106th NPRA Annual Meeting

106th NPRA
Annual Meeting
Conference Daily
Published by Hydrocarbon Processing
Day Two, Tuesday
March 11, 2008
Presentations from two national figures
kick-start Monday’s general session
The NPRA’s 106th Annual Meeting opened Monday with a general session meeting featuring presentations on
important current topics by two national
figures—John Stossel of ABC News and
Stuart Rothenberg, editor and publisher
of the Rothenberg Political Report.
Charles Drevna, NPRA’s president,
opened the session with a state-ofthe-association report that praised the
industry for its steadfast work. He was
followed by James Mahoney, NPRA’s
chairman, who noted that the success of
the industry could be found at home—in
its employees.
Mr. Mahoney also announced that
the winner of the Distinguish Safety
Award is ExxonMobil’s polyolefins plant
in Baton Rouge, Louisiana.
John Stossel, co-anchor of “20/20”
for ABC News, was introduced through
a video report he did for “20/20” on the
myths of “record high” gasoline prices.
Mr. Stossel introduced his presentation by saying that his brain has changed
from when he started out as a reporter.
John Stossel, news correspondent and
co-anchor of ABC News’ “20/20,” discusses
his progression as a consumer reporter
during Monday’s general session.
He said he came out of college thinking
that, like most reporters, “Capitalism is
okay. It brings us some good, but by and
large it is cruel and unfair. That’s why we
need government to protect us. It seemed
natural to think that way, and I made a
career of bashing business.”
The award-winning journalist said
that his decision to become a consumer
NPRA National Safety
Conference
May 7–8
The Woodlands, Texas
Register at npra.org
Inside this issue . . .
Breakout sessions. . . . . . . . . . . . . . 3
Gasoline blend scheduling
software. . . . . . . . . . . . . . . . . . . . 4
advocate came when he had a chance to UOP’s customer appreciation
dinner. . . . . . . . . . . . . . . . . . . . . . 5
see regulators at work.
MILESTONE
controls fouling. . . . 7
“It became obvious that regulations
Rigorous
simulation
in process
almost always do more harm than good,”
he said. “The reasons are not obvious.
control projects. . . . . . . . . . . . 10
The first reason is cost, but the bigger Scenes from the meeting. . . . . . 14
cost is the indirect cost of the time and
energy and money that is wasted trying For additional coverage of the
annual meeting, visit HPInformer:
to work in the system instead of deliverwww.hydrocarbonprocessing.com/
ing product, all the creativity that is lost
hpinformer
just trying to understand the rules.”
He noted the steps it takes to deliver
a product appear to be endless with all
Quick fact:
the rules and regulations that need to be
followed.
This year’s annual
“It takes longer to get permission to
meeting has more than
build a house than it does to build the
1,600 attendees from
house,” he said.
30 different countries.
Mr. Stossel said that the more he looked
into the problem, the more he realized that
Today’s
competition worked, solving problems better than regulations. He said that the mirSchedule
acle is in all the good that is done through
the self-interest of companies competing 7:30 am – 9:15 am
See General Session on page 5
Surveying the legislative landscape
The senior leadership of NPRA held a tion will have a dramatic long-term impact trade programs, that leads us to buying
press conference Sunday evening to discuss on the entire US economy and should credits, which I would describe as being
their outlook on current and upcoming therefore be considered very carefully.
taxed. The only other option we have is
energy issues affecting the petrochemical
“We need to understand the eco- to reduce production.”
and refining industries. Legislative issues nomic impact of any climate change
He then shared a guiding concept of
in the US of particular concern included legislation. Given the current technol- the NPRA, which is to “promote a level
the Energy Independence
playing field for all of America’s
and Security Act that was
industries, based on principles
signed into law by President
of a free, open and competitive
market.”
Bush on Dec. 19, 2007, a
Norm Phillips, NPRA viceclimate change bill emerging
chairman
(LyondellBasell Indusout of a Senate committee
tries),
reiterated
Mr. Mahoney’s
and language in a House bill
point
regarding
the underlying
pertaining to petrochemical
tenets
of
the
NPRA.
“The NPRA
facility safety.
will
continue
to
take
principled
“We believe the [Energy
and
unapologetic
positions
on
Independence and Secuissues
that
are
important
to
our
rity Act] puts a significant
Mahoney, NPRA chairman (Koch Industries), Norman Phillips,
industry and the American conburden on the industry. We James
NPRA vice-chairman (LyondellBasell Industries) and Charlie Drevna,
do applaud Congress, how- NPRA president, meet with members of the media Sunday evening. sumer,” he said.
“The House of Representaever, for removing punitive
tax measures and misguided
tives recently passed a bill sinprice gouging measures from the bill,” said ogy in the refining industry, we have gling out the oil and gas industry for puniJames Mahoney, NPRA chairman (Koch limited options to change greenhouse tive taxes to pay for extending renewable
Industries).
gas output,” Mr. Mahoney said. “We can credits,” Mr. Phillips said. “That simply
Mr. Mahoney also voiced concern work on efficiency, but that is not going represents a federally mandated transfer
about a climate change bill in the Senate, to dramatically change our greenhouse of assets from one industry to another. It
and noted that any climate change legisla- gas footprint. When you look at cap and is not consistent with the free-market con-
CEO Breakfast
Featuring:
William R. Klesse, CEO and
Chairman of the Board,
Valero Energy Corporation
9:30 am – 12:00 pm
Technical, Management
and Issues Sessions
12:00 pm – 2:00 pm
Annual Luncheon
Featuring:
Tony Snow, Former White
House Press Secretary
2:00 pm – 4:30 pm
Technical, Management
and Issues Sessions
6:30 pm – 9:30 pm
Closing Event:
Experience the USS
Midway
cepts our economy is based on.”
