A new simple and robust process FT-NIR Spectrometer with small footprint and extended maintenance interval

Transcription

1 Thomas Buijs, Michael B. Simpson, ABB Quebec, BU MA Analytical Measurements Oil & Gas Industry A new simple and robust process FT-NIR Spectrometer with small footprint and extended maintenance interval ABB Group February 25, 2015 Slide 1

2 What is Process FT-NIR? Applicable in general to most refinery hydrocarbon streams It provides Final Product Blending Gasoline & Diesel Naphtha Feed & Conversion Units CCR, HDT, ISOM, NCC HF Alkylation HF, ic4, Olefins Crude Oil, Base Oils & Upgrader Units CDU, HCK, FCC, LBU, RDS Real-time multi-property physical and chemical analyses RON, MON, Cetane, ASTM D86 Distillation, T95, E70, E100, Cloud Point, Freeze Point, Pour Point, Aromatics, Benzene, KV40, PIONA(Paraffins, Isoparaffins, Olefins, Napthenes, Aromatics), RVP etc On multiple physical streams per Analyser And is ideal for linking to APC (low-noise, rapid response) A high-quality input to full economic optimization models

3 Applications - Refining Blending Solutions Gasoline, Diesel, Crude, Fuel Oil In-line release ABB Group February 25, 2015 Slide 3 Conversion Unit / Distillation Solutions Crude Feed characterisation Crude Assay (Lab) Crude Distillation Unit (CDU) Rundown Light Naptha, Heavy Naphta, Kerosene, Light Gas Oil, Heavy Gas Oil Unit Feed and Product characterisation Naptha Complex applications Reforming Unit, Isomerisation Unit, Naphtha Hydrotreating Fluid Catalytic Cracker (FCC) feed and Light Cycle Oil, Light Cat Naphta, Heavy Cat Naphta Vacuum Gas Oil, Base Oils C4 Units, MTBE, Butadiene Cumene / Phenol LPG HF Acid Alkylation recycle Ethylene plant feed (naphtha)

4 Process FT-NIR project delivery Major influences on Project Delivery Sample take-off & sample transport Analyzer location & environment Sample conditioning system Sample flow cells or probes Analyzer performance criteria Application configuration & interface to DCS Calibration & method development On-site Laboratory validation System validation Life cycle management

5 Process hydrocarbon stream analytics FT-NIR

6 The Refinery Naphtha Complex ABB Group February 25, 2015 Slide 6 The naphtha conversion units in a refinery upgrade, hydrotreat and convert natural naphtha from the Crude Distillation Unit (CDU) or cracked naphthas from the Fluid Catalytic Cracker (FCC) and Hydrocracker (HCK) units to create higher-value light hydrocarbon gasoline blending components These include the Naphtha Hydrotreater (HDT), Isomerization Unit (ISOM), Catalytic Reforming Unit (CCR) and in the Olefins (Ethylene) Unit the Naphtha Steam Cracker (NSC) All units have a FEED and a PRODUCT side, and most use a FURNACE and CATALYST to do chemistry Furnace severity, catalyst run-lengths, product quality, throughput and energy consumption all impact Unit economics and real-time on-line FT-NIR can significantly improve ROI.

7 ROI in the Naphtha Complex The main control objective for all naphtha conversion units is to maximise Unit throughput, maintain product quality while avoiding excessive furnace severity leading to catalyst degradation and furnace tube coking To achieve this real-time feed and rundown analysis is essential Naphtha feed streams can in principle be measured on-line by GC techniques, but the qualities required for effective control include PIONA and %Distillation, which require long elution times. FT-NIR offers much faster and more repeatable analysis ABB Group February 25, 2015 Slide 7 The benefits include tight furnace control, improved reformate RON and Benzene / Aromatics quality, more flexible response to naphtha feed transitions and extended catalyst run-lengths. Octane and furnace severity management alone correspond to $M/yr benefits

8 HP260X Process FTNIR Analyzer Naphtha Conversion Unit Feed & Recycle Large multichannel system Purged temperature controlled enclosure ABB Group February 25, 2015 Slide 8

