new techniques in optimizing shale and other opportunity...

© 2015

Topnir Systems

New Techniques in Optimizing Shale and Other Opportunity Crudes

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

© 2015

PresentersPresenters

� Dr. Didier Lambert: Dr. Didier Lambert earned his PhD in Chemistry from 1984 at Paris Pierre and Marie Curie University. He worked for more than 16 years for BP where he invented solutions for real time Quality control for Oil & Gas industry. He has more than 30 patents in the field and was awarded with Engineer Award in 1989 for his invention. He bought out the business he developed in BP and set up Topnir Systems in early 2005.

� Patrick Truesdale: Mr. Truesdale is a Principal Consultant with Emerson Process Management. He started his career with duPont . He has over 40 years worldwide consulting experience in optimization and control and specializes in blending and petroleum and chemical logistics operations and automation. He has a BSEE from North Carolina State University in Raleigh, NC and is a Registered Professional Engineer.


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ContentContent

� Introduction – Challenges vs Opportunities

� Three Step Solution

� Example Results

� Benefit Overview


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The Crude Unit: Gateway to RefiningThe Crude Unit: Gateway to Refining

� Every refinery has a crude unit– Common size for a single train: 120,000 bpd

� As crude feedstock broaden to include shale and opportunity crudes, this unit’s performance becomes critical to flexibility and profitability


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Business ChallengesBusiness Challenges

� Crude operations require process flexibility– Response to market demands for products

– Must be capable of processing varying grades of crude

– Good response to crude switches and operating mode changes

CRUDETANK

CRUDEPIPELINE

DOWNSTREAM PROCESSES


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Process ChallengesProcess Challenges

� Energy efficiency – Heat transfer efficiency loss drives energy costs up

� Crude unit utilization – Sub-optimal temperature control decreases product quality

– Poor fractionator control lower separation efficiency

� Reliability of field assets– Unplanned slowdowns and shutdowns are often caused by failure

of rotating and fixed plant assets

� Safety, Health & Environmental concerns– Fines, personnel issues plague refinery operations worldwide


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Worldwide Assessed Basins Shale Oil/Gas Formation: May 2013Worldwide Assessed Basins Shale Oil/Gas Formation: May 2013


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Energy Research Policy Foundation Inc.

6

USA-Canada Crude Typical PropertiesUSA-Canada Crude Typical Properties


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Crude Unit Utilization: ChallengesCrude Unit Utilization: Challenges

� Frequent crude switching negatively impacts quality

� Corrosion of the overhead condenser and piping

� Plugging and fouling of crude preheat exchangers


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Crude Unit Control & OptimizationCrude Unit Control & Optimization

Vacuum TowerAtmospheric

Tower

Crude Feed

Naphtha

Kerosene

Lt Diesel

Diesel

AGO

Stripping Tower

Steam

Steam

Steam

Steam

Steam

T

T

T

T

T

F

F

F

F

F

F

F

F

F

F

T

T

F

F

F

F

FL

L

L

L

FBP

IBP FBP

IBP

Cong.D360

T P

Flood

O Flash

Gas

F F

D360

O2

HV

Fuel

F

Air

F

CO

T

Fired Heaters

T

P

P

T-7

NaphthaStabilizerSmartProcess™ Fractionation

SmartProcess™ Heater

SmartProcess™ Distillation

F

F

Crude

A

Crude

B

Crude Blender

SmartProcess™ Blend

FTIR/TopNir Crude Characterization

Properties& Targets

Q’s

F

Q’s

Ratio


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Step 1: Crude Feed Online AnalysisStep 1: Crude Feed Online Analysis

Real time Monitoring of Crude transition


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NIR Spectrum

Intensity = Io Intensity = I

NIR Source

Detector

Measurement

Cell

Fourier

Transform

NIR Spectroscopy – Basic PrinciplesNIR Spectroscopy – Basic Principles

� Each NIR Spectrum is unique for each Product

� It is the DNA of the sample

KEY ISSUE in NIR is MODELING !


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TOPNIR™ Database for ModellingTOPNIR™ Database for Modelling

� 20 samples required for calibration

� Densification methodology to maintain the accuracy

� Creation of virtual samples – linear and non-linear mixing rules


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TOPNIR™ Basic Postulate: Pattern RecognitionTOPNIR™ Basic Postulate: Pattern Recognition

Abs. 1Abs. 2

.

.Abs. n

Abs. 1Abs. 2

.

.Abs. n

Spectra A

Prop. 1Prop. 2

..Prop. m

Prop. 1Prop. 2

.Prop. m

Sample

A

Sample

B

Same spectra �� Same sample Same spectra �� Same sample

Same sample �� Same propertiesSame sample �� Same properties

SameSame

Modeling achieved from Reference DatabaseModeling achieved from Reference Database

SameSame

Spectra B


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TOPNIR™ Pattern Recognition TechnologyTOPNIR™ Pattern Recognition Technology

Properties X = f ( Prop[S1, S2, S3, S4, S5, S6] )Properties X = f ( Prop[S1, S2, S3, S4, S5, S6] )

New Sample X

S1S1

S2S2

S4S4S6S6

S5S5

S3S3

NO MODEL TO MAINTAIN EASY MAINTENANCE

All Properties from one Reference Database


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TOPNIR™ SummaryTOPNIR™ Summary

� Patented technology

� Uses only a reference database to predict and calculate sample properties;

� Update is easily done only by adding new sample in the database, with both NIR Spectra and conventional analysis.

� Self-learning method without necessity of remodelling.

� When new sample is added, it is taken into account by Topnir™.