Mr. Phillips was also critical of proposed
legislation in the House that he said would
undermine efforts to secure and protect
chemical facilities by highlighting potential
plant vulnerabilities to the public.
See Legislation on page 5
106th NPRA Annual Meeting  National Petrochemical and Refining Association  Tuesday, March 11, 2008
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Today’s breakout sessions
Tuesday March 11, 2008 – 9:30 AM to 12:00 PM
Issues Sessions
Elizabeth F
Developing Carbon Dioxide
Crude Evaluation and
Profit Improvement
Manchester B
Operations
Strategies
Distillation
Manchester C
Manchester A
Elizabeth G
Elizabeth H
FCC Technology
The Journey to Operational
FCC Revamp
Gasification Technology:
Improve Crude Selection
Demographics and
Economics, CO2 Balance
Excellence
Generating Profit from
By Better Understanding
Engineering Resources:
and Energy Efficiency of
Patrick LeRoy
the Bottom of the Barrel
Crude Oil Quality
Biofuels Production
Kevin Smith
•J
oe Fowler, Texas A&M
TOTAL Refining
Joachim Wolff
Pat Swafford
Stephen McGovern
AM-08-19
9:30am KBC Advanced
Engineering Council
Shell Global Solutions
Spiral Software
PetroTech Consultants
Techologies, Inc.
9:30am
9:30am AM-08-45
AM-08-40
9:30am AM-08-42
AM-08-87
9:30am
10:30 am – 12:00 pm
NEP Panel:
•R
ick Leicht, NCRA
(moderator)
•J
eff Bonnette, CITGO
•B
obby Fischer, TOTAL
•T
ina Drumheller,
FrontierNR
•V
alero
•P
at Casey, Sidley Austin
LLP
•M
ike Mayo, Valero
Energy
9:30 – 10:30 am
Tesoro FCC Regenerator
Maximizing Value for
Managing High Acid
Carbon Dioxide and
Managing Marine
Upgrade Project, Salt
Refinery “Orphan”
Crudes
Refining – Trends and
Logistics: What You
Lake City
Products
Challenges
Don’t Know CAN Hurt
Craig Winslow
You
Reza Sadeghbeigi
Randy Velarde
John Jenkins
GE Infra Water
Gerry Bemberg
RMS Engineering, Inc.
10:00am The Plaza Group
Jacobs Consultancy Inc AM-08-68
10:00am TOTAL Petrochemicals
AM-08-58
10:00am AM-08-17
AM-08-39
10:00am
AM-08-49
10:00am
A Bold Move in
Cheyenne Yield
GHG Emissions
hydrocracking catalyst
Improvement Project Performance
selection resulted in a
Recovering Maximum
Measurement and
record run length and
Diesel from Crude Oil
Management – The
significant boost in
Fractionation Process at
Missing Ruler
hydrocracker margins
Frontier Oil’s Cheyenne
Bill Trout
Refinery
Tina Swangphol
Solomon Associates
Criterion Catalysts &
AM-08-38
10:30am Tony Freeman
Koch Partners LP
Technologies and
AM-08-43
11:30am
Zeolyst International
AM-08-92
10:30am
Diesel Recovery Options
Carbon & Energy
A New Process Approach
in Crude Unit Product
Management: Innovative
to Hydrotreating Coker
Upgrade and Capacity
Approaches for a
Naptha
Revamps
Responsible Energy
Raj Patel
Future
Andrew Sloley
Haldor Topsoe
Marc Tice
CH2M
AM-08-88
11:00am
AM-08-44
11:00am
Shell Global Solutions
(US) Inc.
AM-08-37
11:00am
A New Technology for
Tank Farm and Terminal
Reducing NOx Emission
Automation: Developing
from FCC Regenerators
a Business Case
Ye-Mon Chen
Patrick Truesdale
Shell Global Solutions
Emerson Process
(US) Inc.
Management
AM-08-16
10:30am AM-08-46
10:30am
Capturing Value Through
The Dawn of a New Age
Optimization of FCC
in Gasoline Blend
Catalyst Technology for
Scheduling
Processing Opportunity Dean Trierwiler
Feedstocks Derived from
Haverly Systems, Inc.
Canadian Oil Sands
AM-08-86
11:00am
Joseph McLean
BASF Catalysts LLC
AM-08-21
11:00am
Impact of bitumen derived Stoichiometric Combustion
Monitoring and Reducing Rerun and Off-Spec
Results of Antifoulant in
Product Recovery: New
feeds on the FCC
a Refinery’s Carbon
Control
Delayed Coker Furnace
Opportunities with
Footprint
Keith Couch
Andy Wheeler
Jeff Williams
Industry Wide Benefits
Diego Polanco
UOP LLC
Bambeck Systems Inc.
Delek Refining
Monica Mills
11:30am AM-08-48
KBC Advanced
11:30am
AM-08-93
11:30am AM-08-20
INTERSOURCE LLC
Technologies, Inc.
10:30am
AM-08-41
11:30am AM-08-85
Tuesday March 11, 2008 – 2:00 PM to 4:30 PM
Renewable Fuels
Elizabeth F
Management
Elizabeth G
Workforce
Elizabeth H
Reliability
Manchester C
Hydrogen & Refinery
Energy Economics
Off-gas Systems
Manchester B
Manchester A
Ethanol – Absorbing the
Gasoline or Diesel?
Where Have All the
How Marathon Petroleum’s Hydrogen Costs and Issues Economics of Refinery
Deluge
Workers Gone?
Reliability Initiative
– Gasification vs. SMR
Energy Saving Projects
Joseph Jacobs
Changed MPC
In a Changing Market
Kevin Waguespack
Paul Weissgarber
Dale Simbeck
KBC Advanced
Lance Holmer
Douglas White
Baker & O’Brien, Inc
AT Kearney
SFA Pacific, Inc.
