monthly optimization
monthly optimization
monthly optimization
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
MOTOR FUELS PRODUCTION<br />
OPTIMIZATION IN SLOVNAFT REFINERY<br />
Ing. Roman Svitaň, Ing. Michal Mihálik, Ing. Peter Boháček<br />
SLOVNAFT, a.s.
Agenda<br />
• MONTHLY OPTIMIZATION<br />
• DAILY SCHEDULING – BLEND2000<br />
• ONLINE OPTIMIZATION<br />
• TOPNIR MODEL<br />
2
BLENDING<br />
Petchem<br />
LPG<br />
GASOLINE BLENDING<br />
C4 fr.<br />
Izomerate<br />
RPR<br />
Aromat. . Extract,<br />
Red. Reform.<br />
Alkylate<br />
FCC<br />
ETBE<br />
LBi HCK<br />
Alkylation<br />
Diesel B.<br />
VGH GO<br />
Arom. Fr.<br />
HCK GO + KE<br />
HDS 6 KE<br />
HDS 7 GO<br />
HDS 7<br />
Izomerization<br />
ETBE<br />
MONTHLY OPTIMIZATION<br />
GAS SEPAR.<br />
The most products shipped<br />
from refinery are blends of<br />
different components and<br />
Reforming<br />
Light Naphtha<br />
different quality<br />
Heavy Naph.<br />
KERO<br />
GASOIL<br />
VGH<br />
VAD<br />
Crude Oil<br />
Blending = Overall Economy<br />
FCC<br />
DESTILLATION<br />
ATM.RESID<br />
Refinery benefits could be lost by<br />
BLENDING the products SUB-<br />
OPTIMALLY<br />
HCK<br />
Vacuum Resid<br />
HDS 6<br />
RHC
MONTHLY OPTIMIZATION<br />
PIMS (Process Industry Modeling System):<br />
•Flexible tool for production processes economical planning<br />
•GOAL – processes harmonization, satisfy demand, maximize profit<br />
•Optimizes based on Linear Planning, raw materials costs and<br />
product prices<br />
CRUDE<br />
SUPPLY<br />
MATERIALS PRODUCTION<br />
INVENTORIES UNITS<br />
PRIMARY PRODUCTS<br />
DISTRIBUTION INVENTORIES<br />
MATERIAL Flow<br />
MARKET<br />
INFORMATION Flow<br />
4
MONTHLY OPTIMIZATION<br />
•Processes information inserted to PIMS by EXCEL based submodels<br />
•Data transferred into LP Matrix<br />
•Solution – optimized ROLLING PLAN - for each submodel ->production unit/process<br />
Blending D95<br />
95 2,5% EtOH ETBE<br />
Blend W eights M T/M ONTH AUG SEP O CT NO V<br />
1 M O N T H 1 M O N T H 1 M O N T H 1 M O N T H<br />
ETB E from 3rd p . 2 410 2 128 2 3 54 1 9 79<br />
RAFFINA TE E TBE 238 0 304 1 4 77<br />
ALK YLA TE C3 /C4 7 062 4 470 3 7 60 2 4 24<br />
GA SO LIN E FC C 0 3 970 4 5 33 3 6 92<br />
HC K L IG HT N AP HTH A+C5 4 873 429 5 5 27 4 2 14<br />
ISO M E R ATE C 5/C6 8 656 10 646 6 5 41 5 9 57<br />
BUTA NE 0 0 1 018 0<br />
R-STR E AM 21 979 18 282 20 007 17 1 91<br />
Tota l 45 218 39 924 44 043 36 9 35<br />
Product Q ualities AU G S EP O CT NO V<br />
1 M O N T H 1 M O N T H 1 M O N T H 1 M O N T H<br />
REID VAP PR ESS , kPa 58 ,0001 58,0001 73,8 474 80,7 790<br />
ethan ol e quiv. conte 2,5 000> 2,50 00> 2,50 00> 2,500 0><br />
ethan ol a s a dd 0,1596 0,1 596 0,1 596 0,15 96<br />
SP ECIFIC G R A VITY 0,7469 0,7 470 0,7 450 0,74 30<br />
RO N(C LEA R ) - QC D 95,4 000> 95,4 000> 95,40 00> 95,40 00><br />
M O N(C LEA R) - Q C D 87 ,6197 86,9282 86,5 895 86,3 511<br />
PCT O FF AT 70 °C - s 26 ,4894 29,7253 30,3 544 31,8 270<br />
PCT O FF AT 100°C 47 ,9046 48,9567 51,5 437 52,4 759<br />
PCT O FF AT 150 °C 81 ,9217 81,9375 84,3 559 85,9 626<br />
PCT O FF AT 180 °C 94 ,4773 94,2676 94,5 579 94,8 268<br />
M AX CO NTE N T SUL FU R 0,0003 0,0 003 0,0 004 0,00 04<br />
M AX CO NTE N T ARO M A TES 34,0 000< 34,0 000< 34,00 00< 34,00 00<<br />
M AX CO NTE N T BE N ZEN E 0,5682 0,5 089 0,7 824 0,79 00<br />
M AX CO NTE N T O XYG E N 0,8369 0,8 368 0,8 390 0,84 13<br />
M AX CO NTE N T O LEFIN E S 0,7270 3,9 650 6,0 460 4,19 65<br />
M A X CON TEN T C 4 - sum 0,5253 0,0 000 3,00 00< 4,000 0<<br />
5
Agenda<br />
• MONTHLY OPTIMIZATION<br />
• DAILY SCHEDULING – BLEND2000<br />
• ONLINE OPTIMIZATION<br />
• TOPNIR MODEL<br />
6
Daily scheduling = BLEND 2000<br />
BLEND 2000<br />
Creates<br />
optimal<br />
recipes<br />
Set up a<br />
blended<br />
volume<br />
Follow<br />
the planned<br />
shipment
Program screenshot<br />
Blend 2000<br />
UNITS<br />
Blending<br />
components<br />
Header<br />
Product<br />
tanks<br />
Product<br />
specification
Optimization<br />
CALCULATED<br />
RECIPE<br />
by BLEND 2000<br />
BRC<br />
Blend Ratio Control<br />
components ratio is kept<br />
constant during the whole blend<br />
BPC<br />
Blend Property Control<br />
!OPTIMIZATION!
