UNISIM DESIGN - Honeywell...Honeywell Confidential - © 2018 by Honeywell International Inc. All...

UniSim® Design Next Generation ModelsUNISIM DESIGN

Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved. Core to the Honeywell Connected Plant

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UniSim Design EO

Next Generation Reactor Models

Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.

Motivation for EO Development

• An Equation Oriented (EO) modeling capability is a great

compliment to a Sequential Modular (SM) capability

- The strengths of EO are the weaknesses of SM and vise-versa

- Combining the approaches broadens the potential for model based

applications of the future

• EO Strengths/SM Weaknesses

- Specification flexibility, supports lifecycle modeling, calculation

parallelization potential, higher accuracy solutions, difficult recycle

and highly interacting flowsheets, independent of solver technology,

easier model code maintenance, online applications (optimization)

• EO Weaknesses/SM Strengths

- Difficult thermos

- Diagnostics for solver failures

- Limited use of logic in model code


Motivation for EO Development

• Modeling uses in the future is also being looked at broadly by the

manufacturing industry

- See “Implementing 21st Century Smart Manufacturing - Workshop

Summary Report

- https://smartmanufacturingcoalition.org/

• Expand UniSim into Online Model Based Applications (OMBAs)

- Process Monitoring

- Operator Advisory/Decision Support

- Early Event Detection

- Optimization (Offline and Online)

• Business Cases for OMBAs are improving as issues continue to

be addressed

https://smartmanufacturingcoalition.org/


UniSim EO History

• UniSim EO (Equation Oriented) was referred to as Genesis

• Genesis was a development of Hyprotech to implement a next

generation simulation system with life cycle modeling capabilities

• Honeywell continued this development after acquisition of Hysys from

Aspen which became UniSim

• Honeywell marketing conducted VOC that indicated there was no

pressing need for EO capability, although it is common knowledge

there are classes of problems not well-handled by sequential modular

architectures

• UniSim EO development currently moving forward based on joint

funding from UniSim budget and customer inputs


UniSim EO

• UniSim EO (Equation Oriented) is a new functionality in UniSim to

use a better modeling approach for complex flowsheets and

problems with an optimization aspect (parameter estimation,

economic optimization)

• EO architecture separates modeling from the solution procedure,

thus simplifying model development and offering more solver

options

• Limited functionality released in UniSim Design so far

• Equation Oriented capability compliments sequential solution

strategies

• More capability under development in projects for customers

• Current version allows embedding a Unisim EO flowsheet into a

Unisim design model as a subflowsheet


UniSim EO Functionalities

• Enable more powerful optimization capability

• Enable solution of highly integrated complex

flowsheets

• Enable specification flexibility

• Potential to realize “lifecycle” modeling goals

- Same model for multiple applications/uses

• Create flowsheet models suitable for external applications

- Model deployment architecture

- Performance monitoring, model based optimal control

• Simple custom model integration capability

• Solver Library/Framework (NOVA, others)

• Powerful Modeling Language (4GL)

- MATLAB (like)

- Access to properties, streams, etc


UniSim EO Views

UniSim EO

Element

UniSim EO

Sub flowsheet

UniSim EO

Ops


UniSim EO Specification Views


UniSim EO Blowdown

9


2005

2013

2015

UniSim Design R350

Depressuring Dynamics

(Legacy)• Code identical to the Aspen

HYSYS Depressuring Utility

After the IP acquisition by

Honeywell

• Equilibrium calculations

• Need to link to stream in the

main flowsheet in order to

configure

Blowdown Utility Predecessors

UniSim Design R430

Blowdown Utility• Introduced non-equilibrium

calculations

• Improvements to the heat

transfer between phases

• Improvements to the vessel

geometry

• Still need to link to stream in

the main flowsheet in order to

configure

UniSim Design R440

EO Blowdown Utility• Transferred utility to EO environment

(single vessel + RO only)

