2012-01-04

MPC at Statoils Kalundborg Refinery

17th Nordic Process Control Workshop

Technical University of Denmark, Kgs Lyngby, Denmark

January 25-27, 2012

Anne-Katrine Ipsen, Advisor Refining

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Content of presentation

1. About Kalundborg Refinery

2. APC history

3. Statoils InHouse MPC tool Septic

4. Examples of MPCs

5. GORTO – Gas Oil Dynamic RTO

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First a little about Kalundborg Refinery

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Statoil Kalundborg – Main products

Condensate

Crude oil/

Propane

Gasoline

Jet Fuel

Diesel

Heating oil

Heavy fuel oil

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Yearly production 2010

2010 total production: 4755 Mill tons

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Crude oil/ Condensate throughput 2010

2010 total throughput: 4521 Mill tons

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APC history

• Honeywell DCS from 1986

• Implementation of conventional APC in coorperation with Exxon

• MPC study by Exxon 1995 – first MPC planned on Condensate Fractionator,

using AspenTech DMC+. Never completed due to technical problems.

• First MPC implemented in 1999 – using SEPTIC, close coorperation with F&T

• Kalundborg MPC strategy in 2001

• Continued MPC implementation 1999-201x

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Classificati

on: Internal

(Restricted

Distribution

) 2011-

11-15

The process control hierarchy

9 Distributed Control System

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0

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10 -

Kalundborg

#17

#2 Gullfaks/Tordis

Kårstø

#25

Kollsnes #5

Mongstad #22

#7 Åsgard Norne Heidrun

Snøhvit

#2

Sept-2011: 80 Applications

Note: oppdatert SM og KLB sept 11

Statoil Estimation and Prediction Tool for Identification and Control

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Applications

• Oil Refining (Mongstad and Kalundborg)

− Distillation

− Product blending (Gasoline and Gas Oil)

− Steam production and consumption

− Crackers, reformers, hydrotreaters

− Heat exchanger network (RTO)

− Optimization (RTO/DRTO)

• Gas Plants (Kårstø, Kollsnes, Snøhvit)

− Distillation

− Gas quality

− Pipeline pressure control

− Optimization

• Offshore

− Extended slug control, buffering

− Crude mixing

− Produced Water Reinjection

− Gas quality

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2012 APC status

• 18 MPCs running – 124 MVs, 266 CVs

• gasoil production and blending dynamic RTO (GORTO)

• gasoline batch blending

• total MPC incentive 142 MDkr/year

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Classificati

on: Internal

(Restricted

Distribution

) 2011-

11-15

HFO

Crude

oil

Sec. 200

Atmospheric

Distillation

370-480 m3/hr

Sec. 1000

Vac. Distil.

140-200

m3/hr

Kero/ Gasoil

Hydrotereating

C-

201

Overhead

Sec. 300/400

HT/ Reforming

45-60 m3/hr

Sec. 550

Jet Fuel Plant

15-40 m3/hr

Sec. 800

Gasoil HT

65-130 m3/hr

Kero 60 m3/hr

LGO 80-110 m3/hr

HGO 25 m3/hr

LVGO 10-20 m3/hr

HVGO

90-120 m3/hr

Visbreaking

60-80 m3/hr

ThermoCracking

90-115 m3/hr Fractionation

VB

Nap

hth

a

VB

GO

Tar

Gas

Naphtha

Jet

Fuel

Diesel

Gasoil

Gasoline

Gas &

LPG

Sto

rag

e a

nd

Ble

nd

ing

Sec. 700 Gas Plant

10-15 m3/hr

Condensate/

crude oil

C-

4201

Overhead

Light Kero 6-20 m3/hr

ULGO 51 m3/hr

LAGO 10-25 m3/hr

Light Ends HT & Fractionation

220 m3/hr

Sec. 850 Kero/

Gasoil HT

40-90 m3/hr

Vac. Btm. 70 m3/hr

Sec. 200/250 Light

Ends Fractionation

80-120 m3/hr

Sec. 4800

Gasoil HT

145 m3/hr

To Kero/ Gasoil

Hydrotreating

To Gasoil

HT & HDA

Sec. 4400

Reforming

105 m3/hr

Sec. 4600

Isomerisation

95 m3/hr

Gas Plant

LV

BN

HV

BN

Naphtha to Light Ends

HT & Fractionation

LVN

HVN

To Vacuum

Distillation

Sec. 4700 Gas Plant

16-24 m3/hr

Sec. 4200

Atmospheric

Distillation

230-280 m3/hr

Sec. 600

Notation: Running Application Implementation ongoing Future Application

MPC at Kalundborg Refinery

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Classificati

on: Internal

(Restricted

Distribution

) 2011-

11-15

Desulphurisation

reactor R-4801

MPC example: Kalundborg Synflex Unit

Feed drum

D-4801

Feed preheat

(R-4851 btm.)