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Provides Properties of Crude OilProvides Properties of Crude Oil

Property Accuracy per ASTM

TBP curve +

API +

Sulphur, % +

Assays Yield, % +

TAN +

Crude Assays +

GOR +

Carbon-Hydrogen ratio +

Asphaltenes +

RVP +

others


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Asphaltene Stability Index (ASI) for Crude OilsAsphaltene Stability Index (ASI) for Crude Oils

Asphaltene Stability (Crude Compatibility) Index is a function of:

� Asphaltene / Resin ratio

� Saturates / Aromatics ratio

� Light Fraction yield

� API Gravity

� Viscosity

Dispersion of Asphaltene in Crude Oils Asphaltene Equilibrium


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Step 2: Optimum Crude BlendStep 2: Optimum Crude BlendFTIR Analyzers/TOPNIRSmartProcess Blend

TankCrude A

TankCrude B

TankCrude C

TankCrude n

TCAC

AC

Pass 1

Pass 2

Pass 3

Pass 4

TI

TI

TI

TI

TI

FC

FC

FC

FC

FC

Total Charge

Flow

TC

Coil Outlet

FC

TI

TI

TI

TI

FI

AI

Fuel

PC

PC


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Step 3: Smart Refining – Crude HeaterStep 3: Smart Refining – Crude Heater� Control total process flow to target

� Control outlet temperature

� Pass Balancing

� Adjust inlet air and draft dampers to minimize excess air

� Stabilize heater against changes in fuel gas and feed temperature

� Combustion control including fuel/ air cross limiting

� Operate within all heater constraints

� Heater efficiencies are calculated as well as estimated stack gas compositions and emissions


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Step 3: Smart Refining FractionatorStep 3: Smart Refining Fractionator

Fired Heater

Vacuum Tower

Atmospheric Tower

Crude Feed

Naphtha

Kerosene

Lt Diesel

Diesel

AGO

To Vacuum System

LVGO

HVGO

Residue

Stripping Tower

Steam

Steam

Steam

Steam

Steam

Steam

T

T

T

T

T

F

F

F

F

F

F

F

F

F

F

T

T

FuelF

HV

F

F

T

T

F

F

F

T

T

O2

F

F

T

T

F

F

F

F

T

T

T

TF

F

F

F

FL

L

L

L

FBP

IBP FBP

IBP

Cong.D360

T

T

P

P

Flood

O Flash

Flood

T P

Gas

F F

D360

O2

O2

HV Fuel

F

Ai

r

F

CO

CO

T

Fired Heaters

F

HV Fuel

T

P

P

T-7NaphthaStabilizer

SmartProcess™ Fractionation


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Step 3: Smart Refining - DistillationStep 3: Smart Refining - Distillation

FT

LC

FC

QR

LC

Feed Flow

TI

FC

QR

75# Steam

Reflux

Control Temp

Propane Product

Butane Product

PC

C4’s

C3’s

PredictPro

CV

CV MV MVMV

MV

SmartProcess™ Distillation


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Crude Value Added Benefit ChainCrude Value Added Benefit Chain

Suboptimum

Blending

Optimum

Blending

CrudeMixing Penalty


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TOPNIR™ Crude DistillationAramco, Yanbu, Saudi ArabiaTOPNIR™ Crude DistillationAramco, Yanbu, Saudi Arabia� 200,000 BPD refinery

� 9 Streams – Crude, LSRN, HSRN, CDU HSRN, KERO, LDO, ADO, HDO, RCO

� On-line analysis 117 Properties

� Analyzer integrated in a shelter


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Example Results: Raw Crude CharacterizationExample Results: Raw Crude Characterization

Family 4

Family 3

Family 1

Family 2

Property min max units

TAN 0.2 3.7 mg KOH/gTotal Sulfur 0.02 4.9 wt%Gravity, API 18.8 66.4 deg

More than 70 Crude Oils


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TOPNIR™ Crude Oil Ecopetrol, ColombiaTOPNIR™ Crude Oil Ecopetrol, Colombia

� Crude Pipeline Transportation Optimization

– >140 Crude; Blend in Pipeline 3 to 40 Crudes

– Crude Composition Known

– Blend Ratio Unknown

– Five Pumping Stations; Two Refineries -Barrancabermeja & Cartagena

� Scope

– Crude Identification and Characterization

� Project Completed in 9 months

� ROI less than 6 Months

EMPRESA COLOMBIANA

DE PETRÓLEOS


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FTIR + TOPNIR™: On-line Crude SolutionFTIR + TOPNIR™: On-line Crude Solution

� Better Crude Allocation and Segregation

� Crude Blending Optimization

� Crude Switch Optimization

� Distillation Curve (TBP) Continually Available

� Crude Stability Index

� Feed Preparation Giving Greater Stability

� Feed Optimized for Different CDU Modes

� Crude Throughput Increase

Benefits: $2-3 Million/year


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Example Results:Fractionator Control PerformanceExample Results:Fractionator Control Performance

CV

SP

MV

Lab

Spec

Controller ON

Naphtha

Kero AGO

Hvy Kero

Crude Change


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SummarySummary

� Refineries have unique challenges that significantly impact their economic operating margin;

� Shale (LTO) and other unconventional heavy crudes provide significant advantages to optimize crude feed

� Emerson Process Management and TopNir Systems offer new technology and application packages that provide high performance while substantially reducing both implementation costs and maintenance/support costs. These include:– TOPNIR™ Crude Characterization using Online FTIR– SmartProcess ™ Blending– SmartProcess™ Fractionation– SmartProcess™ Heaters– SmartProcess™ Distillation


© 2015

Where to get more information?Where to get more information?

� To discuss your specific requirements

� Contact: • Patrick Truesdale ([email protected])

• Didier Lambert ([email protected])

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