07_benefits of rapid deployment of refinery wide model_gautam

Using Engineering Simulations to Sustain Refining Profit Margins

Gautam Pradhan, Sr. Principal Business Consultant

© 2015 Aspen Technology, Inc. All rights reserved. 2 © 2015 Aspen Technology, Inc. All rights reserved. 2

Agenda

• Why use Engineering Simulations in Refining?

• What is HYSYS® Petroleum Refining?

– Improved Components

– Petroleum Properties

– Assay Management

– Reactors

– Refinery Wide Models

– Planning and Scheduling Support

– Benefits of Refinery Wide Models

– Success Stories

• Demos

– Crude distillation with improved properties and assays

– Refinery Reactors (FCC, Reformer)

– Refinery Wide Models

– Planning and Scheduling Support

• Q & A

© 2015 Aspen Technology, Inc. All rights reserved. 3

Why Use Engineering Simulations in Refining?

• What do you tell the refinery manager in one minute?

– How does it make money for the refining owner/operator?

• Engineering simulations are used to predict yields and properties

– Predicts how to turn crude oil into products which is the main business of refining

– If you don’t use simulations, you are guessing about key decisions for feed stocks and operating

conditions

– Simulations can play a key role in refinery profit margin analysis


How to Use Engineering Simulations

• Planning and scheduling support (Aspen PIMS and Aspen Petroleum Scheduler)

– Shared assays allow Engineering models to validate PIMS predictions of CDU performance

– Engineering simulations improve PIMS assay table and reactor submodel accuracy

– Refinery wide engineering model partners with PIMS for more accurate decisions

• Standalone unit models (crude distillation and reactors)

– Predict changing feed stocks

– Predict changing catalysts (FCC, semi-regen reformer)

– Optimize plant set points

– reactor temperatures, column cut points

– Equipment revamp studies

• Multi-unit and refinery wide models

– Predict gasoline or diesel production train

– Predict new refinery configurations


aspenONE® Engineering focused on process engineering and optimization

The refining “branch”

HYSYS® Petroleum Refining

focused on margin analysis


Refining Features Predict Yields and Properties

Aspen HYSYS®

Aspen HYSYS® Petroleum Refining (RefSYS)

Refining Components

Petroleum Properties

Assay Management

Refinery Reactors

Multi-unit Simulation

PIMS & APS Support


Traditional Hypos (Pseudo-components) Produced by HYSYS Oil Manager

Crude - 1

Crude - 2

Crude Feed after

Mixer

• Each feed has a separate set of hypos

• Flowsheet stream compositions are awkward combination of all feed hypos

• Hard to manage yields and properties across the flowsheet

• Hypo properties cannot change in flowsheet

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

Crude Oil Mixer

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*


Aspen HYSYS® Petroleum Refining Hypos Produced by Assay Manager

Crude - 1

Crude - 2

Crude Feed after

Mixer

• Feed share the same hypos

• Flowsheet uses a single set of hypos

• Easier to manage yields and properties across flowsheet

• Hypo properties change in the flowsheet.

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

Crude Oil Mixer


Petroleum Properties A Complete Set is Available for Hypos and Streams

Over 50 Petroleum Properties


How Can AspenTech Help Refineries Maximize Profits?

Sustain Profit Margins by ensuring planning models are up to date.

Maximize Profit Margins from rigorous profit margin analysis.

