Application Note AN/Refinery/PGC5009-EN

ABB Analytical –The Fast Process Analyzer PGC5009Controlling refinery processes to enhance profitability

Measurement made easy

Industry:Chemical, Petrochemical, Refining

IntroductionIncreasing the profitability of industrial processes is strongly driven by minimizing quality compromise, avoiding off-spec product and reprocessing. When multiple products are manufactured, the ability to increase production of the high margin products, while reducing production of lower margin products significantly enhances the bottom line. These scenarios are always present in oil refineries. Accurate and faster measurements enable the tight control needed to optimize and maintain profits. The performance and reliability of the fast simulated distillation process gas chromatograph (PGC) has several desirable features making it ideal for a variety of process control applications.

BenefitsThe PGC5009 simulated distillation analyzer can change the way blending is accomplished in the production of gasoline and diesel. Using a faster analysis technique allows the refiner to blend to a pipeline, eliminating storage costs, as well as

maximizing the blending revenues by tighter control of the process. This fast analysis time can also alert refineries if equipment is not functioning to specifications based on the quality of the products produced. Properties such as vapor lock index and drivability index both require boiling point information to control processes. Figure 1 is an example of feeds used in gasoline blending. The boiling points of these components in the distillate is crucial for refineries. Refineries producing diesel fuel are always looking for ways to improve the yield rate of high-value components, such as, ultra-low sulfur diesel (ULSD). The refinery is also continuously looking for ways to cut operating costs by increasing the life of the catalysts, and gain from additional catalyst runtime. By proper management of the feed cut point, DBTs (Dibenzothiophenes) can be excluded, which will allow for optimization of throughput, with operation at a lower unit severity. Operation at lower severity also extends catalyst life. Fast GC with simulated distillation and temperature programming capability impacts these refinery objectives by accurately and consistently monitoring the production quality of ULSD feed. The fast analysis can potentially save a refinery millions of dollars every year, by optimizing production results.

2 AD/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

Fast ResultsASTM D3710 is used for gasoline fractions up to260ºC. The standard has specific requirements forthe 19 components concentration. The chromatogram shownin Figure 4 is a calibration standard overlaid with a gasolinesample. The sample is within the calibrations initial and finalboiling points, which are required for accurate results.The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for columncooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having lower boilingranges from 55 to 538ºC. The chromatogram shownin Figure 5, is a calibration standard overlaid with a dieselsample. The calibration ranges from C5 to C32, elutingwithin 125 seconds. These examples are only the first ofmany application possibilities for the PGC5009 due to itsextraordinary speed.

Fig. 1. Example of Gasoline Blending

Fig. 2. TPGC Hardware Configuration

Heated Flame Ionization Detector

Column Module (Patented)

LSV

Fast ResultsASTM D3710 for gasoline fractions up to 260ºC

AN/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

AnalyzerThis Fast TPGC design implements a simple hardwareconfiguration consisting of three basic elements; a liquid sample vaporization (LSV) valve, a heated column module,and a flame ionization detector (FID) as shown in Figure 2.The column is contained within a column housing. It is designed for rapid thermal response, able to reach programmed temperatures ranging up to 280-320ºC, depending on the application. The micro-packed metal column has an electrical connection on each end. When a lowvoltage, direct current (DC) is applied, the column becomes a heating element, as shown in Figure 3. The column has a low thermal mass, so it will heat and cool extremely fast.

Fast ResultsASTM D3710 is used for C3 to C15 hydrocarbon gasoline fractions with temperatures up to 260ºC. The standard has specific requirements for the 19 components’ concentration. The chromatogram shown in Figure 4 is a calibration standard overlaid with a gasoline sample. The sample is within the initial and final boiling points of the calibration, which are required for accurate results.