Technologies, Inc.
AM-08-77
2:00pm AM-08-59
2:00pm Marathon Petroleum Co. AM-08-74
2:00pm Emerson Process
2:00pm AM-08-72
Marty Moran
Management
Meridium Inc
AM-08-62
2:00pm
AM-08-64
2:00pm
Commercialization of
Rapid Excel Modeling
How will Biofuels
The Potential Contribution Managing the Challenges Gray Matter(s) in Human
Reliability
New Low-cost H2
for the Optimization of
Challenge Petroleum
of Coal-to-Liquids
of Complex Operations
Refinery Energy Systems
Refining?
Technology to the US
and Work Force
Recovery Process
Jim Stephanou
and Global Energy Pool
Changes. Are You
from ExxonMobil and
Charles Der
Ronald Cascone
Bayer Corporation
Ready?
Bruce Burke
Iraj Isaac Rahmim
AM-08-67
2:30pm QuestAir Technologies:
Praxair, Inc.
Rapid-Cycle Pressure
Tom Ratajczak
AM-08-61
2:30pm
Nexant, Inc
E-MetaVenture, Inc
Swing Adsorption
AM-08-78
2:30pm AM-08-56
2:30pm UOP LLC
Bal Kaul
AM-08-69
2:30pm
ExxonMobil Research
And Engineering Co.
AM-08-73
2:30pm
Capital Projects Survey
The Challenges and
Wireless Retrofits for
Economic LPG Recovery
Sustaining Refinery
Biofuels: New
Vance Scott
Rewards of Hiring Hourly Enhanced Plant Asset
from Stranded Low
Energy Improvement
Opportunities for CoEmployees
Management
Pressure Gas
Using Solomon’s NCM3
Processing Renewable
AT Kearney
Methodology
Feeds in Refinery
AM-08-89
3:00pm Clarence Trowbridge
Dave Siegel
Kevin Currence
Process Equipment
Chris Bustamante
BP
AirSprite Technologies
Black & Veatch
Brian Watkins
AM-08-70
3:00pm AM-08-47
3:00pm AM-08-76
3:00pm Solomon Associates
AM-08-60
3:00pm
Grace Davison
AM-08-80
3:00pm
A Fresh Look at Project
Enhancing Operator
Inspection and Monitoring Refinery Off Gas Treatment Energy Management
Converting Pyrolysis
Evaluation & Execution
Effectiveness with Tools,
of Coke Drum for Life
and Recovery –
System
Oils to Renewable
Training and Processes
Extension and Safety
Challenges of Designing Nick Spates
Transport Fuels:
James Jones
ROG Units
Processing Challenges
David Holden
Tej Chadda
Turner, Mason & Co.
MPC
& Opportunities
Sheng-Yi Chuang
AM-08-57
3:30pm Invensys Process
Foster Wheeler USA
AM-08-63
3:30pm
Jennifer Holmgren
Technip USA
Systems
Corp
3:30pm
UOP LLC
AM-08-71
3:30pm AM-08-65
3:30pm AM-08-75
AM-08-81
3:30pm
Value Engineering in an
Evolving Best Practices
Renewable Raw
Escalating Business
Through SimulationMaterials for Fuels
Environment
based Training
and Petrochemicals
Production
David Nash
Dennis Nash
Andrea Pinho
Chicago Bridge and Iron
Control Station
AM-08-55
4:00pm Ron Smith
Petrobras
AM-08-79
4:00pm
Chevron Products Co.
AM-08-90
4:00pm
Problem-Free Sulfur
Exponential gains through
incremental change
Plant Startups with
Pre-Activated Tail Gas
Jim Brigman
Catalysts
Ingenero Inc.
Mike Schmidt
AM-08-94
4:00pm
Axens NA, Inc.
AM-08-91
4:00pm
New gasoline blend scheduling software
meets the demands of a changing world
D. TRIERWILER, Haverly Systems Inc, Houston, Texas
If you are interested in a more in-depth
discussion of this subject, Haverly Systems
will be presenting “The Dawn of a New
Age in Gasoline Blend Scheduling” at 11
AM today in Manchester A.
Achieving optimal operations concerning the movement and blending of
gasoline has always been challenging,
but it is even more so today. It was stated
in a talk at last Fall’s Q&A that gasoline is no longer produced as a fuel, but
more as a mixture of chemicals. While
this statement is somewhat perplexing,
it does speak to the dilemma gasoline
production has become. The quality
of gasoline as a fuel has largely become
secondary to its chemical make-up and
resulting environmental effects.
As refiners have learned, it is Fig. 1. Sample of the H/Gal-XE scheduling system.
expensive to clean up gasoline. The
least expensive gasoline components
are always the dirtiest. Through costly therefore important for gasoline pro- that finished gasoline production be
additional processing, many undesir- ducers to daily strike a balance between maximized, while taking maximum
able chemicals can be removed from blended gasoline qualities (both envi- advantage of price differentials and
these streams, but only with a loss in ronmental and performance), and grade split opportunities, as the costs
total production, as well as often a finished gasoline production vol- of producing gasoline blend stocks are
reduction
in performance1/30/08
quality.6:54:28
It is umes.
Optimal operation demands minimized.
KBC_CapExAd_08.pdf
AM
This balance has always been the
goal of gasoline producers, but the complexities added to gasoline production in
recent years have made reaching it much
more difficult. Planners used to rely on
operation’s ability to work within their
flexibilities to meet plan requirements
while dealing with day-to-day operational variances. Operators had more
latitude to trim blends when necessary—
to position or produce the right stocks
required to blend the products needed at
the times they were scheduled—to preblend like components with confidence
that the resultant mix would still meet
blender requirements. But restrictions
primarily related to tankage limitations
have reduced or eliminated much of the
operational flexibility gasoline producers
had previously enjoyed.
