2014 Software Global Client Conference

Transcription

SS DES-08:
New Advances in
Design…
Refinery Reactor
Models in PRO/II
Larry Balcom
Rujun Li
PRO/II Reactor Units
Reactor Types
● Conversion Reactor
● Equilibrium Reactor
● Gibbs Reactor
Kinetic Reactor Types
● Plug Flow
● CSTR
Reactor Types
● Combining reactors for
sophisticated processes
Customizing Reactor Units
Custom Reactors
Custom Kinetics
● Reaction Control
● Power Law Kinetics
● Shared Kinetics Procedures
● User Added Subroutines
● FORTRAN Calculator
● Excel Kinetics
● Kinetics Basis
● Liquid or Vapor
● Mole Concentration, Fugacity,
or Activity
Custom Catalysts
Easily share reactor
configuration and
operational data.
Refinery Reactors in PRO/II
An Engineered Solution combining
PRO/II and ROMeo
Why Refinery Reactors?
● PRO/II could not rigorously
simulate key refining
processes.
● SimSci Refinery Reactor
models are only available in
ROMeo online and offline
● Some SimSci reactor models
are written in a language not
compatible with PRO/II
The Engineered Solution
● The Excel unit operation in
PRO/II 9.3 has been enhanced,
allowing more data to be
transferred to and from Excel.
● ROMeo (ARPM) can be
programmed to reconfigure
reactors, and import stream
data.
The solution: Add Reactor models to PRO/II through the Excel unit
operation and the capabilities of ROMeo to run autonomously.
Capabilities of Refinery
Reactors in PRO/II
PRO/II and ROMeo
Rujun Li
Conceptual Overview
● ROMeo (ARPM) does the heavy lifting
● Flowsheet, thermo, component slates
● Model pre-configured to the actual unit and calibrated with process/lab data
● Inputs and outputs pre-defined for easy access
● Solve the model with new inputs from Excel
● Excel Interface
● Communication between PRO/II and ROMeo for inputs/outputs
● Reactor model configuration
● PRO/II
● Send feed properties to the reactor model
● Product properties get updated by the reactor model
Conceptual Overview
● Reactor Models are developed for online application, not for design
● Models are not off the shelf, need to be calibrated by plant data
● Large operating conditions change requires re-calibration of the model
● Reactor models with PRO/II are for offline simulation
● Case study, what if scenario
● Troubleshooting, debottlenecking
Limitations
● Reactor model has to be configured and solved in ROMeo before being
connected to Excel
● Excel interface has limited configuration capacity and cannot be used
for initial model configuration
● The bounds in Excel are set to avoid non-convergence of the reactor
models, but they cannot guarantee convergence
Training, Model Configuration & Tuning Service
● Offer
● 3-day training
● Model configuration and tuning service
●Configure ROMeo model
●Tune the model with plant data
●Configure the Excel interface
●FAT
● 16 hr post-FAT support
Reformer
● Reformer model
● CCR
● 4 beds, catalyst weight from 38 klbs—189 klbs
● Reactor pressure 15 kg/cm2, WAIT(weight average inlet temperature) 510C
● Fresh feed heavy straight run naphtha
● What changes are allowed
● In PRO/II
●Feed rate, composition, pressure, temperature
● In Excel
●Bed inlet temperatures, bed coke weight%, catalyst overall activity, H2
recycle ratio
Reformer
HydroProcessing Units
● HDP model
● 2 beds, one HT and one HC, catalyst vol 30 ft3
● Pressure: 1300psia, Temperature: 630oF
● Feed synthesis included, can specify feed properties and run model in datarec mode to adjust feed
● What changes are allowed
● In PRO/II
●Fresh feed & makeup H2 rates, compositions, pressures, temperatures
● In Excel
●Bed Temperatures, %Coke on the Bed, Recycle ratio, Overall Activity
coefficient
HydroProcessing Units
FCC
● FCC model
● The same model created by the template
● Esso Model IV type design
● Reactor T: ~546oC, Regenerator: 640oC
● Slide valves on both lines
● What can be changed
● In PRO/II
●Feed rate, composition, pressure, temperature
● In Excel
●Catalyst Activity, Spent and Regenerated Catalyst Valve Positions
FCC
Related Support, Services & Training
Support
> Support for the base Software functions is
included in the software license.
> Model support will require a Customer First
support contract after the initial installation.
Services
> Reactor Model Initial Tuning Services
> Model Maintenance Services
Training
> Model Familiarization training is included in
the standard Engineered Solution project
scope.
> Software training is available in both Public,
and Private On-site course formats.
Confidential Property of Schneider Electric
25
Linking PRO/II to the
Refinery Reactors
PRO/II and ROMeo
Larry Balcom
Conceptual Overview
● PRO/II Model
● All versions supporting the Excel Unit
operation
● Excel Interface
● Reactor configuration
● Component Lumping and Delumping
● Store results
● ROMeo
● Limited Model functionality
● Standardized Interface
● No user access required!
Conceptual Overview
● Reactor model
configuration
● Feed component
Mapping
● Product component
mapping
● Reactor results displays
Conceptual Overview
● Inputs stored in standard
format using Input collection.
● Common Interface program
in ROMeo TCL.
● Solve the ROMeo model.
● Output is stored in standard
format from the Output
collection.
What are the model requirements?
● Create any required
components and petrocomponents.
● Create all required input
and output streams.
● Connect streams to the
Excel unit.
● Map the PRO/II and Reactor
stream names in Excel.
● Configure the reactor operating
parameters to model operating
conditions.
● Understand the normal reactor
operation, and create reasonable
streams for the reactor model to
process.
● Component mapping for the
lumping (input) and delumping
(output) streams.
● “Many to many” mapping is
supported in all tables.
● Automated mapping using PRO/II
standard component names, and
library IDs.
● Manual mapping allowed for all
components.
How is it built?
● Reformer and
Isomerization models
● Input requirements:
● Hydrocarbon feed stream
● Reactor operating
conditions
How is it built?
● Hydro-processing unit model
● Hydrocarbon assay profile
● H2 feed stream
● Reactor operating conditions
●Including Catalyst
selection.
How is it built?
● Delayed Coker unit model
● Feed RIP Properties
How is it built?
● FCC unit model
● Feed RIP properties
● Feed Distillation curve
● Utilities feeds; air & 2 steam
Viewing Results
● Run your reactor model.
● You can see the results in the
product streams.
● By right-clicking on the Excel
unit, and selecting “View
Results”.
● Open the Excel interface to see
the reactor process graphics
and calculated outputs.
©2014 Schneider Electric. All Rights Reserved.
All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.
41

2014 Software Global Client Conference

Transcription

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