2 AD/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

Fast ResultsASTM D3710 is used for gasoline fractions up to260ºC. The standard has specific requirements forthe 19 components concentration. The chromatogram shownin Figure 4 is a calibration standard overlaid with a gasolinesample. The sample is within the calibrations initial and finalboiling points, which are required for accurate results.The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for columncooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having lower boilingranges from 55 to 538ºC. The chromatogram shownin Figure 5, is a calibration standard overlaid with a dieselsample. The calibration ranges from C5 to C32, elutingwithin 125 seconds. These examples are only the first ofmany application possibilities for the PGC5009 due to itsextraordinary speed.

Fig. 1. Example of Gasoline Blending

Fig. 2. TPGC Hardware Configuration

Heated Flame Ionization Detector

Column Module (Patented)

LSV

Fast ResultsASTM D3710 for gasoline fractions up to 260ºC

Fast and accurate resultsASTM D3710 and D2887

2 AD/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

Fast ResultsASTM D3710 is used for gasoline fractions up to260ºC. The standard has specific requirements forthe 19 components concentration. The chromatogram shownin Figure 4 is a calibration standard overlaid with a gasolinesample. The sample is within the calibrations initial and finalboiling points, which are required for accurate results.The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for columncooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having lower boilingranges from 55 to 538ºC. The chromatogram shownin Figure 5, is a calibration standard overlaid with a dieselsample. The calibration ranges from C5 to C32, elutingwithin 125 seconds. These examples are only the first ofmany application possibilities for the PGC5009 due to itsextraordinary speed.

Fig. 1. Example of Gasoline Blending

Fig. 2. TPGC Hardware Configuration

Heated Flame Ionization Detector

Column Module (Patented)

LSV

Fast ResultsASTM D3710 for gasoline fractions up to 260ºC

2 AD/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

Fast ResultsASTM D3710 is used for gasoline fractions up to260ºC. The standard has specific requirements forthe 19 components concentration. The chromatogram shownin Figure 4 is a calibration standard overlaid with a gasolinesample. The sample is within the calibrations initial and finalboiling points, which are required for accurate results.The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for columncooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having lower boilingranges from 55 to 538ºC. The chromatogram shownin Figure 5, is a calibration standard overlaid with a dieselsample. The calibration ranges from C5 to C32, elutingwithin 125 seconds. These examples are only the first ofmany application possibilities for the PGC5009 due to itsextraordinary speed.

Fig. 1. Example of Gasoline Blending

Fig. 2. TPGC Hardware Configuration

Heated Flame Ionization Detector

Column Module (Patented)

LSV

Fast ResultsASTM D3710 for gasoline fractions up to 260ºC

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for column cooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having boiling pointsfrom 55 to 538ºC. The chromatogram shown in Figure 5 is a calibration standard overlaid with a diesel sample. The calibration ranges from C5 to C32, eluting within 125 seconds. These examples are only the first of many application possibilities for the PGC5009, which takes advantage of its extraordinary application speed.

2 AD/Refinery/PGC5009 | Fast Process Analyzer PGC5009 | Process Gas Chromatographs

Fast ResultsASTM D3710 is used for gasoline fractions up to260ºC. The standard has specific requirements forthe 19 components concentration. The chromatogram shownin Figure 4 is a calibration standard overlaid with a gasolinesample. The sample is within the calibrations initial and finalboiling points, which are required for accurate results.The highest boiling point component C15 elutes within 140seconds, leaving the remainder of cycle time for columncooling and boiling point calculations.

ASTM D2887 is used for diesel fractions having lower boilingranges from 55 to 538ºC. The chromatogram shownin Figure 5, is a calibration standard overlaid with a dieselsample. The calibration ranges from C5 to C32, elutingwithin 125 seconds. These examples are only the first ofmany application possibilities for the PGC5009 due to itsextraordinary speed.

Fig. 1. Example of Gasoline Blending

Fig. 2. TPGC Hardware Configuration

Heated Flame Ionization Detector

Column Module (Patented)

LSV

Fast ResultsASTM D3710 for gasoline fractions up to 260ºC

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AN/Refinery/PGC5009

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

Process Gas Chromatographs | Fast Process Analyzer PGC5009 | AD/Refinery/PGC5009–EN 3

Conclusion:Tight control of blending operations by the fast simulateddistillation TPGC is possible based on the speed at which ananalysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy. As a result of thisanalytical speed, these process analyzers become integral toimproved process control strategies and distillate blendingoperations, which could result in refineries savings millionsevery year.