Today’s gasoline blending realities dictate that keeping blending components
as segregated as possible increases their
value to the overall gasoline pool. Regulations, regional concerns and specialty
fuel vehicles have led to greater diversity
With a thorough understanding of the key drivers in the business
in the quality and number of grades of
environment and within the plant, KBC's specialists can provide you
finished gasolines produced. Such new
with the expert strategic business advice to assist you in making the
most efficient use of your investment capital.
requirements have severely strained existFrom initial feasibility reviews and configuration/design work to
ing gasoline storage facilities. Justifying
integration and optimization, KBC can provide you with independent
new facilities is proving impossible when
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over 300 clients in 50 countries. After nearly three decades of
experience in the process industries, we understand the complex issues
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the purpose to do so is only to provide
additional operational flexibility.
The primary purpose of gasoline
storage tankage was to provide surge
volumes to quickly meet demands or
provide ample volume for blend batches.
Tanks have now become more like buckets—whose purpose is to be emptied as
quickly as possible, and then refilled, possibly with streams of differing qualities.
Often now, tanks are entirely bypassed as
product is blended and charged directly
to a product pipeline or loaded directly
onto a vessel for immediate transport.
Such efficiencies save significant logistical costs, but make scheduling of volume
movements very difficult.
So, in order for gasoline producers
to achieve optimal operation within an
ever more constraining environment,
they must turn to advanced computerbased scheduling systems. Spreadsheet
balancing is no longer adequate to
forecast gasoline blend and transport
operations. More than just simple simulation is needed to ensure that gasoline
production will indeed be as profitable
as possible, given the constraints under
which it must be performed.
Haverly has developed such an
advanced computer-based scheduling
system for gasoline blend scheduling,
H/Gal-XE. H/Gal-XE provides all the
graphical and user interactive features
users have come to expect in today’s
software tools; plus, it provides producers with the ability to forecast the
specific operational events required to
result in the most effective and profitable use of gasoline stocks and facilities.
H/Gal-XE is an expert system in which
most factors concerning gasoline production have been identified and solutions provided to optimize their effect.
H/Gal-XE uses a proprietary eventbased technology Haverly calls Progressional LP (PLP). In addition to
performing all necessary scheduling
simulation calculations, PLP works to
maximize profit, minimize delays and
optimize equipment usage. ■
Dean Trierwiler is the technical manager at
Haverly Systems, Inc. During his 18 years with Haverly, Dean has been involved in the development,
application, support and promotion of the company’s planning and scheduling decision software
products. Dean spent the first 16 years of his career
working in various software development, planning
and engineering capacities with Citgo, Chevron
and Unocal.
Plan to attend
the 2008 NPRA Reliability
and Maintenance
Conference and Exhibition
in San Antonio, May 20 –23
Tuesday, March 11, 2008  National Petrochemical and Refining Association  106th NPRA Annual Meeting
UOP’s customer appreciation
dinner was well attended
High TAN Crudes?
On Sunday, UOP hosted its annual customer appreciation dinner at the San
Diego Natural History Museum. The attendees enjoyed sushi and refreshments
among the fossils and exhibits. Over 170 refining industry friends and colleagues
from around the world celebrated the growth, partnerships and innovation that
have brought success to the petrochemical and refining industries during the
past year.
Carlos Cabrera, president and CEO of UOP, briefly addressed the group,
focusing on some issues facing the industry in 2008. His comments touched upon
climate change initiatives, crudes becoming increasingly sour and heavy and integrating biofuels into the supply chain. Music was provided by a string quartet.
with each other. He told the group that if
you want to win in business, you have to
give good products to your customers. “If
you are making a better product, then you
are making America wealthier.”
Stuart Rothenberg was the final
speaker of the general session. As the
editor and publisher of the Rothenberg
Political Report, he is considered by
many as the go to authority on elections
of all stripes.
Mr. Rothenberg stated his intent to talk
about politics, a subject he deemed really
scary. He described himself as a person on
the lower end of the political chain. “I’m
the handicapper,” he said. “My job is to tell
you who is going to win, who is going to
lose and what you should be watching for
over the next six to eight months.”
Legislation continued
from page 1
He summed up what he thought the
industry should be working on by saying,
“We need to do a better job of informing the public and policymakers about
our industry, about how it benefits the
American economy and creates good paying jobs. We need to point out how our
employees safely and reliably meet the
needs of consumers.”
Charlie Drevna, NPRA president, succinctly synthesized Mr. Mahoney’s and
Mr. Phillips’ points by saying, “We hope
Congress would use the Hippocratic Oath
He said that the mood of the country is sour, and that people want change.
“Typically, when people want that it
means taking on an establishment figure,” he observed.
Mr. Rothenberg commented that
John McCain’s brand is good, according
to the polls. He also said Barack Obama’s
brand is good and that Hillary Clinton’s
brand is currently even.
“The desire for change in the country
is so strong, particularly in the Democrat
party, that Obama’s message for change
may well have trumped that old line
establishment trend,” he said.
As for his predictions, he forecast that
the Democrat nomination could go to
the floor of the convention. He also said
that the Democrats will pick up additional seats in the Senate and House,
which is “another reason the presidential
election is important.” ■
of first do no harm,” in their approach to
legislating.
Several other topics discussed included
accountability for tailpipe emissions
and the impact of fuel regulations. Mr.
Mahoney stated the belief that the refining
industry should not be held accountable
for tailpipe emissions, because the industry
does not control the miles per gallon of
automobiles sold nor control how many
miles consumers choose to drive. On the
fuel regulations front, it was pointed out
that the recently mandated production of
ultra-low-sulfur diesel results in an increase
in greenhouse gas output. ■
Be Prepared
For more information, visit our website www.bakerhughes.com. © 2007 Baker Hughes Incorporated.