Integration of Aspen PIMS® and Aspen HYSYS ® allows

• Quick development of an ‘Easy to Use’ Refinery Wide Process Model for

Margin Analysis

• Easier updates of Aspen PIMS Planning Models using Aspen HYSYS


Aspen Assay Manager

Process Engineers and Planners Share Assays

Lab Data

Assay Manager

Components for Aspen HYSYS® Petroleum Refining

Main and Swing Cuts for Aspen PIMS

Share Assays with .AFAM file


Crude Distillation Model Support HYSYS® Petroleum Refining used to Calibrate Assay Manager Fractionation Effects

Plant data

HYSYS® Petroleum Refining Model

Fractionation Effects

PIMS Assay Manager Main and Swing Cuts

Accurate representation of non-ideal separation achieved through integration of

Engineering and Planning Distillation Models

Cut points and Fractionation

Factors (SI Factors) PIMS Assay Table


Crude Distillation (CDU) Support: Two Steps

• Step 1: Yields (Cut Points)

– Use HYSYS® Petroleum Refining model to get product cut points

– Cut points define the yields used in PIMS Assay Tables

• Step 2: Properties (SI Factors)

– Use HYSYS® Petroleum Refining model to get fractionation factors (SI factors) that match plant

product overlaps

– Use fractionation factors to improve property predictions that are sensitive to fractionator overlap

like cloud point and sulfur.


Aspen HYSYS Petroleum Refining Model for Cut Points and SI Factors

Blend CDU products

to get crude assay

PIMS LP crude

model in HYSYS

Petroleum Refining


Fractionation Model Provides Fractionation Factors (“SI Factors”) for Product Overlaps

SI Factors for PIMS Main and Swing Cuts


Cut points and SI Factors In PIMS Assay Manager

Used to Cut New Main and Swing Cuts


Aspen HYSYS® Petroleum Refining Reactors

Gas Processing

Naphtha Hydrotreater

Kerosene Hydrotreater

Isomerization

Catalytic Reformer

Hydrocracker

Alkylation

Fluid Catalytic Cracking (FCC)

Delayed Coker

Atm

osp

heri

c D

isti

llati

on

Vacu

um

Dis

tillati

on

Pro

du

ct

Ble

nd

ing

Visbreaker

Diesel Hydrotreater

GasOil Hydrotreater

Resid Hydrotreater Di-Olefin HDTR

Selective HDS

Cat. Gas. Hydrotreater


Aspen HYSYS® Petroleum Refining Reactors Fluid Catalytic Cracking (FCC)

Select FCC from palette and place on flowsheet.

Model is reactor and regenerator with heat balance.

Feed and reactions based on 21 lumps.

Reactor can be one or two risers with dilute phase.

Regenerator can be one or two stage.

Model contains calibration for matching plant data.


Aspen HYSYS® Petroleum Refining Reactors Naphtha Reforming (Reformer)

Select Reformer from palette and place on flowsheet.

Model is reactor beds and recycle gas system.


Reactor can be three to six beds.

Model options include semi-regenerative and continuous.



Aspen HYSYS® Petroleum Refining Reactors Isomerization (C4/C5/C6)

Select Isomerization from palette and place on flowsheet.

Model is standalone reactor bed. Use two reactors for lead and lag reactor systems.


Supports C4/C5/C6 isomerization.

Normally used in flowsheet with reformer.

Default kinetics may need manual calibration to match plant.


Aspen HYSYS® Petroleum Refining Reactors Heavy Oil Hydroprocessing (HYSYS Hydrocracker)

Select Hydrocracker from palette and place on flowsheet.

Model is reactors and recycle gas system.


Each reactor can be one to six beds.

Hydrotreating and hydrocracking are modelled.

Feeds can be distillate, gas oils or resids.



Aspen HYSYS® Petroleum Refining Reactors Naphtha (Light Oil) Hydroprocessing (NHT and CGH)

Select hydrotreater from palette and place on flowsheet.

Three reactors are available.

1. NHT reactor is for treating reformer feed

2. Cat Gas SHU is for FCC naphtha selective hydrotreating

3. Cat Gas HDS is for FCC naphtha desulfurization

Each reactor is a standalone bed


Aspen HYSYS® Petroleum Refining Reactors Thermal Cracking (Delayed Coker and Visbreaker)

Select from palette and place on flowsheet.


Coker is feed heater with drum.

Visbreaker is feed heater with optional soaker.



Aspen HYSYS® Petroleum Refining Reactors Alkylation (H2SO4 and HF)



Models for H2SO4 and HF.