Agenda<br />
• MONTHLY OPTIMIZATION<br />
• DAILY SCHEDULING – BLEND2000<br />
• ONLINE OPTIMIZATION<br />
• TOPNIR MODEL<br />
10
Fixed ratio recipe blending - BRC<br />
Situation without online optimizing<br />
• Blending recipes are calculated based on quality data of component tanks.<br />
• Quality of input streams and the component tanks varies slightly in time.<br />
• The blending ratios are not changing during blending.<br />
Components<br />
tanks<br />
Final products<br />
tanks<br />
Final tanks are sampled for<br />
inspection certificate. If off spec,<br />
reblend is needed.<br />
Quality of mixed final product is checked only 1x during<br />
blending, if off spec, recipe is slightly modified<br />
11
Impact of Fixed Blending Ratio - BRC<br />
• Quality offspec<br />
- reblend needed (costs of reblends, reanalysis)<br />
- expedition delay (your credibility in the customers eyes)<br />
- some cases it can be blocked expedition tank<br />
• Quality giveaway<br />
- minimize probability of quality offspec<br />
- produce final product with quality in the “safe area”<br />
- non-economical using of expensive components (expense increasing)<br />
12
Online <strong>optimization</strong> - BPC<br />
• Software Blend2000 calculates preliminary recipes based on QC quality data.<br />
• Quality of input streams and component tanks varies slightly in time.<br />
• The online NIR analyzer identifies quality changes of the blend and DCS<br />
continuously optimizes the preliminary recipes.<br />
NIR analyzer<br />
MON,<br />
RON,<br />
RVP<br />
Distill.,<br />
... ...<br />
DCS<br />
Components<br />
Recipe<br />
Blend 2000<br />
Components<br />
tanks<br />
Final products<br />
tanks<br />
Final tanks are sampled<br />
for inspection certificate<br />
13
Advantage of online optimizing - BPC<br />
• Profit increasing<br />
- without quality giveaway or quality offspec<br />
- optimizing components consumption<br />
• Reblend / expedition delay reduction<br />
- saves time, money and ensure continuous<br />
expedition of the products<br />
• Production increasing.<br />
14
Agenda<br />
• MONTHLY OPTIMIZATION<br />
• DAILY SCHEDULING – BLEND2000<br />
• ONLINE OPTIMIZATION<br />
• TOPNIR MODEL<br />
15
TOP NIR model<br />
• Essential for online optimizing – blend properties<br />
evaluation<br />
• Model:<br />
- NIR spectrum<br />
- Area of chemical band characteristic vibration<br />
• Principle:<br />
- Spectrum – composition – properties<br />
- Statistic – matrix calculation in multidimensional<br />
space<br />
16
TOP NIR Model – input NIR spectrum<br />
17
TOP NIR model<br />
18
Model reliability<br />
• Functional model ↔ actualization<br />
• Data collection, Evaluation of analysis results,<br />
Database actualization – cooperation Blending<br />
unit, Quality Control, Down Stream<br />
Development and Production excellence<br />
• Linear bonuses calculation (to be done by Down<br />
Stream Development in cooperation with<br />
Blending unit, Quality control and Production<br />
excellence).<br />
19
SUMMARY<br />
Optimization in oil industry covers broad scope of<br />
the activities:<br />
• Monthly Optimization Planning including all<br />
business processes<br />
• Daily Based Scheduling - to satisfy required<br />
daily shipment (Blend 2000, DCS – BRC)<br />
• Online Blending Optimization – minimize<br />
quality giveaway/ final product cost, offspec<br />
quality (online NIR – TOP NIR, DCS – BPC)<br />
• Systematic NIR online analyzer model<br />
updating<br />
20
Change language