All rights reserved. SMARTGUARD is a trademark of Baker Hughes Incorporated. PET-07- 13464
General Session continued
from page 1
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13464.High TAN ads.ARTC.qxp:Layout 1
Control delayed coker
heater tube fouling
High rates of fouling in delayed coker
heater tubes can reduce unit throughput,
decrease conversion and also limit the
refiner’s flexibility in selection of crude
oils processed. Baker Petrolite conducted a
long-term research program to understand
the effects of feedstock composition on
heater fouling tendencies, and to develop
chemical additives to control the fouling
mechanisms observed due to various feed-
1/30/08
8:23 AM
Page 2
High Metals Crudes?
streams did not necessarily correlate well
to the actual fouling rates experienced
in coker furnaces. Consequently, Baker
Petrolite developed the Coking Stability
Index (CSI) to measure furnace feedstock
stability.2 The CSI is a comparative test
that is a better predictor of coker furnace
fouling tendency charging a given feedstock, as measured by furnace run length.
This is illustrated in Table 1.
TABLE 1. Run length vs. CSI, asphaltene/resin
and saturates/aromatics ratios in selected coker
feedstocks
Furnace run
CSI
length
Asphaltene/resin
ratio
Saturate/aromatic
ratio
Canadian
2.4 Months
99.5
0.348
2.63
Midwest
5.0 months
137.1
0.325
3.85
West Coast
9.0 Months
192.0
0.458
2.94
stock characteristics. This work has led to
new fouling control chemical selection
and treatment strategies for high-severity
applications such as delayed coker heaters.
MILESTONE* Heater Fouling Control
Technology can improve refinery profitability by significantly reducing heater
fouling rates.
Causes of delayed coker heating
tube fouling. Heater tube coke forma-
The Baker Petrolite CSI test is used
to measure the stability of asphaltenes
in furnace feeds by determining the
asphaltene flocculation point using a solvent titration method. The CSI system
uses a near infrared (NIR) laser solids
detection method to determine the onset
of asphaltene flocculation. The apex of
the curve corresponds to the point of
asphaltene precipitation and provides a
relative measure of the stability of the
feedstock. The higher the CSI, the more
stable the coker feed.
The CSI method is also used to evaluate the relative stability of furnace feeds
that will be subjected to high temperatures. Example CSI profiles for various
feedstock types are shown in Fig. 1.
In addition to determining a feedstock’s
asphaltene stability, other analytical testing is performed on feedstock and deposit
samples to provide additional insight into
possible inorganic fouling mechanisms.
All of these feedstock properties are benchmarked vs. an extensive database of characterization information developed for a wide
range of unit feedstocks. This benchmarking helps predict how severe the fouling in
the process heater could be, based on the
behavior of similar feedstocks processed in
other units.
tion is caused by a combination of high oil
film temperatures and high oil residence
times, plus the inherent instability of the
hydrocarbon stream being processed.1 Oil
film temperatures are a function of tube
wall temperatures and fluid velocities;
residence time is determined by heater
design and current throughput, plus any
use of velocity steam or condensate in the
heater tubes.
The fouling potential for a given
coker feedstock depends on the amount
of inorganic contaminants, the type and
amount of metals that make up the inorganic contaminants, plus the stability of
the asphaltenes and resins in the hydrocarbon stream. In general, the higher the levels of inorganic contaminants, the higher
the concentration of asphaltenes and the
greater the instability of those asphaltenes,
the higher the fouling potential of a specific feedstock will be.
MILESTONE additive selection
procedures. These proprietary coker
Feedstock evaluation tools. feedstock characterization methods and
Developing the laboratory evaluation benchmarking processes are also used to
tools necessary to understand feed stream develop custom chemical treatment profouling tendencies and to allow the selec- grams for specific unit feedstock types.
tion of suitable additive functionalities The efficacy of the selected additive proand dosages is a key to achieving optimal gram is then confirmed with additional
MILESTONE fouling control program CSI testing (Fig. 2).
performance.
Positive performance of the recomBaker Petrolite evaluated the suitability mended chemical treatment program
of conventional industry feedstock char- (shifting the stability index to a more staacterization methods for predicting heater ble reading) translates very well to positive
tube fouling rates. One finding was that program performance in a high temperastandard feedstock asphaltene/resin and ture furnace experiencing fouling due to
saturates/aromatic ratios on coker charge asphaltene destabilization.
See Heater tubes on page 8
Be Prepared
To help keep your processes running smoothly,
Baker Petrolite delivers specialized skills and
experience. EXCALIBUR Contaminant Removal
Technologies combine industry-leading additives
and expert applications.
For more information, visit our website www.bakerhughes.com. © 2007 Baker Hughes Incorporated.
All rights reserved. EXCALIBUR is a trademark of Baker Hughes Incorporated. PET-07- 13464
Coker feed type
The Baker Petrolite team helps you:
Increase feedstock flexibility
Improve desalter and waste water
treatment operations
Reduce FCC catalyst deactivation
Produce on-spec coke and heavy fuel oils
Meet effluent water quality targets
Processing high metals crudes successfully takes
a team effort. Match our specialized technology,
expertise and responsive service with your
next opportunity.
Contact www.bakerpetrolite.com today.
B e s t - i n - C l a s s
Heater tubes continued
from page 7
Pilot plant studies confirm
MILESTONE program effectiveness. Baker Petrolite is an active par-
ticipant in an ongoing delayed coker Joint
Industry Research Project with a number
of petroleum refining and process licensing companies at the University of Tulsa.
