2014 AFPM (NPRA) Q&A and PADS
Emerson Alignment
2014 AFPM (NPRA) Q&A and PADS
Emerson Alignment
Hyatt Regency Denver
Denver, CO
October 5-8
Reminder!Reminder!
One important note about this event is that the AFPM is very sensitive about anyone speaking about price, even comments/discussion about current oil prices (public knowledge). With refiners all at one location, people speculate about price-fixing… just avoid the subject all together.
Industry ChallengesIndustry Challenges Gasoline demand still down
– Gasoline demand has not returned from the 2009 recession
– The US now exports more fuel products than imports
– Lowest cost producer wins – export to other regions
Tight oil (light) and Canadian (heavy) are the Opportunity Crudes– Challenges processing each
Shortage of skilled resources– Especially with turnarounds
Opportunity CrudesOpportunity CrudesTight Oil Properties: API > 42°, and <0.3 wt% sulfur Concerns: Higher concentrations of light components, large amount of
naphtha, high levels of Ca and Fe that can lead to catalyst poisoning, very paraffinic (lower gasoline octane), and immiscibility concerns when blending tight oil with heavy crude that can lead to fouling and corrosion issues
Heavy Sour Crude Properties: API < 26°, and >1 wt% sulfur Concerns: Yield slate, increased delta coke causes lower conversion
and higher regeneration temperature in FCC, contaminants may harm catalysts, corrosion problems in the crude unit, and fouling problems
Opportunity Crudes (cont.)Opportunity Crudes (cont.)Extra-heavy crude or bitumen Properties: API < 10°, typically also have high metals content, viscosity
100-10,000 cP at 60° F (15.6° C) for extra-heavy oil, and viscosity > 10,000 cP at 60° F (15.6° C) for bitumen
Concerns: Low cetane index for diesel, large amount of resid material, large amount of contaminants may harm catalysts, and fouling problems
High acid crude Properties: TAN >0.5 mg KOH/g, typically also heavy, API < 26° Concerns: Increased corrosion, poor salt removal and separation of oil
and water, fouling reduces plant capacity, degradation of catalyst by calcium, low cetane index for diesel, and may impact product specs
Tight Oil Crude AvailabilityTight Oil Crude Availability
Source: U.S. Energy Information Administration based on Drilling Info and LCI Energy Insight
Did you know?
United States crude oil domestic supply has
increased over one million bpd in each of the past two years, among the highest historical gains worldwide.
Cannot Export…
North America refiners will use a higher percentage of
tight oil
Tight Oil ChallengesTight Oil Challenges
Oil Movement H2S, amines, and high volatility Light Tight Oil (LTO) and crude blending LTO crude blends with Canadian crudes Hot section heat exchanger and fired heater tube
fouling Cold section heat exchanger fouling Variability in API Gravity Filterable solids and desalter operation Corrosion Downstream operations – catalyst and reactor controls
Near FutureNear Future Refiners will process a higher percentage of
tight oil Crude blending and incompatibilities will get
more scrutiny Fouling and corrosion monitoring will get more
attention Catalyst suppliers will make adjustments to get
expected yield and product qualities when processing higher percentage of tight oil
Heat ExchangersHeat Exchangers New opportunity crudes
and new normal with blending different combinations of crudes
Difficult to take measurements– Hot process fluids – Stacked exchangers– Other access constraints
Lack of temperature measurements between bundles
Time consuming to take measurements manually
Up to 50% of the heat delivered to the crude unit comes from the crude unit heat
exchangers
Increase Operations AwarenessIncrease Operations Awareness Early detection of accelerating fouling
– Filterable solids plugging– Paraffin accumulation – Asphaltene precipitation
Continuous health trending – Continuous monitoring and analysis to alert
of accelerated rate of fouling
Configurable Alerts– Email, text or alarm– Can be based on calculated heat transfer
degradation, or process measurements
Determine which exchanger needs cleaning– Fouling is not linear across heat exchanger
bundles– Only clean exchangers that require
cleaning
“With hindsight, many operators believe that a large part of the losses due to heat
exchanger fouling are avoidable”
- Shell Global Solutions International Himanshu Joshi et al
“We improved the efficiency of our crude preheat train,
and reduced emergency shutdowns in two of our
refineries. This reduced our fuel use, improved our capacity and made life
easier for our operators.” – Refining Operations Manager, Major
Refining Company
Convert Data into InformationConvert Data into Information Online system providing timely, actionable information
– Interface to existing control system and plant historian applications – Pre-engineered Monitoring and Analysis modules for Heat Exchangers– Information visibility to multiple departments
Information from heat exchanger on-line monitoring application
Who attends?Who attends? Don’t forget, this is for refiners and petrochemical
manufacturers. Typical audience is process engineers, control
engineers, and decision-makers. This is a big event for catalyst providers, and
they will spend a lot in their hospitality suites.
Dress CodeDress Code Badge Required – Go to Registration First
Business casual – shirts with collars; no ties, no jeans, no sneakers and no shorts.
Emerson Hospitality SuiteEmerson Hospitality Suite Blue Spruce (Room assigned Monday)
– Monday (10/6), 6:30-10:30pm Food and drinks
– Please allow attendees to get food first– Food from 6:30-9:30pm only
Please wear Emerson logo shirt – Business casual
Sunday, Oct 5th Sunday, Oct 5th Registration - Badge Pick-up
– 03:00 pm - 06:30 pm
Q&A Kickoff Networking Event – 05:30 pm - 06:30 pm
If someone attends Sunday, can they please put up a flyer about the Emerson Suite details for Monday night?
Otherwise, Tom plans to put up Monday morning.
Monday, Oct. 6th Monday, Oct. 6th Registration
– 07:00 am - 06:30 pm
General Session and Keynote– 08:00 am - 08:55 am
Plant Automation: Keynote Address – 09:00 am - 10:00 am
Presentations for Principles and Practices, Plant Automation and Decision Support, and the Q&A
– Throughout the day
Lunch in Exhibit Hall– 12:00 pm - 02:00 pm
Reception in Exhibit Hall – 05:15 pm - 06:30 pm
Emerson Hospitality Suite– 06:30 pm - 10:30 pm
Tuesday, Oct 7Tuesday, Oct 7 Registration
– 07:00 am - 05:00 pm
Plant Automation: Cybersecurity - "An Examination of the Challenges of Cybersecurity Implementation for Process Control Systems"
– 08:00 am - 10:00 am
Lunch in Exhibit Hall– 12:00 pm - 02:00 pm
Plant Automation: Refinery Project Development - "Implementation of New Control System"– 02:00 pm - 03:30 pm
Plant Automation: Refinery Project Development (cont.) - "DCS Migration - What We Did"– 03:45 pm - 05:15 pm
Suite open at night– 6:00 pm on
Wednesday, Oct 8Wednesday, Oct 8 Plant Automation: Work Process Automation - "Closing the GAP: Real-time Integration
of Planning, Scheduling and Process Operation"– 08:00 am - 09:30 am
Coffee Break– 09:30 am - 09:45 am
Plant Automation: Instrumentation Technology - "Safety and Operational Excellence with Industrial Wireless Applications"
"Extend Proving and Maintenance Intervals with Meter Verification“ by Tom O’Banion from MMI
– 09:45 am - 11:00 am
More details online - http://www2.afpm.org/forms/meeting/Microsite/QA14,1
Trust FactorTrust Factor This event is primarily a networking opportunity to speak
with potential refining customers. Ask first, listen, and then position your reply to address
the customer’s challenges and needs.