MPC at Statoils Kalundborg Refinerynpcw17.imm.dtu.dk/Proceedings/Session 3 Control...2012-01-04 MPC...
Transcript of MPC at Statoils Kalundborg Refinerynpcw17.imm.dtu.dk/Proceedings/Session 3 Control...2012-01-04 MPC...
2012-01-04
MPC at Statoils Kalundborg Refinery
17th Nordic Process Control Workshop
Technical University of Denmark, Kgs Lyngby, Denmark
January 25-27, 2012
Anne-Katrine Ipsen, Advisor Refining
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Content of presentation
1. About Kalundborg Refinery
2. APC history
3. Statoils InHouse MPC tool Septic
4. Examples of MPCs
5. GORTO – Gas Oil Dynamic RTO
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First a little about Kalundborg Refinery
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Statoil Kalundborg – Main products
Condensate
Crude oil/
Propane
Gasoline
Jet Fuel
Diesel
Heating oil
Heavy fuel oil
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Yearly production 2010
2010 total production: 4755 Mill tons
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Crude oil/ Condensate throughput 2010
2010 total throughput: 4521 Mill tons
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APC history
• Honeywell DCS from 1986
• Implementation of conventional APC in coorperation with Exxon
• MPC study by Exxon 1995 – first MPC planned on Condensate Fractionator,
using AspenTech DMC+. Never completed due to technical problems.
• First MPC implemented in 1999 – using SEPTIC, close coorperation with F&T
• Kalundborg MPC strategy in 2001
• Continued MPC implementation 1999-201x
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Classificati
on: Internal
(Restricted
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11-15
The process control hierarchy
9 Distributed Control System
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Kalundborg
#17
#2 Gullfaks/Tordis
Kårstø
#25
Kollsnes #5
Mongstad #22
#7 Åsgard Norne Heidrun
Snøhvit
#2
Sept-2011: 80 Applications
Note: oppdatert SM og KLB sept 11
Statoil Estimation and Prediction Tool for Identification and Control
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Applications
• Oil Refining (Mongstad and Kalundborg)
− Distillation
− Product blending (Gasoline and Gas Oil)
− Steam production and consumption
− Crackers, reformers, hydrotreaters
− Heat exchanger network (RTO)
− Optimization (RTO/DRTO)
• Gas Plants (Kårstø, Kollsnes, Snøhvit)
− Distillation
− Gas quality
− Pipeline pressure control
− Optimization
• Offshore
− Extended slug control, buffering
− Crude mixing
− Produced Water Reinjection
− Gas quality
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2012 APC status
• 18 MPCs running – 124 MVs, 266 CVs
• gasoil production and blending dynamic RTO (GORTO)
• gasoline batch blending
• total MPC incentive 142 MDkr/year
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HFO
Crude
oil
Sec. 200
Atmospheric
Distillation
370-480 m3/hr
Sec. 1000
Vac. Distil.
140-200
m3/hr
Kero/ Gasoil
Hydrotereating
C-
201
Overhead
Sec. 300/400
HT/ Reforming
45-60 m3/hr
Sec. 550
Jet Fuel Plant
15-40 m3/hr
Sec. 800
Gasoil HT
65-130 m3/hr
Kero 60 m3/hr
LGO 80-110 m3/hr
HGO 25 m3/hr
LVGO 10-20 m3/hr
HVGO
90-120 m3/hr
Visbreaking
60-80 m3/hr
ThermoCracking
90-115 m3/hr Fractionation
VB
Nap
hth
a
VB
GO
Tar
Gas
Naphtha
Jet
Fuel
Diesel
Gasoil
Gasoline
Gas &
LPG
Sto
rag
e a
nd
Ble
nd
ing
Sec. 700 Gas Plant
10-15 m3/hr
Condensate/
crude oil
C-
4201
Overhead
Light Kero 6-20 m3/hr
ULGO 51 m3/hr
LAGO 10-25 m3/hr
Light Ends HT & Fractionation
220 m3/hr
Sec. 850 Kero/
Gasoil HT
40-90 m3/hr
Vac. Btm. 70 m3/hr
Sec. 200/250 Light
Ends Fractionation
80-120 m3/hr
Sec. 4800
Gasoil HT
145 m3/hr
To Kero/ Gasoil
Hydrotreating
To Gasoil
HT & HDA
Sec. 4400
Reforming
105 m3/hr
Sec. 4600
Isomerisation
95 m3/hr
Gas Plant
LV
BN
HV
BN
Naphtha to Light Ends
HT & Fractionation
LVN
HVN
To Vacuum
Distillation
Sec. 4700 Gas Plant
16-24 m3/hr
Sec. 4200
Atmospheric
Distillation
230-280 m3/hr
Sec. 600
Notation: Running Application Implementation ongoing Future Application
MPC at Kalundborg Refinery
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Desulphurisation
reactor R-4801
MPC example: Kalundborg Synflex Unit
Feed drum
D-4801
Feed preheat
(R-4851 btm.)
