ppt template -...
TRANSCRIPT
SS TSS-05 Refinery Reactor Modelsin ROMeo
Rujun LiProduct Manager,
Refinery Reactor Models
@InvensysOpsMgmt / #SoftwareRevolution
/InvensysOpsMgmt
/InvensysVideos
social.invensys.com
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Rujun LiProduct Manager,
Refinery Reactor Models /InvensysOpsMgmt
/Group/SimSci
Agenda
• SimSci Refinery Reactor Portfolio
• Reactor Model Technical Overview and Demo
• New Applications for Reactor Models• Offline Excel Interface
• LP Update Manager
• Summary
Slide 3
• SimSci Refinery Reactor Portfolio
• Reactor Model Technical Overview and Demo
• New Applications for Reactor Models• Offline Excel Interface
• LP Update Manager
• Summary
Reactor Models License Agreement betweenExxonMobil and Invensys
• Since 2004, ExxonMobil has used Invensys ROMeo™software in multiple applications
• ExxonMobil uses versions of these models in its business,among other uses, for optimization, process engineering,design, and operations monitoring.
• ExxonMobil Research and Engineering Company (EMRE) andInvensys have entered into a licensing agreement that willallow Invensys to sub-license EMRE process models to 3rd
parties.• Invensys has full access to the code & will provide all
support and maintenance services to its customers• Invensys is the exclusive supplier of EMRE technology
Slide 4
• Since 2004, ExxonMobil has used Invensys ROMeo™software in multiple applications
• ExxonMobil uses versions of these models in its business,among other uses, for optimization, process engineering,design, and operations monitoring.
• ExxonMobil Research and Engineering Company (EMRE) andInvensys have entered into a licensing agreement that willallow Invensys to sub-license EMRE process models to 3rd
parties.• Invensys has full access to the code & will provide all
support and maintenance services to its customers• Invensys is the exclusive supplier of EMRE technology
Product Overview
FCC•Can modeltypical FCCunit with up to20wt% of1050F+ in feed
•Kinetic modelwith rigorousmaterial, heatand pressurebalance
•Feedcharacterization included
Reformer•Can modelSemi-Regen,Cyclic, or CCR
•Can be usedfor both fueland aromaticsproducing units
•Coke predictionincluded
HDP•Structureorientedlumping (SOL)approach
•Can modelhydrotreatingandhydrocrackingof typical feedtype with asingle reactor
•Feedcharacterization included
HF Alky•Can modelboth UOP andPhillipsprocesses•Can predictalkylate andASO rates, RONand MONnumbers
SF Alky•Can modelboth DuPontStratco andExxonMobilAutorefrigerationprocesses
•Model predictsalkylate yields,RON, MON,acidconsumptionand spent acidcomposition
ISOM• Model light
naphthaisomerizationprocesses
• Model basedon UOPcatalysts forButamer andPenexprocesses
DCU• Model delayed
coker unitincluding cokedrums andfractionator
• Can processresid, FCCslurry and tarsand feeds
• Threeproducts, gas,liquid andcoke
VOM• Model
visbreakingunit includingfurnace,fractionatorand blending
• Take resid,VGO, andcutter stockfeeds
• Threeproducts, gas,naphtha andfuel
ROMeo Refinery Reactor Model Portfolio
Slide 5
FCC•Can modeltypical FCCunit with up to20wt% of1050F+ in feed
•Kinetic modelwith rigorousmaterial, heatand pressurebalance
•Feedcharacterization included
Reformer•Can modelSemi-Regen,Cyclic, or CCR
•Can be usedfor both fueland aromaticsproducing units