This JIP has investigated several facets of
delayed coker operation, using the US
Department of Energy pilot scale delayed
coker unit, including the study of hightemperature fouling. Test runs conducted
by the JIP using MILESTONE additive
Case history 2. High rates of fouling
in another North American delayed coker
heater resulted in rapid increases in tube
skin temperatures and a need to de-coke
the heater every 90 days. The heater was
de-coked primarily by sequentially pigging each tube pass plus occasional steam/
air de-coking. Significant throughput
reductions took place each time the heater
went through a de-coke cycle. While the
heater was online, it was being operated at
its skin temperature limits, and feed rates
were being reduced as fouling continued
resulting in ever decreasing throughput.
These issues were not only impacting
delayed coker operations and flexibility,
CSI coker stability index
furnace feed stability
1,200
West Coast refiner
Midwest refiner
furnace feed
Canadian refiner
furnace feed
1,000
Intensity
800
600
400
200
0
50
0
100
150
CSI
200
250
300
Fig. 1. Example CSI Profiles for various coker feedstocks.
National Petrochemical and Refiners Association
1,200
106th NPRA
Annual Meeting
1,000
Publisher
Mark Peters
[email protected]
Editor
Billy Thinnes
Managing Editor
Wendy Weirauch
Contributing Editor
George Ives
Design and Layout
Beth Cunningham
NPRA contacts
Bill Holbrook
Steve Higley
Hydrocarbon Processing
2 Greenway Plaza, Suite 1020
Houston, TX 77252-77046
www.HydrocarbonProcessing.com
ADVERTISERS:
Baker Petrolite.............. 5, 7, 9
Chevron Lummus Global.... 2
Criterion.............................. 16
Foster Wheeler................... 13
Haverly.................................. 8
8
HMT.................................... 12
Intercat................................ 11
KBC....................................... 4
NPRA................................... 15
Saudi Aramco.................... 10
UOP....................................... 6
Blank
MILESTONE program
800
Intensity
Conference News
Published as three daily editions, March 9/10, 11 and 12 by
Hydrocarbon Processing. If you wish to advertise on the third day
in this newspaper, or to submit a press release, please contact
the publisher via email ([email protected]) or by phone
(832-656-5341).
CSI coker stability index test
Canadian coker feed
600
400
200
0
0
20
40
60
80
CSI
100
120
140
160
180
Fig. 2. Effects of MILESTONE additives on coker feedstock asphaltene stability.
treatment strategies confirmed that the
treatment approaches developed by Baker
Petrolite in the laboratory significantly
reduced pilot coker heater fouling rates
for the feedstocks tested.
Commercial evaluations of
MILESTONE. A field test of this new
approach to controlling heater tube fouling
with chemical additives was conducted at
a North American refinery in 2005.3 This
field test proved that the chemical treatment strategies developed in the laboratory
and shown to be effective in both bench
scale and pilot plant testing could significantly reduce fouling rates in a commercial
delayed coker heater, and is now an ongoing application. Since that time, this technology has been used successfully in several
additional North American refineries.
they were also having a negative effect on
overall refinery operations. Attempts by
the plant to control the rates of fouling,
such as limiting changes in crude slate,
were only partly effective. Fig. 3 shows
a typical heater run during this time of
rapid fouling.
A MILESTONE Heater Fouling Control evaluation was performed to identify
the major fouling mechanisms. A thorough review of unit operations and crude
oil feeds was conducted by a team of refinery and Baker Petrolite personnel. Coker
feedstocks were analyzed in Baker Petrolite’s laboratory, including use of the proprietary CSI test. Results of these efforts
revealed the main cause of fouling was
inorganic materials from high metals content feeds. The CSI test results indicated
acceptable asphaltene stability, which was
Tuesday, March 11, 2008  National Petrochemical and Refining Association  106th NPRA Annual Meeting
further confirmed by feed characterization. The operations review suggested that
newly cleaned tube metal surfaces from
the regular pigging cycles may have been
accelerating tube coking rates.
Based on the investigation results and
previous Baker Petrolite experience in
high-temperature heater fouling control,
a MILESTONE additive program was
recommended to inhibit the catalytic
fouling effects seen in the furnace tubes,
and to control agglomeration and particle growth of both organic and inorganic materials in the bulk oil. Based on
Baker Petrolite recommendations, the
MILESTONE additive program was
allowed continuous high throughput
rates at the crude unit. The financial
return to the refinery has been well over
ten to one relative to the MILESTONE
program costs.
Conclusion. Continued high worldwide demand for gasoline and diesel,
plus weakness in heavy fuel oil demand
and pricing, has created significant
improvements in refinery delayed coker
operating margins in recent years. Refiners need to maximize delayed coker
throughputs to take greatest economic
advantage of these higher unit margins.
MILESTONE Heater Fouling Con-
Untreated run
1,300
Skin temperature, °F
260
1,100
1,000
220
900
180
800
Tube skin temperature
Flow
0
20
40
60
80
Days online
100
120
Throughput, b/hr/pass
300
1,200
700
Opportunity Crudes?
140
140
Fig. 3. Throughput and heater skin temperature from an untreated run.
Treated run
Tube skin temperature
Flow
Skin temperature, °F
1,200
300
260
1,100
1,000
220
900
180
800
700
Throughput, b/hr/pass
1,300
Be Prepared
0
20
40
60
80
Days online
100
120
When processing opportunity crudes increases
your overhead corrosion risk, Baker Petrolite
brings proven technology and experience to help
you reach the top safely. The Baker Petrolite
team works with you, using TOPGUARD Overhead
Corrosion Control to:
140
140
Fig. 4. Throughput and heater skin temperature with the MILESTONE Program.
trol Technology can be a valuable tool
for helping refiners meet their delayed
coker throughput targets in situations
where heater tube fouling is limiting
unit throughput. ■
LITERATURE CITED
arletta, T., “Conditions Influencing Coke
B
Formation,” Petroleum Technology Quarterly,
2004 Revamps and Operations Issue, pp. 21
- 25.
