Transcript PPT Template

Slide 1
Reactor Models in Romeo
Abhay Sawant
Technical Support
October 2012
© 2012 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.
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Agenda
Slide 3
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Refinery Overview
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Refinery Reactors Overview
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Demonstration
Typical Refinery Overview
Slide 4
Refinery Reactors
• Crack heavier gasoil to lighter more useful products
– Fluidized Catalytic Cracker (FCC)
– Hydrocracker
– Delayed Coker
– Visbreaker
• Upgrade gasoline quality
– Reformer: Convert straight run naphtha to high octane product
– Alkylation: Add Isobutane to low molecular weight C5- alkenes
• Hydrofluoric Acid and Sulfuric acid Alkylation models
– Isomerization: Convert n-paraffins to iso-paraffins to increase octane values
• Remove impurities from reactor feeds and products
– Hydrotreater: Remove sulfur from petroleum products to reduce emissions
Slide 5
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© Invensys
Reactor Models License Agreement between
ExxonMobil and Invensys
• Since 2004, ExxonMobil has used Invensys ROMeo™ software in
multiple applications
• ExxonMobil Research and Engineering Company (EMRE) and
Invensys have entered into a licensing agreement that will allow
Invensys to license EMRE process models to 3rd parties
• ExxonMobil uses versions of these models in its business for
optimization, process engineering, design, and operations
monitoring
• Invensys has full access to the code and will provide all support
and maintenance services to its customers
• Invensys is the exclusive supplier of EMRE technology
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Refinery Reactors Overview
ROMeo Refinery Reactor Model Portfolio
Most Comprehensive list of Refinery Reactor Models based on ExxonMobil operating experience
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Key Features
• Full suite of reactor modeling technology available for Refinery-wide
Optimization
• Based on years of operating experience by ExxonMobil
• Rigorous kinetics based models allows accurate modeling over wider
operating range
• User-friendly GUI for tuning
• Sim4ME Portal provides simple and user friendly Excel interface for
offline simulation and what-if case studies
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Benefits
Slide 9
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ROMeo Open equation based modeling enables robust, broader
scope modeling and optimization of a refinery
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Offline simulation and engineering study capabilities
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Planning with LP vector update from the reactor models
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Performance monitoring of the reactor and catalyst
Reformer Reactor
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Purpose: Reform naphtha to increase octane value
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Feedstock: Straight-run heavy naphtha from crude tower
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Reactions:
• Isomerization of normal paraffins to isoparafins
• Dehydrogenation of naphthenes and dehydrocyclization of paraffins to aromatics
• Some hydrocracking side reactions
Process:
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• Semi-regeneration: All reactors running and regenerated at the same time
• Cyclic: One reactor is regenerated at a time and switches online and offline
• Continuous Catalytic: Continuous regeneration
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Reformer Reactor Model
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Can model Semi-regen, Cyclic and CCR
by changing catalyst types
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Very flexible configuration, can be
configured to have 1 or more reactors
(beds), to include pre-heater,
intermediate heaters and product flash
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Product RON & MON (with the octane
model), total aromatics, total C5+
Yield predicted
•
ExxonMobil has 10+ successful
implementations. Invensys has
validated the model with 2 sites and 3
units
FCC Reactor
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Purpose: Crack heavy gas oil to produce lighter more valuable
products
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Feedstock: Mainly heavy gasoil from crude and vacuum towers
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Products:
• Light gases: Fuel gas
LPG: To Alkylation
• LCO: Fuel oil or diesel HCO: Fuel oil
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Gasoline: Fuel
Slurry/Decant oil: Fuel
Different designs available from ExxonMobil, Shell, Shaw Stone
Webster, CBI Lummus, UOP, and Kellogg
• Reactor: Riser, Reactor, and Regenerator form a closed circuit
• Catalyst: Circulated and regenerated in the circuit
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FCC Reactor Model
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Rigorous Kinetic Model
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Energy and pressure balances
rigorously modeled
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Can model different designs,
ExxonMobil has more than 20
successful implementations
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More detailed than KBC FCC-SIM
model
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Feed synthesis/characterization
included
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Hydroprocessing (HDP) Reactor Model
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Rigorous kinetic model of four major reaction types, coke effect can
be modeled through reducing catalyst activity
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Can model both hydrotreating and hydrocracking reactors by
switching catalyst type
