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Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience
Session Name: SimSci-Esscor Solutions
Session ID #: PBSS311
Junichi Watanabe
Nov./10/2011
Slide 3
Agenda
• APAC RTO Projects Experience in last 10 years
• Some case studies of RTO (CDU, RFCC, CCR)
• Difficulties of Development and maintaining Utilization for RTO
• RTO with Production Planning/Scheduling
Slide 4
Invensys Enterprise Control OfferingsM
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g /
Pro
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cti
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Op
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tio
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Co
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rate
Inte
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C
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bo
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Pla
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Automation Invensys and Third Party
Software ApplicationsInvensys and Third Party
Enterprise Control System
Corporate Systems
Slide 5
Integration & Collaboration
Platform
EnterpriseIntegration
Workflow
Open DeviceIntegration
Web Portal
ApplicationToolkit
Historian
Th
ird
-Pa
rty
Off
eri
ng
sS
oftw
are
Ap
plic
atio
ns
Execution
Manufacturing Execution Systems
BatchEnterprise Asset
ManagementMobile Workforce
Management
Performance
Enterprise Manufacturing Intelligence
Performance Measurement and Reporting Visualization Quality
Asset Performance
Optimization
Operator Training DesignAdvanced Process
ControlSimulation / Optimization
Control
DCS PAC SCADA HMI
Safety
Safety Instrumented Systems General Purpose Safety Turbomachinery Control
Measurement & Instrumentation
Instrumentation Controllers Recorders
Au
tom
atio
nS
oftw
are
Ap
plic
atio
ns
Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System
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APAC RTO Projects Experience in last 10 years
Slide 7
APAC Optimization Project Experience
40 Actual ROMeo Projects have been implemented in Asia since 2000 (Excluding feasibility study projects)
• Closed Loop : 18 Projects
• Open Loop : 13 Projects
• Planning : 3 Projects
• Performance Monitoring, Others : 6 Projects
Total 10 engineers are RTO engineers in APAC (Japan, Korea, India, China, Thailand and Singapore)
Slide 8
RTO/Performance Monitoring Implemented in Japan Since Y2000
Idemitsu Chiba:Site Wide
JX,Negishi: CDU, RFCC
Idemitus Aichi: Utility, H2
JX Chita: H2 Management
OPC : EthyleneJX Mizushima: Utility,CDU3,CDU2Asahi Chemical : Ethylene
Idemitsu Tokuyama : CDU, FCCEthylene
Idemitsu Hokkaido : H2 Management
Showa Denko : Ethylene
Refinery : 13PetroChemical : 7
Slide 9
Real-Time Optimization (ROMeo, ARPM) Business in APACKorea : HDO, SK, STC
China : Petrochina
Taiwan : FPCC
Thailand : Thai Oil
BCP,PTTGSP
Malaysia : Petronas
Singapore : SRC
India : RelianceASEAN
India
Slide 10
APAC Optimization Project Experience
94% projects come from Refineries, Utility, Ethylene projects
RTO Industries Break
59%17%
18%
3%
3%
RefineryUtilityEthyleneUp- StreamGas Separation
Slide 11
APAC Optimization Project Experience
CDU/VDU, FCC, Reformers, H2 management are majorities from Refineries projects
RTO Refinery Break
37%
17%
21%
4%
17%
4%
CDU/ VDUFCC/ RFCCReformerHDS/ HCU
H2Refinery Wide
Slide 12
APAC Optimization Project Experience
Closed loop projects are nearly half
RTO Control System Break
44%
33%
23%
Closed LoopOpen Loop
Monitoring
Slide 13
APAC Optimization Project Experience
ROMeo doesn’t rely on APC package.
RTO APC (Closed) Break
33%
38%
17%
6% 6%
DMC
RMPCT
SMOC
Connoisseur
Others
Slide 14
APAC Optimization Project Experience
ROMeo don’t rely on RTDBS
RTO RTDB Break
52%
8%
18%
22%
PHDPIIP21
Others
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Case Study CDU RTO
SAT: 2007 Jun
Closed Loop with DMC+
Slide 16
Heater Outlet Temp.
No.3 Side Reflux flow
Kero Stripping Steam Ratio
kg/KL
℃ KL/H
PVRTO Target
APC controls to OPT targets
Change of Optimization Variables (Independent Variables)
Slide 17
Cold Reflux Flow
LGO Draw Flow Heater Inlet Temp.