2
Falkler, T. J. and J.L. Stark,, “Index Correlates
Asphaltene Stability to Coker Furnace Fouling
Potential,” Oil & Gas Journal, Sept. 13, 2004,
pp. 34–36.
3
Stark, J., Falkler, T. and J. Dennie, “New
Technology for High Temperature Furnace
Fouling Control,” NPRA Annual Meeting paper
AM-07-61, San Antonio, Texas, March 20,
2007.
1
* MILESTONE is a trademark of Baker
Hughes Incorporated.
Increase feedstock flexibility
For more information, visit our website www.bakerhughes.com. © 2007 Baker Hughes Incorporated.
All rights reserved. EXCALIBUR is a trademark of Baker Hughes Incorporated. PET-07- 13464
implemented immediately after one of
the regular de-coking cycles.
Upon startup, the tube skin temperature equilibrated and remained steady as
the throughput was gradually increased
to the target rate. As time progressed, the
refinery was able to continue to increase
the feed rate through the delayed coker
unit, resulting in an overall increase in
throughput of about 20%. This initial
treated run is shown in Fig. 4.
This change in delayed coker operations also increased refinery throughput and flexibility, including the ability to run a wider range of crude oils
at the crude unit. Overall plant operations were significantly improved as a
result of the MILESTONE program,
by overcoming the throughput restriction at the delayed coker, which in turn
Manage increased overhead corrosion potential
Define the optimum operating envelope for
any feedstock
Quickly respond to changing unit conditions
Ensure integrity and safety of your operations
Processing opportunity crudes successfully takes
a team effort. Match our specialized technology,
expertise and responsive service with your
next opportunity.
Contact www.bakerpetrolite.com today.
B e s t - i n - C l a s s
Utilizing rigorous simulation in advanced
process control projects—Part I
J. Ferrer, AspenTech, Burlington, Massachusetts
One of the few books1 that describes
commercial model predictive control
(MPC) technologies dedicates a section
to dynamic flowsheet simulation:
“For more than 20 years, students
in process design courses and engineers
involved in process design have had as
a major tool steady-state simulation
programs such as FLOWTRAN™,
ASPEN™, PROCESS™, HYSIM™,
etc. This has removed the drudgery of
routine simulation calculations and
allowed process designers to test potential design through flowsheet simulation. Unfortunately, until recently,
there was nothing comparable available for dynamic flowsheet simulation. Individual companies have built
ad hoc dynamic flowsheet simulators
that have been applied to specific processes to great benefit, but nothing very
general was commercially available.
More recently, several new packages
for dynamic flowsheet simulation have
become available.
“Such dynamic simulation packages
are essential tools for configuring control schemes that span several units in
10
Pre-test
Check operating objectives
and constraints
Check regulatory control
(Dyn)
Identify new instrumentation
(SS)
Inferential feasibility check
(SS)
Estimate potential benefits
(SS)
Develop initial controller
design
Plant tests
Detailed design
Develop initial plant
model for SmartStep
(Dyn)
Develop the plant
model (Dyn)
Finalize controller
design
Initial tuning and
rigorous simulation
of a DMCplus
controller (Dyn)
Develop inferential
measurements
Commission
Test operation of
the DMCplus
controller (Dyn)
Train plant operators
and engineers (Dyn)
Fig. 1. All APC project phases can benefit from steady-state (SS) or dynamic (Dyn)
simulation.
a flowsheet, for studying propagation
of upsets and disturbances through a
process, for testing control strategies for
transition between product grades in
a multiproduct plant, and for designing crisis control schemes for handling
alarm situations. Clearly, dynamic flowsheet simulation will play an important
role in the design of future control systems.”
The fact is that the this book was
written in 1994, so the proposition to
use rigorous simulation as a tool for
process control is not new and the benefits have been clearly identified and
documented.2,3,4 But in today’s practice,
only a small fraction of process control
engineers are common users of rigorous
simulation.
Myths and barriers. Steady-state
and dynamic simulations can be used in
advanced process control (APC) projects, but while steady-state simulation
is widely known and adopted by almost
all operating and engineering companies, dynamic simulation is still often
seen as a difficult and time-consuming
discipline.5
Process engineers are the traditional
users of rigorous simulation, primarily
steady-state, since their objective is to
design plants at nominal conditions.
On the other hand, control engineers
are focused on maintaining these nominal conditions in a stable and operable
state. They should be the true users of
rigorous dynamic simulation, but due to
several myths, they still are not making
wide use of dynamic models for their
daily work. Let’s analyze these myths:
1. Lack of mature products. Commercial dynamic simulators were
released more than 10 years ago. From
the product perspective, dynamic simulation is a mature and well-proven technology.
2. Requires expert skills. Some
dynamic simulators are highly intuitive
and interactive, requiring little training.
See AspenTech on page 13
Tuesday, March 11, 2008  National Petrochemical and Refining Association  106th NPRA Annual Meeting
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The patented computerized IMS
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controllers have enabled refineries
to increase their profitability by
increasing throughput, improving
yields, and simultaneously reducing
overall fresh catalyst additions. This
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As a result, refiners are able to
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high fresh catalyst additions and
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Aspentech continued
from page 10
of dynamic simulation,” Proceedings of   8 Butler, D.L., et al., “Virtual Plants for
the Chemical Engineering Chemputers II
Hands-on Advanced Process Control,” ISA
Conference, March 1994.
Conference, Houston, Texas. September
 3
Stanley, P., “Dynamic simulation for insight,”
2001.
 9
Chemical Processing, December 1999.
Trivella, F. and G. Marchetti, “Integration
 4
James, G. and J. Reeves, “Dynamic simulafor innovation,” Hydrocarbon Engineering,
Use in APC projects. Deep process tion across project and facility lifecycles,” 6th November 2004.
understanding is the first step in APC World Congress of Chemical Engineering, 10 Mantelli,, V., et al., “Integration of Dynamic
Simulation and APC: a CDU/VDU case
projects and rigorous models can help.8   5 Melbourne, Australia, September 2001.