•Coke predictionincluded
HDP•Structureorientedlumping (SOL)approach
•Can modelhydrotreatingandhydrocrackingof typical feedtype with asingle reactor
•Feedcharacterization included
HF Alky•Can modelboth UOP andPhillipsprocesses•Can predictalkylate andASO rates, RONand MONnumbers
SF Alky•Can modelboth DuPontStratco andExxonMobilAutorefrigerationprocesses
•Model predictsalkylate yields,RON, MON,acidconsumptionand spent acidcomposition
ISOM• Model light
naphthaisomerizationprocesses
• Model basedon UOPcatalysts forButamer andPenexprocesses
DCU• Model delayed
coker unitincluding cokedrums andfractionator
• Can processresid, FCCslurry and tarsand feeds
• Threeproducts, gas,liquid andcoke
VOM• Model
visbreakingunit includingfurnace,fractionatorand blending
• Take resid,VGO, andcutter stockfeeds
• Threeproducts, gas,naphtha andfuel
Most Comprehensive list of Refinery Reactor Models based on ExxonMobil operating experience
ROMeo Refinery Reactor Model Portfolio
ReactorModel
HF Alkylation
Sulfuric AcidAlkylation
FCC
Reformer
Hydrotreating
Hydrocracking
Slide 6
Hydrocracking
Visbreaking
DelayedCoking
Isomerization
Competitive Differentiator
• Full suite of reactor modeling technology for Refinery-wideOptimization
• Based on years of operating experience by ExxonMobil
• Rigorous kinetics based models allow accurate modeling over wideroperating range
• Open equation based modeling, enabling robust & broader scopemodeling & optimization
• User-friendly GUI designed by Invensys, drag and drop to Excelcapability
Slide 7
• Full suite of reactor modeling technology for Refinery-wideOptimization
• Based on years of operating experience by ExxonMobil
• Rigorous kinetics based models allow accurate modeling over wideroperating range
• Open equation based modeling, enabling robust & broader scopemodeling & optimization
• User-friendly GUI designed by Invensys, drag and drop to Excelcapability
Development Timeline (2009-2013)
Agreement signed ROMeo 5.3.1• Reformer
ROMeo 6.0.2• HDP
• FCC Feed Synthesis
• Reformer enhancement
May 2010 Aug. 2011 Mar. 2013Oct. 2009 Sep. 2011 Sep. 2012
Slide 8
ROMeo 6.0• DCU
• VOM
• ISOM
ROMeo 6.1• LP Update
Manager
ROMeo 6.1• LP Update
Manager
May 2010 Aug. 2011
ROMeo 5.3• FCC
• HFAlky
• SFAlky
Mar. 2013Oct. 2009 Sep. 2011 Sep. 2012
Refinery Reactor Model TechnicalOverview
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
SimSci Reformer Reactor Model• Can model semi-regen, cyclic and CCR
by switching catalyst type
• Very flexible configuration, can beconfigured to have 1 or more reactors(beds), to include pre-heater,intermediate heaters and product flash.More flexible than KBC REF-Sim model,for instance can handle bypasses.
• Product RON & MON (with the octanemodel), total aromatics, total C5+Yield , coke predicted
• ExxonMobil has 10+ successfulimplementations. First customerimplementation by SK for aromatics.
Slide 10
• Can model semi-regen, cyclic and CCRby switching catalyst type
• Very flexible configuration, can beconfigured to have 1 or more reactors(beds), to include pre-heater,intermediate heaters and product flash.More flexible than KBC REF-Sim model,for instance can handle bypasses.
• Product RON & MON (with the octanemodel), total aromatics, total C5+Yield , coke predicted
• ExxonMobil has 10+ successfulimplementations. First customerimplementation by SK for aromatics.
