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SS TSS-05 Refinery Reactor Modelsin ROMeo

Rujun LiProduct Manager,

Refinery Reactor Models

@InvensysOpsMgmt / #SoftwareRevolution

/InvensysOpsMgmt

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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


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


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


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


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


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


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


Slide 15

• Structure

• Configuration

• Beds

• Component Slate

• Specifications

• Catalyst

• Mixer


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


• Tuning

Slide 17

• Thermo and Component Slate Configuration

• Reactor configuration, single vs. train


• 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


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

Create New Cases

Slide 25

Excel InterfaceCase Comparison Interface

Slide 26

User defined Worksheet

Slide 27

Excel Offline Demo

• Login/out, Change Database

• Create new case

• Run and Compare cases

Slide 28

LP Update Manager Tool for Planning


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

LP Update Manager Overview

Slide 32

Generated Worksheet – updated coefficients

Slide 33

Tracking Coefficient Values

Slide 34

All updatedcoefficientsare “blocked”

Updated LP Sub-model or Module

Slide 35

All updatedcoefficientsare “blocked”

LP Update Manager Demo

• Map variables

• Generate worksheet

• Compare LP Vectors

Slide 36

Q & A

Slide 37

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