KERO, LGO, HGO
Naptha Complex applications – Reforming Unit, Isomerisation Unit, Naphtha Hydrotreating
Upgrader Unit applications – Hydrocracking Unit, Gasoil Hydrodesulphurisation Unit
FCC feed and LCO, LCN, HCN
VGO, Base Oils
C4 Units, MTBE, Butadiene
Cumene / Phenol
LPG
HF Acid Alkylation recycle
Ethylene plant feed (naphtha)
Refinery Process UnitsNaphtha Steam Cracker – Olefins Unit
Natural naphtha feed variation in quality
Often blended on-line, various sources (CDU, NG condensate etc)
Feed mixed with steam and briefly cracked at 850degC
Very high speed, high temperature process
Huge downstream compressor requirement
Light / Heavy naphtha transitions can impact coking rate or flood downstream compressors / de-methaniser
Very energy-intensive: heat-recovery and steam production important
PyGas by-product as Petrochems Feed
FTIR Applications in Naphtha Conversion Units
© ABB Group November 14, 2014 | Slide 7
Light Naphtha Feedto ISOM unit
Reformate Rundownfrom CCR
Heavy Naphtha Feed
to CCR unitHF Acid
Recycle in HFU
Isomerate Rundownfrom ISOM
C-number Breakdown for SPYRO Optimiser
iC6 v%
R2 = 0.96SECV=0.26
8
9
10
11
12
13
8 9 10 11 12 13
pC6 v%
R2 = 0.98SE CV = 0.21
7
8
9
10
11
12
13
14
7 8 9 10 11 12 13 14
-
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
PC4
PC5
PC6
PC7
PC8
Tot P
araffin IC
4IC
5IC
6IC
7IC
8
Tot i
-Par
affin
Tot O
lefin
NC8
Tot C
yclopa
raffi
n
Tot A
romat
ics
vol % FTIR
Actual
© ABB Group November 14, 2014 | Slide 9
Fractionation only – no chemistry
Pre-heat, De-salter & fired furnace
No heat direct on column – heat dissipation by pre-heater exchangers and pump-around
Inferential models of side-draw qualities based on lab data and mass-flow, temperature & pressure instruments
Or – use of PPAs
HP260 + multiple heated cells on feed and sidedraws
Refinery Process UnitsCDU – Crude Distillation Unit
Feed – Crude OilProducts – LPG, LN, HN, Kero, LGO, HGO, Atm Residue
© ABB – Analytical Measurement Group November 14, 2014 | Slide 10
Refinery Process UnitsCDU – Crude Distillation Unit
Optimize CDU control and throughputwith ABB process FT-NIR analyzers
Use fast real-time process FT-NIR analyzers to minimize CDU disturbance during feed changes, and keep tighter control of product cut-points and qualities, while maximising unit throughput
HP260 with ACC115 Flow Cell Cabinets (Heated)
Crude Feed (On-Line or MB3600-HP10 Lab)- TBP curve, API gravity
Sidedraws- LN, HN, KERO, LGO, HGO- D86 Distillation, Kinematic Viscosity, Cloud Point, Flash point, T95, T90, RON etc
© ABB Group November 14, 2014 | Slide 11
CDU – API, Flash, KV40, Cloud Point of Kero/LGO
KERO-API PREDICTION
35.00
37.00
39.00
41.00
43.00
45.00
47.00
49.00
35.00 37.00 39.00 41.00 43.00 45.00 47.00 49.00LAB(unit)
NIR
(uni
t)
NIR-CALIBNIR-PRED
SEC =0.08SEP =0.08ASTM=0.15
KERO-Flash point PREDICTION
30
35
40
45
50
55
60
65
70
30 35 40 45 50 55 60 65 70
LAB( )
NIR
()
NIR-CALIBNIR-PRED
SEC =0.7SEP =1.3ASTM=1.1
LGO-API PREDICTION
25.00
27.00
29.00
31.00
33.00
35.00
37.00
25.00 27.00 29.00 31.00 33.00 35.00 37.00
LAB
NIR
NIR-CALIBNIR-PRED
SEC =0.11SEP =0.14ASTM=0.15
LGO-Cloud Point PREDICTION
-2
2
6
10
14
18
-2 2 6 10 14 18
LAB( )
NIR
()
NIR-CALIBNIR-PRED
SEC =1.1SEP =1.2ASTM=2.0
LGO-CFPP PREDICTION
-2
2
6
10
14
18
-2 2 6 10 14 18
LAB( )
NIR
()
NIR-CALIBNIR-PRED
SEC =0.9SEP =1.1ASTM=2.5
LGO-VISCOSITY PREDICTION
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0LAB(cSt)
NIR
(cSt
)
NIR-CALIBNIR-PRED
SEC =0.05SEP =0.06ASTM=0.10
KERO API KERO Flash Point LGO API
LGO Cloud Point LGO CFPP LGO Viscosity(40 )
© ABB Group November 14, 2014 | Slide 12
Refinery Process UnitsHCK – Hydrocracking Unit
Heavy Oil Upgrader Unit
Cracks and hydrogenates heavy oils
Also removes sulphur and nitrogen
Large scale Hydrogen consumer
Feeds – HVGO, HGO, LVGO, LCO
Products - LN, HN, Diesel, Kero
Very flexible, high added-value Unit
HP260 + multicells on Reactor Feed and Fractionator
Main Reactor Stage
Main Fractionator Stage
© ABB Group November 14, 2014 | Slide 13
FT-NIR: Example Application HCK Feed & Products
Use fast real-time process FT-NIR analyzersto monitor feed quality and maximise diesel product yield and distribution, minimise distillate loss to UCO
HP260X with Flow Cell Cabinets
Feeds – HVGO, HGO, LVGO, LCO
Products - LN, HN, Diesel, Kero
Density, Aniline Point, Conradson Carbon Residue, Asphaltenes, KV, API, T90 / T95, Flash Point / Freeze Point, Aromatics
Main Reactor Stage
Main Fractionator Stage
HGO-API PREDICTION
22.00
23.00
24.00
25.00
26.00
27.00
28.00
29.00
22.00 23.00 24.00 25.00 26.00 27.00 28.00 29.00LAB
NIR
NIR-CALIBNIR-PRED