℃KL/H
KL/H
PVPredict
All CVs move as predicted
Change of Optimization Variables (Dependent Variables)
Slide 18Time
Benefit
Crude Change
APC Start
Start RTO
Set the base point when RTO started
RTO Benefit
- After RTO -
Time
Benefit
Crude Change
APC Start
- Before RTO -
Set the base point when APC made stable operation
PI Data is used for evaluation
How to Evaluate Benefit
Slide 19
Change of Benefit before/after RTOBefore RTO (+287K Yen/day) After RTO (+2,362K Yen/day)
After RTO, every case shows increasing benefit and above base
Slide 20
Change of Benefit before/after RTOBefore RTO (+287K Yen/day)
After RTO (+2,362K Yen/day )
After RTO, every case shows increasing benefit and above base
Yearly Benefit = 493MYen/Year※(2,362 - 287)KYen/Day×0.72( Run Time % )
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Case Study RFCC RTO
SAT: 2010 Jun
Closed Loop with RMPCT
Slide 22
RFCC Feed Modeling
Slide 23
RFCC Modeling (Rx/Rg)
Slide 24
RFCC Optimization Variables Optimization Variable
No. Service Tag UOM OPT ON/OFF RMPCT MV STS1 TOTAL OIL FD TO REACTOR FC73108.PV M3/HR O O2 RISER OUTLET TEMP TC73014.PV DEGC O O3 HOT FEED TO 7303-D TC73068.PV DEGC O O4 2ND STG REGEN TEMP TC73112.PV DEGC O O5 R1 CO/CO2 RATIO RX73004.PV MOL % X X6 REGEN 2 FULE GAS %O2 AI73001.PV V/V % O O7 2ND STG RG TOP PC73014.PV KG/CM2 X X8 REGEN 1ST TO 2ND DIFF PC73018.PV KG/CM2 X X9 MF OVHD RECEIVER PC73188.PV KG/CM2 O O
10 ABSB GAS CONT KO DRM VAP PC75041B.PV KG/CM2 O O11 O2 SUPPLY TO 7301B FC73A03.PV KG/HR O O12 OM LSFO FCJ1104.PV m3/h O13 OM VGO FCJ1105.PV m3/h O14 H/NAPH LEAN OIL TO 7503E FC73060.PV M3/HR O O15 ROMeo ONLY 7503-F TEMP TI75012.PV DEGC O16 FRAC OVHD TO 7307-C TC73052.PV DEGC O O17 LCO PRODUCT TOTAL FLOW (FC73044T)FC73044.PV M3/HR O O18 HCO P/A TO FRACT #21 FC73043.PV M3/HR O O19 SLURRY P/A TO 7301-E FC73057.PV M3/HR O O20 DEBUTA BTMS TO 7505-CLR FC75023.PV M3/HR O O21 Debuta Top Corrected Temp TX75034.PV DEGC O O22 DB BTMS PMP DISCH,RVP AI75003.PV KPA O O23 STPR BTMS TO 7504-E TC75029.PV DEGC O O24 DP BTMS,GC C3S AI75009D.PV MOL % O O25 DEPRO REFL TO 7505-E FC75035.PV M3/HR O O26 DEPRO OVHD TO 7509-C PC75031.PV KG/CM2 X O27 STPR BTMS TO 7513-C TI75015.PV DEGC O O28 LCO P/A FC75018.PV M3/HR O O29 H/NAPH LEAN OIL TO 72#/LCO FC75553T.PV M3/HR O O30 HCO EX RCC TO 152F FC73R19.PV M3/HR X X
Optimization Variable
No. Service Tag UOM OPT ON/OFF RMPCT MV STS1 TOTAL OIL FD TO REACTOR FC73108.PV M3/HR O O2 RISER OUTLET TEMP TC73014.PV DEGC O O3 HOT FEED TO 7303-D TC73068.PV DEGC O O4 2ND STG REGEN TEMP TC73112.PV DEGC O O5 R1 CO/CO2 RATIO RX73004.PV MOL % X X6 REGEN 2 FULE GAS %O2 AI73001.PV V/V % O O7 2ND STG RG TOP PC73014.PV KG/CM2 X X8 REGEN 1ST TO 2ND DIFF PC73018.PV KG/CM2 X X9 MF OVHD RECEIVER PC73188.PV KG/CM2 O O