Svrcek, W.Y., D.P. Mahoney and B.R. Young,
study,” ERTC Conference, Budapest, Hungary,
Better integration of the simulation tools A Real-Time Approach to Process Control, 2000, May 2005.
with the advanced controllers facilitates John Wiley & Sons, pp 8-12.
 6
González, R. and J.M. Ferrer, “Analyzing the JoseMaria Ferrer is an advanced control and
the use.9,10
value of first-principles dynamic simulation,” simulation consultant for AspenTech. He can be
LITERATURE CITED
Hydrocarbon Processing, September 2006.
reached at [email protected].
 1
Ogunnaike, B. and W.H. Ray, Process   7 Edgar, T.F., et al., “Renovating the
Dynamics, Modeling and Control, Oxford
Undergraduate Process Control Course,”
University Press, 1994, pp 1089.
Computers and Chemical Engineering. Pick up tomorrow’s conference daily
 2
Mahoney, D.P. and B. D. Tyréus, “Applications
Elsevier. July 2006.
for the final part of this article.
NPRA_rev1:Layout 1 28/02/2008 15:28 Page 1
els should be shared between process and
control engineers. Both will benefit from
their use.
They do not require deep knowledge of
thermodynamic and numerical methods
or computer programming skills.
3. Not oriented for control. Some
dynamic simulators include in the standard object palette a complete set of
control oriented objects to reproduce
almost all basic and advanced control
structures, including MPC commercial
controllers.
4. Excessive time for modeling.
An article from 2006 analyzes modeling efforts from the user perspective.
Although the modeling time depends on
the process to model, it has been reduced
considerably.
5. Requires big computers. They are
designed to run on standard PCs or a
network of PCs.
All the above myths are related to the
software and hardware used in the simulation, but there are other educational
and ownership barriers that are even
more important when a control engineer
is asked to use rigorous simulation:
1. Educational barriers. An increasing number of chemical engineering
universities incorporate the use of rigorous simulation packages in the academic program, and a subset of those
also cover rigorous dynamic simulation.
The trend is to include more rigorous
simulation content along with existing
disciplines such as: mass and energy balances, thermodynamics, unit operations
and process control.7 Dynamic models can be used in the control course
to improve understanding of a given
process, give students experience in running complex units in real-time, change
control configurations and introduce
perturbations to the process, thus providing more “real world” experience to
the students. But most current control engineers in the process industry
have not received education on rigorous dynamic simulation at university,
so they still believe most of the myths
described above.
2. Simulation ownership barrier.
Since the first commercial simulation
packages ran only in steady-state mode,
they were primarily adopted by process
engineers. As a result, process engineers
became established as the owners and
expert users of the simulation packages.
When commercial dynamic simulation
packages appeared, they were delivered
and targeted to the same process engineers, but these engineers found only
limited value for their typical process
design work, and dynamic simulation
was only used for certain dynamic compressors studies or depressuring studies.
The historical perception of process
engineers as simulation owners (steadystate and dynamic) continues to exclude
control engineers from simulation usage.
Control engineers can realize the same
value from simulations tools as process
engineers do for their daily work. Building and maintenance of simulation mod-
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106th NPRA Annual Meeting  National Petrochemical and Refining Association  Tuesday, March 11, 2008
13
Scenes from the NPRA 2008 Annual Meeting . . .
To see more, visit www.hydrocarbonprocessing.com/hpinformer
The team from Onyx Engineering
makes a splash at the welcome
reception.
With attendance expected to exceed
1,600, registration started early
Sunday morning.
Stuart Rothenberg, editor and
publisher of The Rothenberg Political
Report, discusses the current political
scene for the general session.
Greg Raley, Pat Monsour and Jody
Monsour of Motiva Enterprises LLC
are enjoying their time in San Diego.
As the sunset colors the clouds,
John and Bonnie Leerkes, SGS
Petroleum Service, warm up by
the fire with Mini Boparai, SNCLavalin.
Takao Yoshida, Toyo Engineering
Corp., and Chandra Khulbe, National
Centre for Upgrading Technology
(Canada), find the NPRA Annual
Meeting invaluable for networking
and the exchange of ideas.
James Turner, Flour Corp., Iraj Issac Rahmim, E-Meta
Venture, Inc., and Steve McGovern, PetroTech
Consultants, chat on the pool deck at the Manchester
Grand Hyatt.
14
The opening reception was held
poolside, accompanied by San Diego’s
usual gorgeous weather.
Mary Bellinger, Sinclair Oil Corp., and
Diane Delgado, Criterion Catalysts,
enjoy the ocean breeze at the end of
a lovely day.
At Monday’s Government
Relations breakfast, Michael
Miller, director of environment
for the Electric Power Research
Institute (EPRI), provided
substantive food for thought
about challenges the electric
power industry is facing in
regard to climate change.
Twilight descends upon the welcome reception.
Tuesday, March 11, 2008  National Petrochemical and Refining Association  106th NPRA Annual Meeting
Rock-Solid
VALUES.
Safety. Reliability. Responsibility.
American refiners and petrochemical manufacturers supply a broad variety of
products that enhance individuals’ quality of life—as well as strengthen our
economy and national security.
NPRA members’ employees work hard every day to maintain safe, reliable
and affordable supplies of fuels and materials for American consumers. Our
members also reinvest billions of dollars every year to maintain and upgrade
facilities for cleaner, more efficient operations.
Today’s refining and petrochemical businesses.
The more you know about us, the better we look.
NATIONAL PETROCHEMICAL & REFINERS ASSOCIATION
I 202.457.0480 I npra.org
In Summer 2008, NPRA will move to 1667 K Street, NW « 7th Floor « Washington, D.C. 20006
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