Models are standalone reactors.

User adds IC4 recycle and fractionation system.



Aspen HYSYS® Petroleum Refining Reactors Short Cut Reactor (PIMS Reactor LP Submodel)


Short cut reactor model based on PIMS reactor LP submodel.

Uses “Base & Delta” LP method

Reduces complexity in multi-unit or refinery wide models by replacing rigorous reactor models


Reactor Support Process Data from Aspen HYSYS® Petroleum Refining Drives Aspen PIMS Submodel Coefficient Formulas

Case Study Output from HYSYS Petroleum Refining transfers to

PIMS Submodel sheet

Process data table drives submodel coefficients


Refineries Run on Tight Profit Margins

Profit Margin Analysis is CRUCIAL


Challenge with rigorous refinery wide model

Very Cumbersome Models

Long Time to Develop

Long Run Time to Converge

Demands High Expertise to Develop and Use Models

Keeps Refineries DEPENDENT on Expensive Consultants to Make and Use these Models


Aspen Tech’s Solution

Leverage the Integration between Aspen PIMS & Aspen HYSYS to

Reproduce the refinery wide

PIMS Model in Aspen HYSYS

Selectively upgrade rigorous sub model units

Use the Refinery wide Model to find

ways to boost profit

A Refinery wide model that is a ‘mix of shortcut and rigorous sub-models’ keeps it

Manageable and Accurate!


Refinery wide model can be used to

Pin down specific process areas for profit improvement

Come out with alternative improvement plans

Predict impact of each alternative on refinery profit

1

2

3


So the gist of it is….

We can Deliver a Refinery wide model which is

• Easier and faster to develop

• Accurate

• Much faster to run

when compared to our competitors.

Refineries can maximize profits from analysis using refinery wide process model.


Solution Overview

Business Challenge & Objective Results & Benefits Business Challenge & Objective

Solution Overview

Results & Benefits

• Aspen HYSYS Petroleum Refining (RefSYS) to model

multiple units including crude distillation and reactor units.

• Aspen HYSYS (RefSYS) Reformer model improved LP

models for Aspen PIMS and Aspen Petroleum Scheduler

(Orion).

• Aspen HYSYS (RefSYS) CatCracker model helped to plan

plant operating strategy and update the RefSYS/LP model.

• Aspen HYSYS Petroleum Refining (RefSYS) incorporates

plant data to calibrate reactor models.

CASE STUDY: Taiyo Oil Company Ltd.

Refinery margin improvement

• Data available in timely manner improves crude selection.

• Model enabled profitable operation from the startup.

• Continuous review and update of the RefSYS/LP model increased profitability.

• A 12.7% profit increase reported for the refinery.

• The complex business and operational challenges for

refinery planning and scheduling.

• Improving the accuracy of yield in scheduling.

• Understanding RFCC behavior for improving operational

constraints.

Ref: Koichi Takeda, Taiyo Oil Co. Ltd.,

AspenTech Global Conference: OPTIMIZE 2011, Washington, D.C., May 2011


Solution Overview

Business Challenge & Objective Results & Benefits

Hydrocracking model to support crude selection process

Business Challenge & Objective

Solution Overview

Results & Benefits

• Aspen HYSYS Petroleum Refining used to simulate the entire

complex.

• Aspen HYSYS Hydrocracker to simulate multiple reactor

units.

• Aspen Simulation Workbook (ASW) for input data and link to

BP’s Excel-based LP vector generation tool (Autovec) for

Aspen PIMS.

• Uncertainty analysis performed with Deterministic Equivalent

Modeling Method (DEMM).

CASE STUDY: BP

• Update refinery site heat and mass balance.

• Unit health monitoring of yields and catalyst bed activity.

• Production and planning support for crude selection.

• Identifying Hydrocracking model uncertainties and

performance gaps.