Separation
drum
D-4803
Heater
H-4801
Desulphurisation
reactor R-4851
Separation drum
D-4853
Feed-
pre
cooling
De-
Aromatisation
reactor
R-4852
Gasoil flows
Treat Gas flows
Mixed
Gasoil product
to stripper
Treatgas to
Recycle
Treat Gas
compressor
K-4851
Gasoil feed
from other
units
Treatgas
Treat Gas
liquidKnock
Out drum
The purpose of this unit is desulphurisation and dearomatisation of diesel.
One product is swedish City diesel.
There are 2 catalytic desulphurization reactors and 1 catalytic dearomatisation reactor.
The processes uses hydrogen.
Reactor pressure 60 barg. Reactor temperature app.. 350ºC. Design throughput 145 m3/hr.
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Distribution
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Desulphurisation
reactor R-4801
MPC example: Kalundborg Synflex Unit
Feed drum
D-4801
Feed preheat
(R-4851 btm.)
Separation
drum
D-4803
Heater
H-4801
Desulphurisation
reactor R-4851
Separation drum
D-4853
Feed-
pre
cooling
De-
Aromatisation
reactor
R-4852
Gasoil product
to stripper
Treatgas to
Recycle
Treat Gas
compressor
K-4851
Gasoil feed
from other
units
Treatgas
Treat Gas
liquidKnock
Out drum
Avanced process control in this plant is 1 MPC for total optimisation.
- Optimises unit throughput
- Controls all relevant product qualities
- Respects all relevant contraints - reactors, furnace, treatgas system
10 MVs
29 CVs
2 DVs
MV
DV
DV Reactor
Inlet
Temp.
CV
H2/oil
MV Treatgas
flow
Total
feed rate
Feed
temp.
CV H2/oil
MV
H-4801
Coil Outlet
Temperatur CV Contraints
(Heater, reactors,
treatgassystem)
CV
MV Manipulated variables
Controlled variables
MV
MV
Treatgas
flow
CV Product qualities
(sulphur, Aromatics,
Initial Boiling Point)
CV Treatgas/ H2 balance
CV H2/oil
R-4852
feed rate
MPC example: Kalundborg Synflex Unit
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- Models with fast dynamics
- Models with slow dynamic
- Models with inverse response
MPC example: Kalundborg Synflex Unit
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GORTO - Gas Oil Dynamic RTO
M
Analyzers/
Sample
M
Analyzers/
Sample
Kalundborg Gas Oil Production:
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Objectives:
• Maximizing the total Gas Oil Production
• Coordinating the operation of Main Fractionators
• Controlling and coordinating the gas oil Hydrotreaters
• Minimizing Give-Away on the end-products
• Minimizing production of lower valued heavier products
• Minimizing production costs
• Maximizing reactor catalyst cycle time
• Managing the rather large time delays throughout the production processes.
M
Analyzers/
Sample
M
Analyzers/
Sample
GORTO - Gas Oil Dynamic RTO
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• 100+ Product Quality estimators on all Fractionator and Hydrotreater Streams
• Automatic use of Lab data
• Automatic Gas Oil lineup check
• Automatic coordination of Fractionator MPC’s
• MPC’s on Gas Oil Hydrotreaters
• Automatic control of Gas Oil Blendstocks from Tank
• Tank Quality Tracking & Control on Gas Oil Feed Component Tanks
• Tank Quality Tracking on Gas Oil Product Tanks
GORTO parts:
• Number of Variables
Manipulated Variables (MV’s): 39
Controlled Variables (CV’s): 97
Disturbance Variables: 44
Logic Variables (i.e. line-up indicators): 37
GORTO - Gas Oil Dynamic RTO
• Statoil presented GORTO at the European Refining Technology Conference in
Lisbon in 2008
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GORTO - Gas Oil Dynamic RTO
MPC at Statoils Kalundborg Refinery
Anne-Katrine Ipsen
Advisor Refining
E-mail address [email protected]
Tel: +45 59 57 45 37 www.statoil.com
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