10 ABSB GAS CONT KO DRM VAP PC75041B.PV KG/CM2 O O11 O2 SUPPLY TO 7301B FC73A03.PV KG/HR O O12 OM LSFO FCJ1104.PV m3/h O13 OM VGO FCJ1105.PV m3/h O14 H/NAPH LEAN OIL TO 7503E FC73060.PV M3/HR O O15 ROMeo ONLY 7503-F TEMP TI75012.PV DEGC O16 FRAC OVHD TO 7307-C TC73052.PV DEGC O O17 LCO PRODUCT TOTAL FLOW (FC73044T)FC73044.PV M3/HR O O18 HCO P/A TO FRACT #21 FC73043.PV M3/HR O O19 SLURRY P/A TO 7301-E FC73057.PV M3/HR O O20 DEBUTA BTMS TO 7505-CLR FC75023.PV M3/HR O O21 Debuta Top Corrected Temp TX75034.PV DEGC O O22 DB BTMS PMP DISCH,RVP AI75003.PV KPA O O23 STPR BTMS TO 7504-E TC75029.PV DEGC O O24 DP BTMS,GC C3S AI75009D.PV MOL % O O25 DEPRO REFL TO 7505-E FC75035.PV M3/HR O O26 DEPRO OVHD TO 7509-C PC75031.PV KG/CM2 X O27 STPR BTMS TO 7513-C TI75015.PV DEGC O O28 LCO P/A FC75018.PV M3/HR O O29 H/NAPH LEAN OIL TO 72#/LCO FC75553T.PV M3/HR O O30 HCO EX RCC TO 152F FC73R19.PV M3/HR X X
Slide 25
Test Data: (MVPC + RTO) Vs MVPC Only June 2010
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Case Study CCR/BTX RTO
SAT: 2008 May
Closed Loop with SMOC
Slide 27
Real-Time Optimizer Scope
Kerosene
( 113 ,000 T/Y)
( 364,000 T/Y)
Propane
Butane
Naphtha
B - C
Crude
#2 LER
#2
C
D
U
LPG
Naph
Kero
Gas Oil
Benzene
P-Xylene
#1 Naph
AR to VDU/DCU
AR
#2 NHT
Gas Oil
#2 LMX
#2 PLT BTX
#1 KGHT
#1 KHT
#3 GHT
( 3%)
( 20%)
( 17%)
( 20%)
( 40%)
#2 GHT
#1 Gas oil
Slide 28
No. Unit Description UOM
1#2 NHTNaphtha Splitter
Heavy Naphtha Dist.5%(RQE)
DEG C
2#2 NHTNaphtha Splitter
Naphtha SPLITTER REFLUX FLOW M3/HR
3#2 NHTNaphtha Splitter
#2 NHT FEED FLOW M3/HR
4#2 NHTNaphtha Splitter
Naphtha Stripper REFLUX FLOW M3/HR
5#2 PLATReactor
#2 PLAT FEED FLOW M3/HR
6#2 PLATReactor
#2 PLAT REATOR WAIT DEG C
7#2 PLATReactor
H2/HC Mole Ratio -
* BTX section considered as constraints * BTX section considered as constraints
Optimization Points
Slide 29
BZBZ
P-XP-X
NN
SS
PP #2NHT#2NHT
BTXBTX
#2PLT#2PLT
#2CDU
REF-SIM
for PLT Reactor Model
Use NIR data
For Feed comp.
Scope for Online model
OFF
NIR
NIR
Only for Simulations
Current Online model(using NIR for feeds)
Slide 30
BZBZ
P-XP-X
NN
SS
PP #2NHT#2NHT
BTXBTX
#2PLT#2PLT
#2CDU
REF-SIMNIR
OFF
HN5%
HNFEED
T/NFEED
RXWAIT
R/NFEED
FIXED
SRNFeed
L/N
Main Benefit Points
* Found extra space for BZ product with maximizing P-X Product* Found extra space for BZ product with maximizing P-X Product
Slide 31
>> Decreasing 3.3% of Feed SRN [ Saving Operation cost )
>> Increasing 3% of BZ ( Fixed P-X Product ]
Price Y2008 Price Y2007 Price Y2006Average
(Y2006-Y2008)
EstimatedProfit
1.2 Million 1.7 Million 1.0 Million 1.3 Million
Profit Estimation
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Difficulties of Development and Maintaining Utilization for RTO
Slide 33
Difficulties for CDU RTO Based on our Experience
Unit Difficulties Explanation
Accuracy of inferential properties.ROMeo cannot ignore the inforentialproperties because those are APC CVs.
The inferential properties are accurate at local area.However, sometimes, the properties are different afterrelatively big change by RTO
Inferential properties up- date
Depending on the type of inferential propertiesmethods, but most of inferential properties are requiredbias up- date by LAB or on- stream analyzer. The biasup- date can cause big bump on APC and RTOoperation.