Fig. 5. Diesel Calibration and Sample Overlay

Fig. 3. TPGC Column Module

Fig. 4. Gasoline Calibration and Sample Overlay

Micro-Packed Metal Column

Direct Heating Electrical Connection

Cool Down Air In + Out

ConclusionTight control of blending operations by utilizing the fast simulated distillation is possible based on the speed at which an analysis is conducted. This speed is possible without sacrificing measurement capabilities or accuracy.

As a result of the short analysis cycle time, the PGC5009process analyzers become integral to improved process control strategies and distillate blending operations, which can result in refineries saving millions every year.

AD

/Refi

nery

/PG

C50

09–E

N

08.2

016Contact us

DS

/WM

–EN

Rev

.O01

.201

3ABB LimitedProcess AutomationOldends LaneStonehouseGloucestershire GL10 3TAUKTel: +44 1453 826 661Fax: +44 1453 829 671instrumentation@gb.abb.com

ABB Inc.Process Automation125 E. County Line RoadWarminsterPA 18974USATel: +1 215 674 6000Fax: +1 215 674 7183

ABB Engineering (Shanghai) Ltd.Process AutomationNo. 5, Lane 369, Chuangye Road201319, Shanghai,P.R. ChinaPhone: +86 (0) 21 6105 6666Fax: +86 (0) 21 6105 6992Mail:china.instrumentation@cn.abb.com

www.abb.com

NoteWe reserve the right to make technical changes ormodify the contents of this document without priornotice. With regard to purchase orders, the agreedparticulars shall prevail. ABB does not accept anyresponsibility whatsoever for potential errors orpossible lack of information in this document.

We reserve all rights in this document and in thesubject matter and illustrations contained therein.Any reproduction, disclosure to third parties orutilization of its contents in whole or in parts – isforbidden without prior written consent of ABB.

Copyright© 2013 ABBAll rights reserved

3KXF211101R1001

Sales

Service

Software

Contact us

ABB Inc. Process Automation Analytical Measurements 843 N. Jefferson Street Lewisburg, WV 24901 USATel.: 1 304 647 4358Fax: 1 304 645 4236 www.abb.com/measurementwww.abb.com/contacts

NoteWe reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreedparticulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents - in whole or in parts – is forbidden without prior written consent of ABB.

Copyright© 2016 ABBAll rights reserved

Contact us

DS

/WM

–EN

Rev

.O01

.201

3ABB LimitedProcess AutomationOldends LaneStonehouseGloucestershire GL10 3TAUKTel: +44 1453 826 661Fax: +44 1453 829 671instrumentation@gb.abb.com

ABB Inc.Process Automation125 E. County Line RoadWarminsterPA 18974USATel: +1 215 674 6000Fax: +1 215 674 7183

ABB Engineering (Shanghai) Ltd.Process AutomationNo. 5, Lane 369, Chuangye Road201319, Shanghai,P.R. ChinaPhone: +86 (0) 21 6105 6666Fax: +86 (0) 21 6105 6992Mail:china.instrumentation@cn.abb.com

www.abb.com

NoteWe reserve the right to make technical changes ormodify the contents of this document without priornotice. With regard to purchase orders, the agreedparticulars shall prevail. ABB does not accept anyresponsibility whatsoever for potential errors orpossible lack of information in this document.

We reserve all rights in this document and in thesubject matter and illustrations contained therein.Any reproduction, disclosure to third parties orutilization of its contents in whole or in parts – isforbidden without prior written consent of ABB.

Copyright© 2013 ABBAll rights reserved

3KXF211101R1001

Sales

Service

Software

AN

/Ref

iner

y/P

GC

5009

–EN

10.

2016