SEC =0.11SEP =0.14ASTM=0.15
HGO-VISCOSITY PREDICTION
10.0
12.0
14.0
16.0
18.0
20.0
22.0
24.0
10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0LAB(cSt)
NIR
(cSt
)
NIR-CALIBNIR-PRED
SEC =0.3SEP =0.4ASTM=0.5
HGO API
HGO KV(50)
HGO – API and Viscosity (KV50)
Distillation T5% over 2 days with Process Swing
390
392
394
396
398
400
402
404
© ABB Group November 14, 2014 | Slide 15
Refinery Process UnitsOFFSITES – Main Fuel Blending
Blending components feed to gasoline and diesel blend headers
Can be from combination of tank storage, or live streams direct from process units
Can be either a batch blending process with frequent product grade changes, or continuous in-line blending direct to pipeline or ship
Extremely intensely optimized and monitored – product qualities regulated by legislation
Throughput or quality give-away improvements are highly profitable
Blend Optimizer Closed-Loop Blending
FTIR
Constrained Properties Monitoring
(Data courtesy of Mr AB Rahim, Petronas, Melaka)
© ABB Group November 14, 2014 | Slide 18
Select the right process FT-NIR for the job
ABB Process FT-NIR Simple & Robust On-line Analyzers for Challenging Refinery Applications
ABB BU Measurement Products, Analytical Measurements, Quebec, Canada
Talys-ASP400 Ex single-channel on-line FT-NIR analyser for refinery process streams
Small Footprint:
Fully integrated in single enclosure.
Unit may be either shelf or wall mounted.
No Analyzer PC required
ExP purge controller integrated with base enclosure
Low cost of ownership with virtually no scheduled maintenance for 5-years
On-board HMI display and embedded Controller
Full ModBUS TCP/IP, RTU and OPC connectivity to DCS
Hardwired I/O and pneumatics for sample system control in ExD ABB PLC
© ABB Group November 14, 2014 | Slide 21
Refinery Process Units Naphtha Complex and Conversion
Units
Main Fuel BlendingCrude Assay
and Crude Blending
Crude Distillation
Units
Special Units – HF
Alkylation
Diesel & Jet Fuel
Blending
Heavy Oil Upgrading & Hydrotreating
Base Oils
Naphtha Steam
Cracker Feed
HF Alky Unit Overview: Operation Objectives
ENSURE SAFETY
Propane
HFStrip
RECT
ISOSTRIPPER
c/w
RX
Butane
Make-Up iC4
Acid Regen
OlefinFeed
SaturatesFeed
AcidSettler Acid
Recycle
DC3
Alkylate
iC4 Recycle
iC4 Recycle
Acid Recycle
MaximizeThroughput
Increase Alkylate Production
Improve Octane Number
Make-UpAcid
Maintain OptimalProduct Quality
Maintain OptimalProduct Quality
MinimizeEnergy
MinimizeEnergy
MinimizeEnergy
Maintain ReactorTemperature
Minimize ASOFormation
Maintain Acid Strength
Minimize Acid Usage
Acid Recycle
FT
FT
FT
Process Optimization Drivers
Safe operation: Real-time confirmation of HF acid strength, avoidance of runaway conditions, and reduced manual sampling
Corrosion avoidance: Balancing HF acid strength and water content
Energy use: Minimize HF rerun tower operation and feed drier operation — by demand, not by schedule
Product quality and unit throughput: Avoid charge-pulling events and maximize alkylate octane-bbl by tuning acid strength and water content
Active monitoring of ASOs: React quickly to olefin feed quality issues and minimize use of HF makeup
Process FT-NIR offers real-time HF acid analysis without the in-built imprecision of the lab methods
HF Alkylation: What Is the Application?
• The analyzer provides rapid, complete, and safe HF catalyst monitoring
• Pre-calibrated and with much improved speed and repeatability compared with lab analyses
• Safe-Area or Ex Zone FT-NIR compact analyser module with embedded controller and 5 year routine maintenance interval for low cost of ownership
• Robust Field Acid-Area sample interface with sample cell, flow monitoring and safety interlocks
Unit Location
Spectroscopy: Typical Spectrum
1.0
0.8
0.6
0.4
0.2
0.0
8,000 7,500 7,000 6,500 6,000 5,500 5,000 cm-1
HF ASO H20
Abs
HF Analysis: Unique signatures
HFH2O
ASO
HF Alkylation Process Data
Source: Data provided by Dr Taito Väänänen, Neste Oil, Porvoo Refinery, Finland)
Acid Addition Acid Addition
ROI Summary
• Improves personnel safety (invaluable)
• Improves corrosion mitigation through better control of acid strength and water content
• Optimizes HF moisture for improved alkylate octane
• “Real-time” corrective act —detection and prevention of acid runaway
• Early detection of feed impurity
ROI Summary
• Reduces production losses due to charge-pulling events (late detection of low acid strength)
• Schedules regeneration cycles on demand
• Bypasses dryers to reduce steam and energy consumption
• Minimizes risks of HF release to flare and costs of ASO neutralization
• Reduces lab costs for analysis