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Table of Contents
Technical Program Abstracts
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98 KBD feed with new reactors and catalyst but with existing
hydrogen supply from Naphtha Hydrotreater (NHT). Expansion
phase was designed to process 125 KBD feed with high pressure
pure hydrogen supply from new Hydrogen Recovery Unit (HRU).
Reactor pressure was increased from 37.2 barg to 55.2 barg in
expansion phase with a new recycle gas compressor and a make-up
gas compressor.
Revamp process design was considered to minimize the capital
investment by maximum use of existing equipment. Unit was
designed to accommodate all distillate components produced in
the refinery with three block operations namely ADO 10, ADO 500,
and Fuel Oil Cutters stock. As existing unit was designed for low
pressure operations (37.2 barg), only reactor section was revamped
to increase operating pressure to 55.2 barg, keeping the rest of
the unit at lower pressure to minimize revamp scope. Four
new reactors were installed with two parallel and two in series
configuration to achieve product Sulphur specifications. Two new
charge heaters and charge booster pumps were required to fulfill
new reactor operating conditions. New steam stripped Product
stripper tower was installed instead of fired heater reboiled tower
and new Sand/Salt filters were added to polish ADO product to meet
copper corrosion and moisture specification.
Post revamp, per market requirement, Samref was required to
produce 500 ppm ADO. With thorough evaluation of catalyst
deactivation, unit capability and Hydrogen availability, Samref has
decided to eliminate Cutters stock run and upgraded total LCO make
to ADO 500. Unit was optimized in terms of operating pressure,
LCO content in feed and evaluating the impact on CHD catalyst life
cycle by sophisticated modelling. Unit feed rate was increased to
138 KBD safely and successfully with detailed assessment of process
safety aspects. In addition to considerable margin improvement of
upgrading 3250 m3/d LCO from fuel oil cutters stock to ADO 500
product, about 40% extension in catalyst cycle life was achieved by
optimized operations strategy. Diesel feed components make rate
was increased by further deep cutting to fill the capacity margin in
Diesel Hydrotreater to maximize refinery profitability.
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Screen all units if there are critical users which need detailed
hydraulic study inside the unit. Potentially critical units/ users will
be the one which CW consumption will be increased or the one
located further from the supply pump.
Modification idea derived from overall system study would be
overviewed and shall be optimized considering the operational
and cost point of view.
Based on analysis of different operating scenarios a comprehensive
report should be prepared. Report should contain comparison of
existing operating condition with future operation and identification
of modification requirement to fulfill future CW demand.
Purpose
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Problem Statement
Plant operators manage to minimize the flaring incidents by adding
excess Hydrogen. But this results in converting not only Acetylene to
Ethylene, but Acetylene can get hydrogenated to Ethane. Moreover,
Ethylene also can get converted to Ethane. Both of these reactions
undo all the cracking that was done in the front end and hence drain
capital spent.
Approach
Analysis of Acetylene in crack gas in faster and in near real time
would allow tighter acetylene hydrogenation process control.
Existing technologies of Gas Chromatography (slow response) and
Filter Photometers (which has interference) inhibits the requirement.
Development of Off-Axis Integrated Cavity Output Spectroscopy
(ICOS) enables a real time analysis of Acetylene in <1 ppm levels.
This laser based technology provides the desired speed, reliability
and accuracy of Acetylene which is very critical to process control
optimization, safety and product quality drivers. ICOS is an
optical absorption spectroscopic technique which is based on the
principle that when a molecule interacts with a light beam at a
specific wavelength it will cause the molecule to vibrate/rotate, and
thereby absorb the energy (the light source). This is determined
from Beers Law.
Results
Conventional laser sensors cannot provide analysis of process gas
samples with spectroscopic interference backgrounds. Utilizing
chemometrics as an analytical enables the same laser-based
technology to analyze and monitor analyte concentrations in the
presence of spectral interferences. Chemometrics model spectral
data allows the Off-Axis ICOS analyzer to accomplish the following:
Ability to monitor real-time component(s) in process streams
Ability to predict multi-components
Ability to provide concentration estimates
CHEMOMETRIC MODEL VALIDATION
Seven gas mixtures with various concentration ranges for Acetylene,
Methyl Acetylene, Ethylene, Methane and Ethane were obtained to
perform model validation. It was observed that the accuracy and
precision of the ICOS prototype for C2H2 application are better over
GC specifications. Due to GC slow response-time for the existing
Methyl Acetylene analysis, this parameter has not been previously
used in the acetylene hydrogenation process optimization control.
Thus, the Methyl Acetylene measurement required specifications
are not available for comparison.
Conclusion
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[4] http://colan.org/
[5] www.prosim.net
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2) Blend RVP is actually quite non-linear with respect to the inlet feed
rates, composition and inlet RVPs.
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products (Ethane plus) figures will increase around 300 Ton/day. The
other cases in between 4% & 0.5% CO2 content will increase Ethane
recovery proportionally.
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The article then goes through the next major phase of Evaluation;
which is the changeover. Monitoring and control of changeover are
critical steps. The article describes in detail the way changeover is
monitored in SAMREF. This is followed by the Post-Audit where you
take a look at the objectives versus the realized benefits; and try
to quantify the advantages and disadvantages of the changeover.
This will also lead to the next step for reformulation and improvement
and any recycling to the future selection process.
The article takes the reader through all these steps with an example
of how this is adopted in SAMREF with the last catalyst changeover
which resulted in a major margin improvement in its FCC operation.
More than 5 years have passed since PRC started to operate this
integrated unit of HOFCC and ECR. Now, it can be said that those
units are operated stably, but to achieve it, we had to face with
several challenges. Through the presentation PRC will explain more
about the major challenges, (L&L) , and sharing how PRC achieved
stable operation.
Over the last five years UOP has introduced significant advancements, both on the process and product side, resulting in significant
improvements in ROI for new unit designs (up to 50% in some cases)
and less than three year paybacks on revamps projects. These
solutions have accumulated a significant track record of successful
commercial experience, validating their fit over many customer
configurations. UOP continues to innovate in this field and further
improvements in process design and product formulation will soon
be introduced. This presentation will exemplify value from our latest
offerings, demonstrated by several commercial case studies, and a
preview of next generation offering.
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This document was produced on 14 September 2015