• Introduced blowdown scheduling

• Link to stream no longer needed

• Migration from R430 at click of button

• Improved reporting

UniSim Design R442

EO Blowdown Utility• Introduced flowsheet customisation on

EO environment

• Extended blowdown scheduling to the

flowsheet environment

• Allowed for 2D heat conduction in the

vessel walls and heads

• Implemented the fire method based on

the API 521 6° edition industry standard

2015


EO Blowdown - Background

• Earlier versions of UniSim Design had a depressuring utility called “Depressuring – Dynamics (Legacy)”

• Starting with UniSim Design R440, the Legacy utility is being phased out and is being replaced by two more rigorous and powerful depressuring utilities called “Blowdown Utility” and “EO Blowdown Utility”.

Depressuring – Dynamics

(Legacy) Utl. (R350)

Blowdown Utl.

(R430)

EO Blowdown Utl.

(R442 on)

Top/Bottom

DepressuringLimited Yes Yes

Geometry of

Vessel HeadsLimited Good

Good – further

enhanced

Rigorous Heat

TransferNo Yes

Yes– further

enhanced

Multiple Vessels

and PipingNo No Yes

Non-Equilibrium

holdup modelNo Yes Yes

Robustness Fair Good Good

Rigor Limited Good Good

Validated against

real dataNo Yes Yes


EO Blowdown Utility Capabilities

• Works by creating a Dynamic sub-flowsheet within the steady state model - Defaults to a single vessel with a single Relief Orifice

- Additional Unit Ops can be added from the EO Unit Op library:

Mixers

Pipes

Non-equilibrium Vessels, and

Relief Orifices

• UniSim Design EO Dynamics Solver- NOVA solver (simultaneous Equation Oriented architecture)

- Uses UniSim thermo (clones FP as necessary)

- Robust solver for convergent Hydraulic network


Blowdown of a of a single volume

• Single Vessel with a single Orifice (default flowsheet)- Utility will calculate transient and settle out conditions

• The utility considers up to 3 phases (V, L1, L2)

• Vessel characterisation- Orientation

- Head Type

- Length/Height and Diameter

- Discharge Nozzle

- Initial conditions

• Orifice characterisation- Diameter

- Discharge coefficient

- State (Open/Closed)


Blowdown of a customized Flowsheet

• Modify the default PFD. Currently EO library has following Unit Ops:

Mixers

Pipes

Non-equilibrium Vessels, and

Relief Orifices


Environment - Adiabatic or Fire mode

• Adiabatic mode- No external heat is applied so no parameters need to be entered in this section

• Fire Methods1. Analytical API 521

2. Basic API 521

3. Empirical

4. Enhanced API 521

5. Radiation

- Each Fire Method has its own Parameters


Heat Transfer Model• Zoned model: up to 3 vessel zones and 3 Wall zones (V-L1-L2)

• Two Wall Model Types

- 1 D: 1 dimension temperature gradient

- 2 D: 2 dimensional temperature gradient

• Wall comprises vessel wall & insulation layers

- Material type & thickness specified

- Heat capacity, density & thermal conductivity could also be specified

• External Convection

- On

- Off

• User Heat Flux

- Vapor Zone

- Liquid Zone

• Heat transfer coefficients are calculated

Vapour and liquid to metal

Metal/insulation to environment

Between fluid phases

x


Orifice Model

• Generic multi phase orifice model for- Subsonic flow

- Sonic flow (Choked Flow)


Rating Mode Only

• Rating mode- User supplies orifice size and depressuring time

- UniSim Design calculates depressuring during given time

• For Orifice Sizing- Select a size, run Blowdown Utility and iterate until desired performance is achieved


Dynamic Scheduling

• Allows dynamic scheduling- Specify events (variable values) at set times


Effective use of EO Blowdown Utility

• Define Vessel

• Define Vessel contents & conditions

• Define Environment (Adiabatic or Fire)

• Define Wall layers

• Define Orifice

• Specify Back Pressure and Integration Parameters

• Run Utility


Results

• Pre-configured strip charts for trends of variables of general interest

Vessel zone pressures & temperatures

Vessel hold ups and liquid level

Vessel wall temperatures

Orifice outlet velocity, mass flow, pressure, temperature and vapour fraction

• New strip charts can be created.

