Transcript PPT Template

Slide 1
Total Performance HF
Optimization through Advanced
Measurement Solutions for HF
Alkylation
Joe Fillion, Value Consultant,
Invensys
© 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.
HF Alkalation
Converts low value Iso-Butane to high value Octane using HF as
the catalyst (1942 technology)
Up until 2000, manual samples / lab tests were the only way to
monitor HF concentration – hi risk
FT-NIR hit the market in 2000 – a good solution that is VERY
expensive and hard to keep running
ACA.HF from Invensys: Trial complete in 2009 with success.
Slide 3
Performance through HF Measurement
Total Performance.HF
Optimization
Optimum.HF
Predictive Control and
First-Principles Based
Online Modeling
Measurement
ACA.HF
Acid Catalyst Analyzer
HCA.HF
Hydrocarbon Analyzer
The ACA.HF is not merely an analyzer, but an essential
element in a comprehensive optimization strategy
Slide 4
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2009 IPS North America Client Conference
Overview
The ACA.HF provides performance equivalent or better to
FTNIR, with an expected installed cost less than half of FTNIR’s
$1.5 million. Ease of installation and reliability are much, much
greater than FTNIR.
Maintenance and cost of ownership for the base sensors is
extremely low
MTBF estimated to be > 29 years for sensors
● This does not take into consideration corrosion issues.
Typical commissioning time is 1-2 days
Breakthrough Product of the year by Process Magazine
Selected as one of the 4 finalist in the Kirkpatrick Award
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© Invensys 7/17/2015
Value Proposition
Safety:
–On-line measurements vs. manual samples taken to the Lab.
Increased value and decreased costs
–Increase Octane by running at optimum (running at 87% HF)
•Closed loop control on temperature control (steam)
–Reduce amount of HF from 45 – 50 bbls to 25 bbls
•At $700 per bbls and less regeneration costs by keeping the
HF in the unit and not have it go out with the ASO
Avoid Acid Run away
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The ACA.HF Measurement Solution
● For online analysis of %HF, %Water and %ASO in HF
alkylation catalyst
● Design objective: Affordable with reliable accuracy
● A multivariable analyzer¹ based on the application of proven
Foxboro measurement technologies that are long-established
in HF service
● Exceeds the precision of HF analysis with FTNIR²
The ACA.HF is the new standard in safety, simplicity, reliability,
and accuracy for HF catalyst analysis
¹ Patent Granted ; international rights apply
² ABB FTPA2000-HP20 FTNIR-based HF Acid Analyzer
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© Invensys 7/17/2015
ACA.HF – Features
Non-spectroscopic analyzer system designed to measure all
components in HF alkylation catalyst: HF, water, and acidsoluble oil (ASO)
Direct chemical measurement
An integrated panel-mounted analyzer system for installation in
the alkylation unit
All wetted parts associated with the analyzer system and
sample handling are made with Hastelloy-C, Monel (optional)
Teflon®, and Kalrez® (Chemraz®).
Measurement is performed on sample flowing continuously
through tubing and components half-inch or larger,
minimizing pressure drops that cause flashing of light
hydrocarbons
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© Invensys 7/17/2015
ACA.HF – Features Cont’d
Unaffected by sample temperature variation
Manual valves to isolate the analyzer system and purge with
isobutane, alkylate, nitrogen, etc.
Modular design for easy swap-out of measurement sensors and
components
Utilizes proven measurement technologies with an established
history of service in HF applications
Internal data logging and historizing of KPI’s to enable quick
and easy diagnostics
No wear elements requiring preventative maintenance
Easy algorithm adjustment if necessary
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© Invensys 7/17/2015
ACA.HF: The IOM Approach to HF
Catalyst Analysis
Goal: Apply a simple solution to a simple problem:
Take a ternary (3-component) sample and characterize using 2
appropriately chosen sensors.
Use industrialized field proven sensors, a rugged automation
controller and industry standard software, combined with
application knowhow.
Package solution to work “out of the box” and have a
significantly low cost of ownership compared with competitive
techniques.
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Ternary Sample (HF Catalyst)
Characterization with Two Measurements*
Conductivity of HF Catalyst
Density of HF Catalyst
● HF and H2O are each almost nonconductive when pure.
● HF and H2O have almost identical
densities—about 1.0 g/cc; therefore H2O
has negligible effect on the density of HF.
● When H2O dissolves in HF, it reacts to
form ions, which are conductive:
2HF + H2O → HF2- + H3O+
● When hydrocarbon (ASO) dissolves in
HF, no conductive ions are formed.
In HF catalyst, conductivity is directly
proportional to H2O content.*
● The acid-soluble organics (ASO) in HF
catalyst have densities of about 0.6 g/cc.
● ASO in HF reduces the density below that
of an HF/H2O mixture.
In HF catalyst, density is directly
proportional to ASO content.*
Conductivity of HF at 0 ⁰C
Density of Ethanol/Water Solutions
1.02
300
1
250
0.98
200
mS/cm
0.96
150
0.94
g/cc
100
0.9
50
0.88
0
0.86
0
1
2
3
4
5
6
%H2O
* Temperature must also be taken into account.
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0.92
0.84
0
20
40
60
% Ethanol
80
100
Ternary Sample (HF Catalyst)
Characterization with Two Measurements
● Two measurements alone give us only “2 equations with 3
unknowns”. However, in addition to the H2O concentration being
proportional to conductivity, and the ASO concentration to density,
the chemical system is also bounded mathematically:
%HF + %ASO + %H2O = 100 (94)
Giving us our 3rd equation.
● For simplicity, we’ve been glossing over the fact that temperature
enters into both the conductivity and density measurements. That’s
because temperature compensation of these measurements is a
long-established technique which is readily implemented.
● Also, the dependence of conductivity solely on %H2O and density
solely on %ASO is not perfect. Therefore we used conductivity and
density terms in our final equations for both %H2O and %ASO.
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All valves are manual shutoff valves:
Measurement of continuously-flowing sample
No automated valves for stop-flow analysis
No wear elements requiring preventative maintenance
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Performance and Validation
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© Invensys 7/17/2015
ACA.HF Validation
• Results cover 4 months (84 run days): July 9 – November 1, 2009
• Refinery process unit was Shutdown August 12 to September 23
• Based on Direct Comparison with FTNIR Results at the ConocoPhillips
refinery in Sweeny, TX
─ 4-minute interval data
• FTNIR analysis on stopped-flow sample
• ACA.HF analyzes continuously-flowing sample conditioned to remove
phase-separated isobutane
─ Only instantaneous readings were used in the current comparison
─ 4-second measurement interval (signal averaging possibilities)
─ Sample temperature not controlled
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Invensys proprietary & confidential
© Invensys 7/17/2015
%HF by Invensys ACA.HF and ABB
FTNIR
92.00
91.00
90.00
89.00
%HF - FTNIR
88.00
%HF - ACA.HF
87.00
86.00
85.00
84.00
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Invensys proprietary & confidential
© Invensys 7/17/2015
%Water by Invensys ACA.HF and ABB
FTNIR
1.100
1.000
0.900
0.800
0.700
%H20
%H2O - ACA.HF
0.600
0.500
0.400
0.300
0.200
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Invensys proprietary & confidential
- FTNIR
© Invensys 7/17/2015
%ASO by Invensys ACA.HF and ABB
FTNIR
9.00
8.00
7.00
6.00
%ASO - FTNIR
5.00
%ASO - ACA.HF
4.00
3.00
2.00
1.00
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Invensys proprietary & confidential
© Invensys 7/17/2015