Cut point change instruction fromscheduler
Occationally, the cut point of distillate such asNaphtha FBP, Kero 95%, LGO 90%, can be changed bythe instruction from scheduler to satisfy the logisticdemand.
CDU
Slide 34
Difficulties for RFCC and CCR/BTX RTO Based on our Experience
Unit Difficulties Explanation
Feed properties identification
Feed properties identification is very important forRFCC such as Distillation, Sp- Gr, CCR, Sulfur, BasicNitrogen. However, there are no such a on- lineanalyzer to measure them
Reactor model accuracyFCC Reactor and Regenerator model accuracy is veryimportant
Feed compositions identification
It is required to identify the feed as pure componentbecause of accuracy of CCR reaction. It is required toidentify the Naphtha from CDU and Naphtha fromother units such as FCC, HCU so on.
Reactor model accuracy CCR Reactor model accuracy is very important
BTX ReactorsThere is no rigorous reactor model for Tatoray (orPxMax) and C9 Isomer with ROMeo.
RFCC
CCR/ BTX
Slide 35
Importance for Utilization of RTO
Important Element ExplanationDaily Monitoring is important;Convergence and Down load rate, Optimization direction,Benefit monitoringPrice Up- date is also important. If price is wrong then theOptimization direction can be wrongSupport is important. What if some measurements becomeswrong, or what if model become not converged, or what ifcommunication wrong happen with RTDB so on.
2Close work with Planning andscheduling engineer
RTO cannot violates logistic constraint and Marketingcondition. The understanding and close communication withPlanning and scheduling are important
3Visualization and appeal tomanagement
It is required and important to expose the RTO performanceto management to understand the RTO performanceperiodically. Some of engineering effort is required to runRTO but need to justify the cost from performancevisualization
Daily Maintenance1
Slide 36
Monitoring System Example Summary Screen
Calculation Successful rateCalculation Successful rateOptimization StatusOptimization Status
Optimization Variables Information
Optimization Variables Information
Economic Effects Reflection Rate
Data handling Successful RateData REC Successful RateOptimization Successful Rate
Optimization Variables Names
Study Low Limit ・ High LimitOptimization Value 、 Operation Value
Slide 37
Constraints Variables Screen
Calculation Successful RateCalculation Successful RateOptimization StatusOptimization Status
Constraints Variable InformationConstraints Variable Information
Constraints Variables Name
The ratio of constraints hit
Check Low Limit ・ High LimitOptimization Value 、 Operation Data
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RTO with Production Planning/Scheduling
The linkage between RTO and
Planning/Scheduling is very important
Slide 39
Operation Cycle in Refinery�Investment plan (Long term Plan)�3 Month Plan (Mid term)�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�RTO (ROMeo for Planning)
�Crude Selection�Demand/Sales/Supply�Exchange
�APC�RTO (ROMeo)�Performance Monitor
Refinery Planning/ScheduleHQ Planning/Sales
Operation
�Process Design�Improvement�Bottle neck�RTO (ROMeo for Analysis and case studies)
Technical
Product Storage
Crude StorageCrude Tanker
Slide 40
Operation in Refinery One Month (Planning/Schedule (1))
�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�RTO (ROMeo for planning)
�Demand/Sales/Supply�Exchange
�APC
�RTO (ROMeo)�Performance Monitor
Refinery Planning/ScheduleHQ Planning/Sales
Import Products
Crude StorageProduct Storage
Crude schedule is
already fixed
Operation
Export Products
Blending and Shipping
Slide 41
Typical Production Planning/Scheduling Work�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�Demand/Sales/Supply
�Exchange�Purchase/Sale �Intermediate product
Refinery Planning/ScheduleHQ Planning/Sales
Day 1 510
1520
A,B…: Crude Type
One Month Operation plan is prepared by LP assuming one month
mixed average Crude or Crude tank by tank with
respecting Tank Inventory as constraint
Scheduler decides Operation targets such as Cut point, Unit
feed rate to meet the daily operation is as similar as One
month planning by Daily bases
Operation Instruction
Slide 42
Relation between RTO and Planning/Scheduling
Day 1 510
1520
Planning/Scheduling
Refinery Wide ROMeo RTO
Unit RTO Unit
RTO
Unit RTO Unit
RTO
Shift Vector Opt.
Yield
Price InfoLogistic
Constraints
Rigorous Marginal Price
Continuously Maximizing
Benefit
Slide 43
Thank You( ありがとうございました)