© by Wagner Araujo/National Geographic Traveler
Population growth
Increased urbanization Growing needs for energy, food, water, ...
High Energy Prices
Growth of interconnection
Increased complexity.
Intense geopolitical shift
Significant imbalances between regions.
More Energy…..but
Optimizing “The Never Ending Story
A global company that seeks the
welfare of people and is a step
ahead in building a better future
through the development of smart
energy.
Our vision
3
What is going on? Population growth
Increased urbanization
Growing needs for energy, food, water, ...
High Energy Prices
Growth of interconnection
Increased complexity.
Intense geopolitical shift
Significant imbalances between regions.
More Energy…..but
4
5
A
Major Refining challenges
Technology Innovation Innovative Tools & Equipment's Efficiency Margin Improvement Different and differentials Products Maximizing Operations
Optimizing “The Never Ending Story
How are the changes
happening?
More Swift
More disruptive
Even simultaneous
With more complex and
also technological
interconnected
.
7
being Flexible
and what could we do ?? Evolution
Adaptability Take advantages of new technologies
Maximize Margin with lowest energy consumption
MHC-FCC Rigorous and Kinetics Model
Maximize interaction and integration target
Optimize Operational Conditions
Energy Consumptions calculations
Monthly
Operation Conditions
Model Calibration
Real Data
Production
Objectives
Test Runs and
Monitoring
MHC Kinetics
Factors FCC Kinetics
Factors
Optimum Goal
Pilot Plant
Catalyst
Selectivity
activity
Could we improve?
slow and un-powerful optimizer
Optimizing “The Never Ending Story
9
Hydrogen Consumptions Compressors
Fractionator Splitter
Constrains Cut Points
Prod. Specs
MHC
Reactor
Cat. Behavior Cycle Time
WABT
Yields
Air Flow Steam Gen.
FCC
Reactor Regenerator
Catalyst Behavior
Yields
Constrains Cut Points
Specs.
Fractionator VRU
PP splitter
Heater Fouling
Energy Consumptions
Heaters Fouling
Stripper
Energy Consumptions
Optimal Goal
Economics Results
Maximum production at
optimum energy consumption
Optimizes margin
24 variables
Personal Computer
Two years ago… Optimizing “The Never Ending Story
Cat/oil
Reaction Temperature
Recycle
Feed Temperature ( Feed Furnace )
Catalyst Activity ( Fresh Cat addition )
Kind of Feed ( less or more Hydrotreated )
Unit Throughput
Operational Mode
Constrains
WABT
Unit Throughput
Catalyst Deactivation
Catalyst Activity SOR, MOR, EOR
Cetane Gain
Hydrogen Availability
Hydrogen Recycle
Poisons Feed
Kind of feed
Constrains
FCC MHC
10
Statistical data filtering
Powerfully Optimizer
development
Daily Feed analysis
Distribution Aromatic Carbon
correlation
Directly PI Connection
Multiple fractionator and splitters calibrations
MHC catalyst Behavior
cycle time
Allows to adjust operational
deviations faster Multiple
Kinetics Models calibrations
Multiple Model predictions
Optimization more
adjusted to feed variations better fit, speed and
flexibility
Using New tools Optimizing “The Never Ending Story
Using New tools
Typical Analysis Density
Distillation Sulfur
Nitrogen Viscosity
Refractive Index
Specialized Analysis
Aromatic Carbon Mono, Di, Tri, Polar
Aromatics Naphthenic Carbon
Mathematical Correlation by type of Feed
Optimizing “The Never Ending Story
12
A
Developed an statistically
program to treat operational data,
filtering the wrong data
Using New tools Optimizing “The Never Ending Story
13 13
Hydrogen Consumption Compressors
Fractionator Splitter
MHC
Reactor
Cat. Behavior Cycle Time
WABT
Yields
FCC
Reactor Regenerator
Catalyst Behavior
Yields Fractionator
VRU PP splitter
Energy Consumptions
Stripper Energy
Consumptions
FCC Kinetics Model +
Products Recovery Simulation
Catalyst Factors (PP+ACE)
Kinetics Catalyst
Base Case ( Calibration)
Recycle Optimizer
Quality cut for different Cut
Unit Constrains
Variations TR, Feed Temp. Throughput
Main Fractionator
Naphtha Splitter
Recycle
MHC Kinetics Model +
Products Recovery Simulation
Kinetics Catalysts PP
Base Case (Calibration)
Fractionator
Quality cut for different Cuts
Unit Constrains
Variations WABT, Pressure, Throughput
Hydrogen Recycle
Hydrogen and Power consumptions
Stabilizer / Steam
Fouling
Correlation by type of Feed
Optimizing “The Never Ending Story
Maximum Energy Efficiency
Crude Oil quality variability
New and Heavier Crude Oil
Products variably
Market Demands Drive Capabilities
MHC and FCC Optimum Throughput is not the same for all Market demands
Faster Global Optimum
Optimizing “The Never Ending Story
Analytical Plan for continuous Feed characterization
Adapted correlations for type of Feed
o Automated
o Optimizer with more than 50 Variables.
o Connected through personal computer
On Home Statistical model and program
Development Data Filtering
FCC Kinetics Commercial Models and Repsol Catalyst Factors
On Home Developed REP MHC Kinetics Models
Lineal Programing Model Adapted to communicated with Kinetics Models
Main Conclusions Optimizing “The Never Ending Story
1962
2017 Never say Never
17
This story will continue…
Guest Stars as Jetsons
Álvarez Rodríguez Maria Nieves
García Carreño Miguel Angel
Montañez Gustavo
Suarez Diez María Luisa.
The Future is coming
Produced and directed by: REPSOL S.A
what do you think
about online analytics
and sensorization in
the hydrocarbon
transformation
industry?