2014 software global client conference - …iom.invensys.com/en/softwaregcc14presentations/simsci/ss...

2014 Software Global Client Conference

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 data-

rec 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

25 Confidential Property of Schneider Electric

Related Support, Services & Training

> 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.

Support

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.

> Reactor Model Initial Tuning Services

> Model Maintenance Services

Services

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 petro-

components.

●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 software global client conference - …iom.invensys.com/en/softwaregcc14presentations/simsci/ss...

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