• Crude Selection: Model used to assess

alternative crudes at a BP site for

benefits of $20+ million by processing

these opportunity crudes

• Planning Support: Margin improvements

from LP submodel updates and other

process changes:

– $71,000 per day summer

– $57,000 per day winter

• Other process modeling projects to

support operations.

– Refinery heat and weight balances

– Unit health monitoring

– Revamps and new unit evaluation

Ref: Bruce Briggs, et. al., BP Refining Technology,

AspenTech Global Conference: OPTIMIZE

2011,Washington, D.C., May 2011; and AspenTech

Webinar: Improve Refinery Margins with

Hydroprocessing Models, Jan 2012.


Success Story : GS Caltex Applications of CCR Models

Notes:

• This was “molecular management” project to introduce “molecules” into PIMS to drive

feedstock selection for BTX production

• Old PIMS used reformer shift vectors like N=2A

• New PIMS used reformer shift vectors based on BTX precursors like MCP.

• These molecules were added to PIMS assay tables to drive shift vectors in four reformer

submodels for the four reformers in the plant

• RefSYS reformer was used to develop the submodel data for all four reformers.


Challenge Solution Result

GS Caltex Planning and scheduling model updates

Challenge

Objective: Improve refinery margins

Improve planning model for increased planning accuracy of aromatics complex

Better prediction of aromatic yields

Ref: Y-J Shin, GS Caltex,

AspenTech User Conference, Berlin, April 2008




Aspen HYSYS Petroleum Refining, Crude Manager (for assays), Reformer model, ASW (with link to Aspen PIMS)

Aspen HYSYS Petroleum Refining model of 4 crude units and 4 catalytic reformers






Significantly improved predictive capability

Model now predicts more accurate yields (within 99% accuracy vs. 97.5% before)

Better visibility into feedstock selection options

Optimized product quality for units downstream of reformer





CEPSA Rigorous reactor modeling for operations and capital projects

Challenge

Quick and accurate assessment of opportunities to improve FCC performance and refinery margins:

– Revamps and other capital projects

– New catalyst selection

– New feedstock scenario

– LP planning model updates




Aspen HYSYS Petroleum Refining

Aspen HYSYS CatCracker

AspenTech services

Ref: Modesto Miranda, CEPSA,





Unit revamps and new catalyst selection increased profit by 18,000 €/day

Other lifecycle applications of the unit model for:

− Feedstock optimization for 8,000 €/day improved margin

− Improved LP model for FCC planning and scheduling purposes

Ref: Modesto Miranda, CEPSA,



Valero CDU Unit Model

Note :

• This refinery is in New Jersey and is now owned by PBF.

• Valero used this model to evaluate crude switches on the CDU.

• When crude mix changed, they ran model to predict product rates to give the operators

guidance on where to set APC targets

• Also, they checked key constraints like ovhd reflux pump HP to make sure they did not

blow this constraint.

• If the HP was too high, they would change the cutpoint spec to reduce flow and not cut the

feedrate.

• Management did not care about the overhead 95% point but they did care about unit feed

rate.



Valero Deploy models to operations

Challenge

Detect and troubleshoot problems early

Reduce operating costs by better insight into the impact of crude blend changes on operating conditions

Enable operations to perform what-if scenarios and increase agility in decision making

Make faster and better operating decisions in response to disruptions or changes




Deploy engineering models in operations in an MS Excel environment

Aspen Simulation Workbook (ASW) interface driven by Aspen HYSYS-based model

Ref: David Schumann & Gregory Davis, Valero,

NPRA Annual Meeting, March 2009 and AspenTech User Conference, Houston, May 2009




Analysis times for new feedstock and operating scenarios reduced from days to minutes

Robust models used by operating personnel through Excel interface to improve decision making

Ref: David Schumann & Gregory Davis, Valero,

NPRA Annual Meeting, March 2009 and AspenTech User Conference, Houston, May 2009

AspenTech is ranked as a top innovative growth company

Thank You

07_benefits of rapid deployment of refinery wide model_gautam

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