• Results can be viewed on strip charts or on tables.


Refinery Modelling Functionalities

Reactor Models

23


The Platform | Next Generation Refining Capabilities

24

Refining

Reactor Models

• Equation Oriented

Reactor Models

• Validated by Honeywell

subject matter experts

• Flexible and easy

calibration with few

parameters

Easy to Tune

and Deploy by User

High Performance EO

Platform

• Equations Oriented

(EO) Platform

• Refining simulation and

optimization in the

same environment

Rapid Deployment &

Conversions of Large

Scale Flowsheets

Refining

Workflows

• Efficient Workflow

• LP vector generation

• Crude selection and

analysis,

• Heat exchanger

monitoring and

optimization

Improve Engineering

Effectiveness

Refinery Modelling

Infrastructure

• Refining Properties

• Crude Environment -

Assay Management

• Supply Chain

Integration - LP Vector

Generation

Best In Class

Technology-Design to

Optimization


UniSim Design Suite | Delivering Value to Refining Customers

Delivering Increased Refinery Profitability

25

Supply Chain

Support

Ensure LP Vectors,

used in feedstock

planning, are updated

to accurately reflect

current refinery

capabilities

Unit Level

Monitoring

Real-time monitoring of

refinery units,

leveraging EO platform,

to support operations

Provides insight into

predicted performance

vs actual

Small

Debottlenecking

Projects

Supports process and

project engineers

doing sensitivity

analysis and project

option evaluation

Off-line

Optimization

Enables ‘what-if’

analysis to provide

unit optimization

across the refinery


Refining Features in UniSim Design26

• Predictive Refining Reactors:

- Hydrocracker

- Hydrotreater

- Catalytic Reformer

- Isomerization

- Alkylation

• Predictive Refining Reactors:

- Fluid Catalytic Cracker

- Delayed Coker

- Visbreaker

Unit Mod. & Opt. -> More Unit Mod. & Opt. -> Refinery-Wide Mod. & Opt. -> Life-Cycle Support

• Assays & Refining

Properties

• Blending Rules

• Import from Spiral Crude

• Link with Haverly H/CAMS

• LP Vector Generation Tool

• Predictive Reactor Support

in Dynamics

• Modeling & Optimization

of Units without

Predictive Refining

Reactors


of Brownfield Refineries

• Remote consulting

services for UOP units


of Units containing the

above reactors for

Greenfield Refineries

• Modeling & Optimization of

all units of any refinery

• Refinery-Wide Optimization

• Refinery-Wide Production

Allocation

• Remote consulting

services for non-UOP units

by other technologists

• Life-cycle Simulation

Support

Featu

res

Cap

ab

ilit

ies

CONFIDENTIAL


• UniSim® Design allows engineers in refining study scenarios to process different crude feeds,

accurately predict yields for various refining products, and keep up-to-date their LP programs

for scheduling and planning purposes.

• Allows variation in process parameters to predict performance of reactor units.

• Allows scenario studies for variations in feedstock, product yields & so on

• Provides refinery unit level optimization capabilities

• Generates LP vectors and the generated vectors can be used to tune scheduling and

optimization applications for production planning

• Capabilities to study reactor performance & its contribution to a wider combination of units

UniSim® Design capabilities

• UniSim Design capabilities fully meet Refinery Modelling objectives


Refinery Reactor in UniSim R460

• UniSim® Hydrotreater for simulating Naphtha, Kerosene, Gas Oil, Slurry and Atmospheric

Residue Hydrotreater reactor models

• UniSim® Hydrocracker for simulating Hydrocracker/Mild Hydrocracker and Base oil production

• UniSim® Reformer for simulating Naphtha Reforming

• UniSim® Isomerization for simulating Light Naphtha Isomerization

• UniSim® Alkylation for simulation Alkylation

• Reactor modules part of UniSim R460 & R470

UniSim® Design | Refinery Reactor

Refinery Reactor in UniSim R470 (2019)