Separation

drum

D-4803

Heater

H-4801

Desulphurisation

reactor R-4851

Separation drum

D-4853

Feed-

pre

cooling

De-

Aromatisation

reactor

R-4852

Gasoil flows

Treat Gas flows

Mixed

Gasoil product

to stripper

Treatgas to

Recycle

Treat Gas

compressor

K-4851

Gasoil feed

from other

units

Treatgas

Treat Gas

liquidKnock

Out drum

The purpose of this unit is desulphurisation and dearomatisation of diesel.

One product is swedish City diesel.

There are 2 catalytic desulphurization reactors and 1 catalytic dearomatisation reactor.

The processes uses hydrogen.

Reactor pressure 60 barg. Reactor temperature app.. 350ºC. Design throughput 145 m3/hr.

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Classificati

on: Internal

(Restricted

Distribution

) 2011-

11-15

Desulphurisation

reactor R-4801

MPC example: Kalundborg Synflex Unit

Feed drum

D-4801

Feed preheat

(R-4851 btm.)

Separation

drum

D-4803

Heater

H-4801

Desulphurisation

reactor R-4851

Separation drum

D-4853

Feed-

pre

cooling

De-

Aromatisation

reactor

R-4852

Gasoil product

to stripper

Treatgas to

Recycle

Treat Gas

compressor

K-4851

Gasoil feed

from other

units

Treatgas

Treat Gas

liquidKnock

Out drum

Avanced process control in this plant is 1 MPC for total optimisation.

- Optimises unit throughput

- Controls all relevant product qualities

- Respects all relevant contraints - reactors, furnace, treatgas system

10 MVs

29 CVs

2 DVs

MV

DV

DV Reactor

Inlet

Temp.

CV

H2/oil

MV Treatgas

flow

Total

feed rate

Feed

temp.

CV H2/oil

MV

H-4801

Coil Outlet

Temperatur CV Contraints

(Heater, reactors,

treatgassystem)

CV

MV Manipulated variables

Controlled variables

MV

MV

Treatgas

flow

CV Product qualities

(sulphur, Aromatics,

Initial Boiling Point)

CV Treatgas/ H2 balance

CV H2/oil

R-4852

feed rate

MPC example: Kalundborg Synflex Unit

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Classificati

on: Internal

(Restricted

Distribution

) 2011-

11-15

- Models with fast dynamics

- Models with slow dynamic

- Models with inverse response

MPC example: Kalundborg Synflex Unit

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GORTO - Gas Oil Dynamic RTO

M

Analyzers/

Sample

M

Analyzers/

Sample

Kalundborg Gas Oil Production:

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Objectives:

• Maximizing the total Gas Oil Production

• Coordinating the operation of Main Fractionators

• Controlling and coordinating the gas oil Hydrotreaters

• Minimizing Give-Away on the end-products

• Minimizing production of lower valued heavier products

• Minimizing production costs

• Maximizing reactor catalyst cycle time

• Managing the rather large time delays throughout the production processes.

M

Analyzers/

Sample

M

Analyzers/

Sample

GORTO - Gas Oil Dynamic RTO

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• 100+ Product Quality estimators on all Fractionator and Hydrotreater Streams

• Automatic use of Lab data

• Automatic Gas Oil lineup check

• Automatic coordination of Fractionator MPC’s

• MPC’s on Gas Oil Hydrotreaters

• Automatic control of Gas Oil Blendstocks from Tank

• Tank Quality Tracking & Control on Gas Oil Feed Component Tanks

• Tank Quality Tracking on Gas Oil Product Tanks

GORTO parts:

• Number of Variables

Manipulated Variables (MV’s): 39

Controlled Variables (CV’s): 97

Disturbance Variables: 44

Logic Variables (i.e. line-up indicators): 37

GORTO - Gas Oil Dynamic RTO

• Statoil presented GORTO at the European Refining Technology Conference in

Lisbon in 2008

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GORTO - Gas Oil Dynamic RTO

MPC at Statoils Kalundborg Refinery

Anne-Katrine Ipsen

Advisor Refining

E-mail address d01ai@statoil.com

Tel: +45 59 57 45 37 www.statoil.com

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