A Nonlinear Integrated Model for Operational Planning of Multi-Site Refineries
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Transcript of A Nonlinear Integrated Model for Operational Planning of Multi-Site Refineries
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A Nonlinear Integrated Model for Operational Planning
of Multi-Site Refineries
Brenno C. Menezes, Lincoln F. Moro Refining Optimization PETROBRAS Petroleo S.A. Rio de Janeiro, RJ
Ignacio E. Grossmann Department of Chemical Engineering Carnegie Mellon University Pittsburgh, PA
1
Jeffrey D. Kelly Toronto, ON
industrIALgorithms
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Thesis Overview
Summary
2
1st- Operational Planning of Sao Paulo Refineries
2nd- Swing-Cuts Improvements
Why Nonlinear?
Why Integrated?
Why Operational Planning?
Why Multi-Site Refineries?
A Nonlinear Integrated Model for Operational Planning
of Multi-Site Refineries
5 min
5 min
5 min
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Quantitative Methods for Investment and Strategic
Planning in the Oil-Refining Industry
Brenno C. Menezes, Lincoln F. Moro Refining Optimization PETROBRAS Petroleo S.A. Rio de Janeiro, RJ
Ignacio E. Grossmann Department of Chemical Engineering Carnegie Mellon University Pittsburgh, PA
3
Jeffrey D. Kelly Toronto, ON
Fernando Pellegrini, Ricardo Medronho Department of Chemical Engineering Federal University of Rio de Janeiro Rio de Janeiro, RJ
industrIALgorithms
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The thesis aims to develop a quantitative method to predict necessaries
structural modifications in the Brazilian refining and logistics assets through time
PETROBRAS Current Tool for Strategic Planning (PLANINV) – LP Tool
No Framework Synthesis
Optimize only the streams transfers (fuel and petroleum import/export, fuel local market supply)
PLANINV Framework OT
4
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The necessity to develop a strategic level supply chain planning models in order to address issues in a quantitative manner rather than the qualitative approaches used till now is acknowledge by the industry and still remains an active research area. (Shapiro, 2004; Papageorgiou, 2008)
Still need modification on the figure. I want to show a scheme with current Investment Methodology
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Jul-13
GAMS Distillation Models (CDU/VDU) Swing-Cuts Improvements
Sep-12 Nov-12
IMPRESS
PIMS
Jan-13 May-13 Aug-12
Nonlinear Operational Planning of Sao Paulo Refineries
EWO
Multi-plant Operational Planning of Sao Paulo Refineries
REPLAN Investments Cases for 2020-2030
Multi-period Investment Planning with NPV as Goal (refining only) MINLP
CAPD & EWO
Multi-period Strategic and Logistics Planning with NPV as Goal (refining, transportation and terminals) MILP
Distillation Models CDF least-square Interpolation
Mar-13
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Binary variables
Blending
Refining Processes
fixed recipes
variable recipes
fixed yields
swing cuts (fixed properties)
Which Surface?
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GAMS
IMPRESS
Planning the Future & Existing Refining Units (MINLP; DICOPT++)
Planning the Future & Existing Refining Units and Logistics (MILP; UOSS/QLQP) 8
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Basic Equations for Modeling Process Unit in a Refinery
Mixer:
u u',s,u
(u',s)
QF = Q
uUS
Feed Properties:
u,p u,p u',s,u u',s,p(u',s) (u',s) ,pPF =f Q ,PF
u u u,sUS US PO
Products from Units:
u,s u,s u u,p u,v vpQS =f QF ,PF ,V
uu VOPI
Products Properties from Units:
u,s,p u,s,p u,p u,v vpPS =f PF ,V
uu VOPI
Splitter:
u u,s,u'
(u',s)
QS = Q
uUS
Mixer Unit Splitter
Splitter
Splitter
9
Qu’,s,u
Qu’,s,u
Qu’,s,u
Qu,s,u’
Qu,s,u’
Qu,s,u’
Qu,s,u’
Qu,s,u’
Qu,s,u’
Qu,s,u’
QSu,s
QSu,s
QSu,s
QFu
QFu Feed Flow
QSu,s Product Flow
Qu,s,u’ Transfer Stream Flow
PFu,p Feed Property
PSu,s,p Product Property PFu,p
PSu,s,p
PSu,s,p
PSu,s,p u units
s streams
p properties
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NLP Monoperiod (Operational Planning)
Find the best quantity of Kero and VGO from REPLAN to: Kero => REVAP VGO => REVAP/RBPC - Today maximum permitted for Kero is 1500 m3/d - From the NLP Model the best value is 2300 m3/d.
