eng simulations improve refining margins - final presentation

Using Engineering Simulations to Improve Refining Planning and Scheduling Decisions Steve Dziuk, aspenONE Business Consultant

April 21, 2015

Bipin Singh, Product Marketing Manager

2015 Aspen Technology, Inc. All rights reserved. 2

Todays Presenters

Steve Dziuk, Business Consulting

Bipin Singh, Product Marketing

2015 Aspen Technology, Inc. All rights reserved. 3 2015 Aspen Technology, Inc. All rights reserved. 3

Agenda

Why use Engineering Simulations in Refining?

What is HYSYS Petroleum Refining?

Demo 1: Improve Planning Crude Distillation Models with Aspen HYSYS Petroleum Refining

Demo 2: Improve Planning Refinery Reactor Models with Aspen HYSYS Petroleum Refining

Q&A


Why Use Engineering Simulations in Refining?

What do you tell the refinery manager in one minute?

How does it make money for the refining owner/operator?

Engineering simulations are used to predict yields and properties

Predicts how to turn crude oil into products which is the main business of refining

If you dont use simulations, you are guessing about key decisions for feed stocks and operating

conditions

You need simulations to help compete for crude oil supplies


How to Use Engineering Simulations

Planning and scheduling support

Planning model is Aspen PIMS. Scheduling model is Aspen Petroleum Scheduler (APS)

Improve crude distillation models in PIMS and APS

Improve reactor models in PIMS and APS

Check PIMS results with engineering simulations

Standalone unit models (crude distillation and reactors)

Predict changing feed stocks

Predict changing catalysts (FCC, semi-regen reformer)

Optimize plant setpoints

reactor temperatures, column cut points

Equipment revamp studies

Multi-unit and refinery wide models

Predict gasoline or diesel production train

Predict new refinery configurations


aspenONE Engineering: The Refining Branch

aspenONE Engineering Suite:

focused on process engineering

and optimization.

HYSYS Petroleum Refining


Refining Features Predict Yields and Properties

Aspen HYSYS

Aspen HYSYS Petroleum Refining (RefSYS)

Refining Components

Petroleum Properties

Assay Management

Refinery Reactors

Multi-unit Simulation

PIMS & APS Support


Aspen HYSYS Petroleum Refining Hypos Produced by Assay Manager

Crude - 1

Crude - 2

Crude Feed after

Mixer

Hypo properties change to follow feeds and unit operations

Flowsheet uses single set of hypos

Easier to manage yields and properties across flowsheet

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

36-40*

40-50*

---*

200-210*

210-220*

----*

450-460*

460-480*

480-500*

----*

580-600*

600-650*

650-700*

700+*

Crude Oil Mixer


Petroleum Properties A Complete Set is Available for Hypos and Streams


Aspen Assay Manager

Powerful Tool for Petroleum Stream Characterization

Lab Data

Assay Manager

Components for Aspen HYSYS Petroleum Refining

Main and Swing Cuts for Aspen PIMS


Aspen HYSYS Petroleum Refining Reactor Suite


Build Multi-unit Simulations

FCC with Feed Hydrotreater

How much FCC feed bypasses

the hydrotreater?

Manage Complexity With A Mix of Short Cut and Rigorous Models


Multi-Unit Can Expand to Refinery Wide Simulation for Margin Analysis Manage Complexity With A Mix of Short Cut and Rigorous Models


Planning and Scheduling Support Workflows with PIMS to Petroleum Scheduler Integration

Workflow 2

Reactor Models


Aspen PIMS Crude Assay Tables

Aspen Assay Manager

Crude Distillation Cut points and Separation Factors

Workflow 1

Crude Distillation Models

Excel

LP Submodels for Reactors

Case Study Runs Base and Shifts

Aspen PIMS

Aspen Petroleum Scheduler


Workflow 3

Integration Features

Workflow 4

SMC file transfer


Crude Distillation Model Support HYSYS Petroleum Refining used to Calibrate Assay Manager Fractionation Effects

Plant data

HYSYS Petroleum Refining Model

Fractionation Effects

PIMS Assay Manager Main and Swing Cuts

Accurate representation of non-ideal separation achieved through integration of

Engineering and Planning Distillation Models

Cut points and Fractionation

Factors (SI Factors) PIMS Assay Table


Why Do We Need Fractionation Effects for CDU Products in Planning and Scheduling?