• UniSim® FCC Reactor for simulating FCC reactor models

• UniSim® Delayed Coker for simulating Delayed Coker


Example: Hydroprocessing Reactor

• Predictive Kinetic reactor model

• Covers all aspects of Hydroprocessing (HCU & HDT)

• Implemented fully in the Next Generation Simulation Environment

Allows for switching of solver: Sequential, Simultaneous & Optimization

• Allows controlling distribution of light & heavy ends

• Catalyst Life Prediction

• Provides overall reactor

performance information

• Requires minimum

configuration & Calibration time

• Hydroprocessing Reactor module part of UniSim R460


Refinery Reactor Parameter Calibration

• Refinery Reactor Parameter calibration helps tuning reaction kinetic parameter

• It allows to match results (component yields, outlet temp) with desired results

• The data input to parameter calibration can be pilot or real plant data

• Parameter Calibration allows

combination of optimizer & data

reconciliation

• Saves effort and time of

manual parameter tuning

• Parameter Calibration and Data Reconciliation within EO environment


Refining Properties• Base environment stream properties required to support Refining

Flowsheet and Crude Environment

• RON, MON, RVP, conradson carbon rate, carbon to hydrogen

ratio, cetane index, refractive index, yield, Aniline, cloud, freeze,

pour, smoke, softening, wax congealing and flash points, X-ring

UV and IP391 Aromatics, Cx Asphaltenes, olefins, naphthalenes,

naphthenes, n-paraffins, paraffins, polynaphthenes,

mercaptans...

• Individual stream properties or multiple stream properties can be

visualized using the stream plot utility

Deeper Dive | Refining Infrastructure

Infrastructure & Unit Operations to Efficiently Create Complete Refining Flowsheet

3131

Crude Environment• Environment for managing Crude

Assay properties

• Direct link to Haverly H/CAMS

crude assay library, can also be read from

MS Excel files or manually entered

• Assays are mapped to components and

pseudo components and propagated to

flowsheet environment

Blending Rules• Pre-defined non proprietary

blending rules included

• Horizontal and vertical

mixing

• Fully customizable


© 2017 by Honeywell International Inc. All rights reserved. Restricted distribution.

Crude Assay Management

• UniSim Design links to Crude Assay Databases

• Haverly H/CAMS

• Spiral

• Other Databases

• Possible to also include proprietary assays

• Assays are imported under the UniSim Crude Manager

environment

• Assay Synthesis

Easy assay import into UniSim Design

32

USD R450/1

• The crude assay import facility makes it easy to import

and manage crude assays.

• This functionality increases engineering effectiveness,

eliminates room for manual data entry, and makes it

easier to model crude storage facilities and refining

processes.


LP Vector Generation• Generate LP vectors from user-configured independent and

dependent variables using simulation model or plant data

• Tune and maintain business planning, scheduling and

optimization applications

• Easy workflow between process engineering and supply chain

ensures continuous improvement of planning models and

profitable refinery operation

• Reduce plan-vs-actual gaps, deliver lost opportunity with realistic

and optimal plans that successfully achieve targets

Delivering Value through Engineering and Operations Effectiveness

3333

High Performance Optimization• Proprietary NOVA solver for online,

real-time optimization across all

process industries

• Well suited for solving hundreds of

thousands of equations with up to a

thousand degrees of freedom

• Unlocks new value with existing assets

Crude Pre-Heat Exchanger Monitoring• Exchanger Network Design, Pinch Analysis and Operational

Analysis solution with UniSim ExchangerNet & ExchangerNet Ops

• Perform “what-if” scenarios,

retrofits, cost optimization and

cleaning cycle optimization

decisions

• Optimize energy consumption

while maintaining product

quality and yield

Deeper Dive | Refining Capabilities Delivering Results


Thank you!

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UNISIM DESIGN - Honeywell...Honeywell Confidential - © 2018 by Honeywell International Inc. All...

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