FCC FCC,RCRFCC FCC FCC,s,RCR FCC,RCR
FCC,s,TRX FCC,s,TCC
QS QF .[Y Y .(PF PF )
Y .TRX Y .TCC] s
FCCSO
CDi,sCDi,s CDi CDi,s i iQS QF . (Y Y . HOT ) s , CD CDiSO CD
PDA,ASFR PDAQS QF .(1 EXT)
k k kHT ,HTs,S HT ,S HT kPF =PF 1 SEV HT HT
Crude recipe: Yields Sulfur Gravity Acidity
Swing Cuts Fractionation-Index Interpolation Regressed CDF
(Moro, Zanin & Pinto, 1998)
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Refining Framework Modeling
11
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CDU Models Yields Properties Modeling Reference
Fixed yields Fixed Fixed LP conventional approach
Delta Base Base+Delta Base+Delta NLP Moro, Zanin & Pinto (1998)
Swing-Cuts Pre-Cut Fixed LP Zhang et. Al. (2001)
Swing Cuts Modificated Pre-Cut with
operational modes
LS, Prop=f(Cum. Yie) NLP Li, Hui & Li (2005)
Fractionation-Index
(Heaviside function to
control FIR and FIS)
Geddes eq.
K=y/x
K=f(T,FIR,FIS)
Non-distribution in T
FIR=FI rectifying section
FIS=FI stripping section
NLP Alattas, Grossmann & Rivera (2011)
Fractionation-Index
(Binary logic to control FIR
and FIS)
Geddes eq.
K=y/x
K=f(T,FIR,FIS)
Non-distribution in T
FIR=FI rectifying section
FIS=FI stripping section
MINLP Alattas, Grossmann & Rivera (2012)
Hybrid
(mass/energy equations +
empirical PLS relations)
Mass/Energy
balance
Tray Temperature
Measurements
PLS only for TBP SLP Mahalec & Sanchez (2012)
Swing-Cuts Improvement Cutting & Blending
Hypos-Swing
Ordination
Volume-Mass weighted
interpolation
NLP Menezes, Kelly & Grossmann (2013)
Linear & Monotonic Spline
Interpolation
Yield=f(T) Prop=f(T) NLP Menezes, Kelly & Grossmann (2013)
Least-Squares Fit of CDF Yield=CDF(T) Prop=CDF(T) NLP Menezes, Kelly & Grossmann (2013)
Fractionation-Index
(Heaviside function to
control FIR and FIS)
Same as above Prop=f(T,FIR,FIS) NLP Menezes & Grossmann (2013)
Fractionation-Index
(Binary logic to control FIR
and FIS)
Same as above Prop=f(T,FIR,FIS) MINLP Menezes & Grossmann (2013)
A
B
C
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Cut-to-Mix Mix-to-Cut
Assay
CDF/Interpolation
Hypos Cutting and blending
Hypos Tcut Functions
Mass Bal + Constrains (Corrections)
Volume/Mass weighted Interpolation
Conventional Approach
Cut-to-Mix Hypos-Swing Ordination
Mix-to-Cut Hypos-Swing Ordination
Hypos -> Cuts -> FCuts Swing-Cuts flows as variables
Hypos -> FCuts (need Hypos-Swing-Cuts Ordination) Hypos flows as variables
Big CDU Hypo
Hypos -> FCuts Tcut as variables [TISW,TESW]
CDF (Weibull Extreme)
Linear Interp.
Monotonic Spline
CDU Hypos per crude
Fraction Index
Yields Distribution (K=y/x)
Properties Distribution
Hypos -> FCuts Tcut as variables [TISW,TESW]
GAMS is not supporting monotonic splines (piecewise Hermite polynomial)
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Motivating Example: Swing-Cuts Model This example is the well-known Swing-Cuts model applied in commercial tools for operational planning like as PIMS. The Swing-Cuts (SW1, SW2, SW3, SW4) are treated as a normal Cuts (LN,HN,K,LD,HD) with constants properties, so if the SWi is going to the upper or lower adjacent cut they will affect the Final Cuts properties (LN,HN,K,LD,HD) equally.