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Has its own feed synthesis and analyzer (for sulfur and nitrogen
prediction) to produce correct feed compositions from reference feed
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ExxonMobil has more than 20 successful implementations
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HF Alkylation (HFAlky) Reactor
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Purpose: Convert light naphtha (C6- olefins) to high octane alkylate
for gasoline blend
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Feedstock: Light naphtha from FCC and Isobutane from hydrocracker
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Reactions: Rapid exothermic reactions with HF as the catalyst
C3, C4, C5 olefins + iC4  Alkylate
• Side reactions product high boiling point acid soluble oils (ASOs)
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Technology from Phillips and UOP
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Reactors: Water-cooled exchangers (UOP) and Differential Gravity
Reactor (Phillips)
iC4 Recycle
iC4
Reactor
C3=
C4=
C5=
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Acid
Settler
LPG, nC4
Separation
Alkylate
HF Catalyst
HF Alkylation (HFAlky) Reactor Model
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Can model both Phillips and UOP
processes
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Model includes both reactor and acid
settler
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Correlative model
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Model predicts Isobutane conversion,
alkylate, ASO rates, RON and MON
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ExxonMobil has been implementing the
reactor model with success
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Key optimization variables
• Optimize Isobutane recycle rate to maximize
profit
Slide 16
Sulfuric Acid Alkylation (SFAlky)
Reactor
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Can model both DuPont Stratco
(Effluent Refrigeration) and ExxonMobil
Auto-Refrigeration processes
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Both reactor and settler are modeled
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Can be used to model entire reactor, or
individual zones
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Model predicts alkylate yields, RON,
MON, acid consumption and spent acid
composition
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Key optimization variables
• Optimize Isobutane recycle rate to maximize
profit
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Delayed Coker
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Purpose: Thermal cracking of residual oil to gasoil and coke
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Feedstock: residual oil from vacuum tower bottom
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Products:
• Offgas: Fuel gas
LPG: To Alkylation
Naphtha: feedstock to reformer
• LCGO and HCGO: Feed to hydrotreating for diesel and other fuels
• Coke: needle ,anode and fuel grades
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Batch-continuous process for coke production (coke drum switch
cycle), main distillation tower does not have steady state, swings
with cycle
Delayed Coker Reactor (DCU)
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Models the unit including coke drum and fractionator and blends the
fractionator liquid products into one liquid product
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Take three feed types: residual oil, FCC fractionator bottoms/slurry
oil, and tar/rock
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Three products: gas (H2S, C1-C4), liquid (C5-302F, 302-430F, 430650F, 650F+) and coke
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ExxonMobil is implementing the reactor model in RTO
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Key optimization variable
• Optimizing coke drum temperature for maximum profit
Slide 19
Visbreaker Reactor (VOM)
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Model the visbreaking unit including
furnace/reactor, fractionator and fuel
oil blend
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Feeds: Resid, VGO (optional), cutter
stocks. Cutters stocks bypasses
reactor and do not crack.
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Products:
• Gas: H2S, C1-C4; Liquid: naphtha, gasoil
(can go to both liquid and fuel);
• Fuel: gasoil, residue, cutter stocks
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Key optimization
• Optimize residence time for max profitability
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Isomerization Reactor
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Purpose: Convert n-paraffins to iso-paraffins to increase octane
values
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Feedstock: Light (C5-) straight-run naphtha
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Reactor: Chloride promoted fixed bed
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Reactions: Moderately exothermic reactions
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UOP Butamer, Pentax for C4 and C5
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Product: isomerate sent to gasoline pool
Isomerization Reactor Model (ISOM)
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Rigorous Kinetic Model
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Model based on pilot plant data
of UOP I-8 catalyst for Butamer
and Penex processes
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Feed and products are all real
components
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No special property prediction
or modification in the model
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Easy to implement because of
usage of real components
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Key optimization
• Manipulate recycle compositions to
maximize product octane numbers
Slide 22
Refinery Reactor Demo
Slide 23