Dr. Michael B. Simpson, ABB Quebec, BU Measurement ... · PDF fileABB Process FT-NIR Classical...

© 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


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


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


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


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


LGO-CFPP PREDICTION

-2

2

6

10

14

18

-2 2 6 10 14 18

LAB( )

NIR

()

NIR-CALIBNIR-PRED


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 )


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


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


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


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)


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


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

Dr. Michael B. Simpson, ABB Quebec, BU Measurement ... · PDF fileABB Process FT-NIR Classical...

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