SimSci Reformer Demo
• Configuration• Adding/removing components
• Coke model
• Specification
• Catalyst
• Tuning
• Operating condition
Slide 11
• Configuration• Adding/removing components
• Coke model
• Specification
• Catalyst
• Tuning
• Operating condition
SimSci FCC Reactor Model
• Rigorous Kinetic Model, energy andpressure balances rigorously modeled
• Can model all major designs with somelimitation on configuration
• More detailed and rigorous than KBCFCC-SIM model, Catalyst circulationrate calculated by pressure balance
• Feed synthesis/characterizationincluded
• ExxonMobil has more than 20successful implementations
• Invensys is working to deliver FCC RTOfor Petrobras and model transition forTonen General
Slide 12
• Rigorous Kinetic Model, energy andpressure balances rigorously modeled
• Can model all major designs with somelimitation on configuration
• More detailed and rigorous than KBCFCC-SIM model, Catalyst circulationrate calculated by pressure balance
• Feed synthesis/characterizationincluded
• ExxonMobil has more than 20successful implementations
• Invensys is working to deliver FCC RTOfor Petrobras and model transition forTonen General
SimSci FCC Demo
• Structure
• Configuration
• Pressure balance
• Specifications
• Geometry
• Catalyst
• Tuning Variables
Slide 13
• Structure
• Configuration
• Pressure balance
• Specifications
• Geometry
• Catalyst
• Tuning Variables
SimSci Hydroprocessing (HDP) ReactorModel• Structure-oriented lumping (SOL) approach, modeling at molecule
level
• Can model both hydrotreating and hydrocracking reactors byswitching catalyst type, while the competitor needs different reactormodels for different feed types.
• Has its own feed synthesis and analyzer (for sulfur and nitrogenprediction) to produce correct feed compositions from reference feed
• ExxonMobil has more than 20 successful implementations
Slide 14
• Structure-oriented lumping (SOL) approach, modeling at moleculelevel
• Can model both hydrotreating and hydrocracking reactors byswitching catalyst type, while the competitor needs different reactormodels for different feed types.
• Has its own feed synthesis and analyzer (for sulfur and nitrogenprediction) to produce correct feed compositions from reference feed
• ExxonMobil has more than 20 successful implementations
SimSci HDP Demo
• Structure
• Configuration
• Beds
• Component Slate
• Specifications
• Catalyst
• Mixer
• Tuning Variables
Slide 15
• Structure
• Configuration
• Beds
• Component Slate
• Specifications
• Catalyst
• Mixer
• Tuning Variables
SimSci HF Alkylation (HFAlky)Reactor Model• Can model both Phillips and UOP processes
• Model includes both reactor and acid settler
• Correlative model
• Model predicts i-butane conversion, alkylateand ASO rates, RON and MON numbers
• ExxonMobil has been implementing the reactormodel for 2 sites with success
• Key Optimization Handles• Optimize i-butane recycle rate to maximize profit
against separation cost
Slide 16
• Can model both Phillips and UOP processes
• Model includes both reactor and acid settler
• Correlative model
• Model predicts i-butane conversion, alkylateand ASO rates, RON and MON numbers
• ExxonMobil has been implementing the reactormodel for 2 sites with success
• Key Optimization Handles• Optimize i-butane recycle rate to maximize profit
against separation cost
SimSci HFAlky Demo
• Thermo and Component Slate Configuration
• Reactor configuration, single vs. train
• Operating condition
• Tuning
Slide 17
• Thermo and Component Slate Configuration
• Reactor configuration, single vs. train
• Operating condition
• Tuning
Simsci SFAlky Reactor Model
• Can model both DuPont Stratco(Effluent Refrigeration) and ExxonMobilAuto-Refrigeration processes
• Both reactor and settler are modeled
• Can be used to model entire reactor, orindividual zones
• Model predicts alkylate yields, RON,MON, acid consumption and spent acidcomposition
• Key Optimization• Optimize i-butane recycle rate to maximize
profit
Slide 18
• Can model both DuPont Stratco(Effluent Refrigeration) and ExxonMobilAuto-Refrigeration processes
• Both reactor and settler are modeled
• Can be used to model entire reactor, orindividual zones
• Model predicts alkylate yields, RON,MON, acid consumption and spent acidcomposition
• Key Optimization• Optimize i-butane recycle rate to maximize
profit
SimSci Delayed Coker Reactor (DCU)
• Models the unit including coke drum and fractionator and blends thefractionator liquid products into one liquid product
• Take three feed types: residual oil, FCC fractionator bottoms/slurryoil, and tar/rock
• Three products: gas (H2S, C1-C4), liquid (C5-302F, 302-430F, 430-650F, 650F+) and coke
• ExxonMobil is implementing the reactor model in RTO
• Key Optimization• Optimizing coke drum temperature for maximum profit
Slide 19
• Models the unit including coke drum and fractionator and blends thefractionator liquid products into one liquid product
• Take three feed types: residual oil, FCC fractionator bottoms/slurryoil, and tar/rock
• Three products: gas (H2S, C1-C4), liquid (C5-302F, 302-430F, 430-650F, 650F+) and coke
• ExxonMobil is implementing the reactor model in RTO
• Key Optimization• Optimizing coke drum temperature for maximum profit
SimSci Visbreaker Reactor Model(VOM)• Model the visbreaking unit including
furnace/reactor, fractionator and fueloil blend
• Feeds: Resid, VGO (optional), cutterstocks. Cutters stocks bypassesreactor and do not crack.