9 Introducing Talys ASP400 Ex Process FTNIR Analyzer Naphtha Conversion Unit Feed / Recycle Compact single channel system Small Footprint: Fully integrated in single enclosure. Unit may be either shelf or wall mounted. No Analyzer PC required (Embeded processor for sensor like integration) 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 ABB Group February 25, 2015 Slide 9

10 Introducing Talys ASP400 Ex Process FTNIR Analyzer Naphtha Conversion Unit Feed / Recycle APPLICATIONS Naphtha Complex (CCR, ISOM) Hydrotreating (HDS, HDT) Naphtha Steam Cracking MOGAS blending ABB Analytical Measurement Group February 25, 2015 Slide 10 PROPERTIES Composition PIONA, C-number, BTX, Aromatics, Olefins, C4s, PAHs Ignition Properties RON, MON, Cetane Number & Index, Flash Point Cold Flow Properties Pour Point, Cloud Point, Freeze Point, CFPP Distillation & Physical Properties D86, KV, API, TBP

11 FTIR Applications in Naphtha Conversion Units Light Naphtha Feed to ISOM unit Heavy Naphtha Feed to CCR unit Reformate Rundown from CCR Isomerate Rundown from ISOM HF Acid & ic4 Recycle On HFU ABB Group February 25, 2015 Slide 11

12 Refinery Process Units CCR Catalytic Reforming Unit Improve CCR operation and flexibility, maximise reformate octane barrels, and lengthen catalyst run-times by better severity control with on-line FT-NIR analyzers Rapid response to naphtha feed quality changes and switches from gasoline to BTX operation Heavy Naphtha Feed -PIONA, T95, RVP Reformate Product Rundown - RON, benzene, aromatics, RVP ABB Analytical Measurement Group February 25, 2015 Slide 12

13 Refinery Process Units ISOM Naphtha Isomerisation Unit Improve ISOM unit operation and flexibility, maximise isomerate yield and quality, for better supply of gasoline blending feedstock Rapid detection of naphtha feed quality changes due to CDU swop-over and cut-point variation Light Naphtha Feed -PIONA, T95, RVP Isomerate Product Rundown - RON, RVP ABB Analytical Measurement Group February 25, 2015 Slide 13

14 Refinery Process Units Naphtha 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

15 Refinery Process Units Naphtha Steam Cracker Olefins Unit Steam-Cracking Optimisation Real-time fast analysis of steam cracker naphtha feed Provides PIONA, %Distillation and C-number breakdown analyses Enables efficient use of SPYRO feed-forward optimiser for management of COT control Minimise coil coking, side-products Correctly manage cracking severity to match downstream volumetric flow (compressor) constraints Maintain optimal P/E ratios in response to feed quality variation ABB Analytical Measurement Group February 25, 2015 Slide 15

16 PIONA estimation by FT-NIR P O A (low) I N A (high)

17 C-number Breakdown for SPYRO Optimiser pc6 v% ic6 v% R 2 = 0.98 SECV= R 2 = 0.96 SECV= vol % 20.0 FTIR Actual PC4 PC5 PC6 PC7 PC8 Tot Paraffin IC4 IC5 IC6 IC7 IC8 Tot i-paraffin Tot Olefin NC8 Tot Cycloparaffin Tot Aromatics

18 C-number estimation by FT-NIR pc6 v% R 2 = 0.98 SECV= pc8 v% R 2 = 0.98 SECV= ic6 v% R 2 = 0.96 SECV= ic8 v% R2 = 0.99 SECV=

19 PIONA estimation by FT-NIR on-line data (w/w%) n-paraffins iso-paraffins Olefins Naphthenes Aromatics Total C4 T10 T30 T

20 Example LPG analysis ic5 in C3/C4 stream

21 Example discrimination of c6 isomers in naphtha FT-NIR spectra of 2,3-dimethylbutane 2-methylpentane 3-methylpentane n-hexane methyl-cyclopentane FT-NIR spectra of analysed samples for calibration set

22 Example discrimination of c6 isomers in naphtha

23 Introducing Talys ASP400 Ex Process FTNIR Analyzer Come and see Talys at IFPAC booth 204 ABB Analytical Measurement Group February 25, 2015 Slide 23

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