LN
K
LD
HN
HD
ATR
CDU C1C2
C3C4
AGBAMI
BARRACUDA
LULA
MARLIM
PCONCHAS
RONCADOR
SW1
SW2
SW3
SW4
VR
HVGO
VDU
LVGO
PFO
PVGO
PHDS
PLDS
PJFUEL
PGLNLN
K
LD
HN
HD
C3C4
C1C2
VR
HVGO
LVGOCUTS=LN,SW1,HN,SW2,K,SW3,LD,SW4,HD
FCUTS=LN,HN,K,LD,HD
SWINGS=SW1,SW2,SW3,SW4
Using this example as a baseline, different approaches are proposed to improve the properties accuracy of the final cuts:
•Swing-Cuts: Cut-to-Mix with Corrections •Swing-Cuts: Cut-to-Mix with Corrections + Volume/Mass Weighted Interpolation •Swing-Cuts: Cut-to-Mix with Hypo-Swing-Cuts Ordination
•Swing-Cuts: Mix-to-Cut with Hypo-Swing-Cuts Ordination
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20 140 160
LN
SW1 HN
180
SW2
LN
HN
Vol
T(ºC) 210
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C1C2
C3C4
LN
HN
SW1 SW2
K
SW3
LD
TI TE
C1C2 -273 -50
C3C4 -50 20
LN 20 140
SW1 140 160
HN 160 180
SW2 180 210
K 210 240
SW3 240 260
LD 260 360
SW4 360 380
HD 380 420
ATR 440 850
LVGO 440 580
HVGO 580 620
VR 620 850
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CUTS Final Pools
Tcuts Assay
Cutting
blending
FCUTS HYPOS
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Big HYPOS FCUTS Final Pools
Hypos-Averaged inside the CDU
Trange
Cutting
blending
HYPOS
Hypos-Swing Ordination
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1- Cut-to-Mix with Corrections (Constrains and Mass Balance)
This approach is just a numerical correction once the properties are averaged values. Appling a mass balance and a sulfur mass balance and a set of constrains in the SWis :
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(0.778*463+0.796*1999)/(463+1999)=0.793
(0.870*488+0.913*764)/(488+764)=0.896
Conventional Aproacch
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2- Cut-to-Mix Correction and Interfacial Interpolation Interpolating the SW1L between the layers (LN,HN).
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QSW1UP
(0.778*463+0.796*1999)/(463+1999)=0.793
(0.878*488+0.907*764)/(488+764)=0.896
(0.778*463+0.796*1999)/(463+1999)=0.793
(0.870*488+0.913*764)/(488+764)=0.896
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normal approach SWis
properties constants
hypos->Cuts>Final Cuts Ready
1 Cut-to-Mix Mass bal and constrains hypos->Cuts>Final Cuts Ready
2 Cut-to-Mix Mass bal and constrains +
Interfacial Interpolation
hypos->Cuts>Final Cuts Ready
3 Cut-to-Mix Swing-Hypos ordination hypos->Final Cuts Need Ordination
4 Mix-to-Cut hypos->Final Cuts Ready
5 Mix-to-Cut Swing-Hypos ordination hypos->Final Cuts Ready
6 Mix-to-Cut Swing-Hypos ordination,
Mass bal and constrains +
Interfacial Interpolation
hypos->Final Cuts Need Ordination
+ interfacial Interpolation
7 CDF Weibull Extreme Tcuts [TISW,TESW] Ready
8 CDF with sin/cos
Weibull Correction
Weibull Extreme
+correction
Tcuts [TISW,TESW] Need Interpolation in GAMS
9 Linear Interpolation Tcuts [TISW,TESW] Need Interpolation in GAMS
10 Spline Tcuts [TISW,TESW] Not started yet
Fraction Index 11 Fraction Index Tcuts [TISW,TESW] Need properties correction
baseline
Swing Cuts
Regressed
Models
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Sahinidis, N. V., Grossmann, I. E., Fornari, R. E., Chathrathi, M. (1989). Optimization model for long range planning in the chemical industry. Computers and Chemical Engineering, 13(9), 1049-1063. Moro, L.F.L., Zanin, A.C. e Pinto, J.M. (1998). A planning model for refinery diesel production. Computers and Chemical Engineering, 22 (1), 1039-1042. Li, W., Hui, C.W. e Li, A. (2005). Integrating CDU, FCC and blending models into a refinery planning. Computers and Chemical Engineering, 29, 2010-2028. Alattas, A. M., Grossmann, I. E., Paulo-Rivera, I. (2011). Integration of nonlinear crude distillation unit models in refinery planning optimization. Industrial and Engineering Chemistry Research, 50, 6860-6870. Alattas, A. M., Grossmann, I. E., Paulo-Rivera, I. (2012). Refinery production planning: multiperiod MINLP with nonlinear CDU model. Industrial and Engineering Chemistry Research (Accepted Aug 23rd). Zyngier, D., Kelly, J. D. (2012). UOPSS: A new paradigm for modeling planning and sheduling systems. ESCAPE 22, June 17-20, London.
References
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