0

0.5

1

1.5

2

2.5

3

0 200 400 600 800 1000 1200 1400 1600

W% Whole Crude

Atmos Flash Zone Tops

Spindle Oil

HGO

LGO

Kerosene

Gasoline

LPG

Vacuum Resid

HVGO

LVGO

LVGO Tops

0

0.5

1

1.5

2

2.5

3

0 200 400 600 800 1000 1200 1400 1600

W% Whole Crude

Atmos Flash Zone Tops

Spindle Oil

HGO

LGO

Kerosene

Gasoline

LPG

Vacuum Resid

HVGO

LVGO

LVGO Tops

Planning cuts as Square Cuts

with no overlap

Real Cuts with Commercial Overlap


Crude Distillation (CDU) Support: Two Steps

Step 1: Yields (Cut Points)

Use HYSYS Petroleum Refining model to get product cut points

Cut points define the yields used in PIMS Assay Tables

Step 2: Properties (SI Factors)

Use HYSYS Petroleum Refining model to get fractionation factors (SI factors) that match plant

product overlaps

Use fractionation factors to improve property predictions that are sensitive to fractionator overlap

like cloud point and sulfur.


Aspen HYSYS Petroleum Refining Model for Cut Points and SI Factors

Blend CDU products

to get crude assay

PIMS LP crude

model in HYSYS

Petroleum Refining


Back-blended Crude Oil Provides Cut Points

TBP distillation

of the backblended

crude oil assay

Cut Points are points on

TBP distillation

Blend CDU products

to get crude assay


Fractionation Model Provides Fractionation Factors (SI Factors) for Product Overlaps

SI Factors for PIMS Main and Swing Cuts


Software Demo

Improve Planning Crude

Distillation Models with Aspen



Cut points and SI Factors In PIMS Assay Manager

Used to Cut New Main and Swing Cuts


Aspen HYSYS Petroleum Refining Reactor Suite


Planning and Scheduling Support Workflows with PIMS to Petroleum Scheduler Integration

Workflow 2

Reactor Models


Aspen PIMS Crude Assay Tables

Aspen Assay Manager

Crude Distillation Cut points and Separation Factors

Workflow 1

Crude Distillation Models

Excel

LP Submodels for Reactors

Case Study Runs Base and Shifts

Aspen PIMS



Workflow 3

Integration Features

Workflow 4

SMC file transfer


Reactor Support HYSYS Petroleum Refining Flowsheets Assemble and Evaluate Plant, Model and LP Submodel Data

ASW links plant data to reactor model flowsheet

Validate FCC model predictions with case study tools

Link plant data to FCC model

Evaluate LP model base and shift vectors with case study tools

Calibrate FCC model to match plant data

Calibration environment forces model to match plant

data


Software Demo

Improve Planning Refinery

Reactor Models with Aspen



Reactor Support Process Data from Aspen HYSYS Petroleum Refining Drives Aspen PIMS Submodel Coefficient Formulas

Case Study Output from HYSYS Petroleum Refining transfers to

PIMS Submodel sheet

Process data table drives submodel coefficients


Viewer Poll

What software do you use for refinery

reactor modeling?

What software do you use for refining

process simulation?

How long does it take you to update

planning assay tables (or Aspen PIMS

assay tables) for a change in cut points

and/or fractionation effects to improve

a match with the real plant?


Webinar Summary Using Engineering Simulations to Improve Refining Planning and Scheduling Decisions

Accurate planning and scheduling models are

critical for sustaining refining margins

Modern engineering models provide a powerful

way to predict product yields and properties

(margins)

Engineering models can improve the crude

distillation and reactor representations in

planning and scheduling to sustain refining

margins


Join the AspenTech Community www.aspentech.com/community

Q&A

Steve Dziuk

[email protected]

Bipin Singh

[email protected]

AspenTech is ranked as a top innovative growth company

Thank You

eng simulations improve refining margins - final presentation

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