• Products:• Gas: H2S, C1-C4; Liquid: naphtha, gasoil
(can go to both liquid and fuel);
• Fuel: gasoil, residue, cutter stocks
• Key optimization• Optimize residence time for max
profitability
Slide 20
• Model the visbreaking unit includingfurnace/reactor, fractionator and fueloil blend
• Feeds: Resid, VGO (optional), cutterstocks. Cutters stocks bypassesreactor and do not crack.
• Products:• Gas: H2S, C1-C4; Liquid: naphtha, gasoil
(can go to both liquid and fuel);
• Fuel: gasoil, residue, cutter stocks
• Key optimization• Optimize residence time for max
profitability
SimSci Isomerization Reactor Model(ISOM)• Model based on pilot plant data
of UOP I-8 catalyst for Butamerand Penex processes
• Feed and products are all realcomponents
• No special property predictionor modification in the model
• Easy to implement because ofusage of real components
• Key optimization• Manipulate recycle compositions to
maximize product octane numbers
Slide 21
• Model based on pilot plant dataof UOP I-8 catalyst for Butamerand Penex processes
• Feed and products are all realcomponents
• No special property predictionor modification in the model
• Easy to implement because ofusage of real components
• Key optimization• Manipulate recycle compositions to
maximize product octane numbers
Excel Offline Simulation Interface
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Excel Offline Simulation Interface
• Excel OPSAddin to ROMeo Environment
• User-friendly interface to ROMeo and refinery reactor models
• Targeting process engineers (PRO/II users) too busy to learn ROMeoand want to use Reactor Models
• Templates available for build cases and do case study andcomparison
• Invensys services: building models and training users
Slide 23
• Excel OPSAddin to ROMeo Environment
• User-friendly interface to ROMeo and refinery reactor models
• Targeting process engineers (PRO/II users) too busy to learn ROMeoand want to use Reactor Models
• Templates available for build cases and do case study andcomparison
• Invensys services: building models and training users
Main Worksheet
• Login and Logout: connect/disconnect from ROMeo model
• Change Database: switch models
• View and run Cases
Slide 24
• Login and Logout: connect/disconnect from ROMeo model
• Change Database: switch models
• View and run Cases
LP Update Manager Tool for Planning
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
LP Model Challenges• How do we update any LP model with rigorous flow sheeting
models?
• There is a great variety in the LP model structures
• Any approach or method should be reliable and easy
Goals• Import LP model coefficients from ROMeo rigorous model run(s)
• Planner retains control of the Mapping process
• Ability to make custom unit conversions if required
• Export results in spread sheet form, ready for use in LP
• Retains record of all model updates and ability to trend coefficient
values over time
Slide 30
• How do we update any LP model with rigorous flow sheeting
models?
• There is a great variety in the LP model structures
• Any approach or method should be reliable and easy
• Import LP model coefficients from ROMeo rigorous model run(s)
• Planner retains control of the Mapping process
• Ability to make custom unit conversions if required
• Export results in spread sheet form, ready for use in LP
• Retains record of all model updates and ability to trend coefficient
values over time
LP Update Manager
PlantRTDB
RTO Model
Plant DataCrude/FeedData
DCS
Slide 31
LP VectorsLP UpdateManager
RefineryLP
All updatedcoefficientsare “blocked”
Updated LP Sub-model or Module
Slide 35
All updatedcoefficientsare “blocked”