© ABB Group February 25, 2015 | Slide 1

Oil & Gas IndustryA new simple and robust process FT-NIR Spectrometer with small footprint and extended maintenance interval

Thomas Buijs, Michael B. Simpson, ABB Quebec, BU–MA Analytical Measurements

What is Process FT-NIR ?

Applicable in general to most refinery hydrocarbon streams

Final Product Blending – Gasoline & Diesel

Naphtha Feed & Conversion Units – CCR, HDT, ISOM, NCC

HF Alkylation – HF, iC4, Olefins

Crude Oil, Base Oils & Upgrader Units – CDU, HCK, FCC, LBU, RDS

It provides

Real-time multi-property physical and chemical analyses

RON, MON, Cetane, ASTM D86 Distillation, T95, E70, E100, Cloud Point,

Freeze Point, Pour Point, Aromatics, Benzene, KV40, PIONA(Paraffins,

Isoparaffins, Olefins, Napthenes, Aromatics), RVP etc

On multiple physical streams per Analyser

And is ideal for linking to APC (low-noise, rapid response)

A high-quality input to full economic optimization models

© ABB Group February 25, 2015 | Slide 3

Applications - Refining

Blending Solutions

Gasoline, Diesel, Crude, Fuel Oil

In-line release

Conversion Unit / Distillation Solutions

Crude Feed characterisation

Crude Assay (Lab)

Crude Distillation Unit (CDU) Rundown – Light Naptha,

Heavy Naphta, Kerosene, Light Gas Oil, Heavy Gas Oil

Unit Feed and Product characterisation

Naptha Complex applications – Reforming Unit,

Isomerisation Unit, Naphtha Hydrotreating

Fluid Catalytic Cracker (FCC) feed and Light Cycle Oil,

Light Cat Naphta, Heavy Cat Naphta

Vacuum Gas Oil, Base Oils

C4 Units, MTBE, Butadiene

Cumene / Phenol

LPG

HF Acid Alkylation recycle

Ethylene plant feed (naphtha)

Process FT-NIR – project deliveryMajor influences on Project Delivery

Sample take-off & sample transport

Analyzer location & environment

Sample conditioning system

Sample flow cells or probes

Analyzer performance criteria

Application configuration & interface to DCS

Calibration & method development

On-site Laboratory validation

System validation

Life cycle management

Process hydrocarbon stream analyticsFT-NIR

The Refinery Naphtha Complex

The naphtha conversion units in a refinery upgrade,

hydrotreat and convert natural naphtha from the Crude

Distillation Unit (CDU) or cracked naphthas from the Fluid

Catalytic Cracker (FCC) and Hydrocracker (HCK) units to

create higher-value light hydrocarbon gasoline blending

components

These include the Naphtha Hydrotreater (HDT),

Isomerization Unit (ISOM), Catalytic Reforming Unit (CCR)

and in the Olefins (Ethylene) Unit the Naphtha Steam

Cracker (NSC)

All units have a FEED and a PRODUCT side, and most

use a FURNACE and CATALYST to do chemistry

Furnace severity, catalyst run-lengths, product quality,

throughput and energy consumption all impact Unit

economics and real-time on-line FT-NIR can significantly

improve ROI.© ABB Group February 25, 2015 | Slide 6

ROI in the Naphtha Complex

The main control objective for all naphtha conversion units

is to maximise Unit throughput, maintain product quality

while avoiding excessive furnace severity leading to

catalyst degradation and furnace tube coking

To achieve this real-time feed and rundown analysis is

essential

Naphtha feed streams can in principle be measured on-line

by GC techniques, but the qualities required for effective

control include PIONA and %Distillation, which require long

elution times.

FT-NIR offers much faster and more repeatable analysis

The benefits include tight furnace control, improved

reformate RON and Benzene / Aromatics quality, more

flexible response to naphtha feed transitions and extended

catalyst run-lengths. Octane and furnace severity

management alone correspond to $M/yr benefits© ABB Group February 25, 2015 | Slide 7

© ABB Group February 25, 2015 | Slide 8

HP260X Process FTNIR AnalyzerNaphtha Conversion Unit Feed & Recycle

Large multichannel system

Purged temperature controlled enclosure

© ABB Group February 25, 2015 | Slide 9

Introducing Talys ASP400 Ex Process FTNIR AnalyzerNaphtha Conversion Unit Feed / Recycle

Compact single channel system

Small Footprint:

Fully integrated in single enclosure.

Unit may be either shelf or wall mounted.

No Analyzer PC required (Embeded processor for

sensor like integration)

ExP purge controller integrated with base

enclosure

Low cost of ownership with virtually no scheduled

maintenance for 5-years

On-board HMI display and embedded Controller

Full ModBUS TCP/IP, RTU and OPC connectivity to

DCS

Hardwired I/O and pneumatics for sample system

control in ExD ABB PLC

© ABB – Analytical Measurement Group February 25, 2015 | Slide 10

APPLICATIONS

• Naphtha Complex (CCR, ISOM)

• Hydrotreating (HDS, HDT)

• Naphtha Steam Cracking

• MOGAS blending

PROPERTIES

• Composition – PIONA, C-number, BTX,

Aromatics, Olefins, C4s, PAHs

• Ignition Properties – RON, MON, Cetane

Number & Index, Flash Point

• Cold Flow Properties – Pour Point, Cloud Point,

Freeze Point, CFPP

• Distillation & Physical Properties – D86, KV,

API, TBP

Introducing Talys ASP400 Ex Process FTNIR AnalyzerNaphtha Conversion Unit Feed / Recycle

FTIR Applications in Naphtha Conversion Units

© ABB Group February 25, 2015 | Slide 11

Light Naphtha Feed

to ISOM unit

Reformate

Rundown

from CCR

Isomerate

Rundown

from ISOM

Heavy

Naphtha Feed

to CCR unitHF Acid &

iC4 Recycle

On HFU

© ABB – Analytical Measurement Group February 25, 2015 | Slide 12

Refinery Process UnitsCCR – Catalytic Reforming Unit

Improve CCR operation and flexibility, maximise

reformate octane barrels, and lengthen catalyst

run-times by better severity control with on-line

FT-NIR analyzers

Rapid response to naphtha feed quality changes

and switches from gasoline to BTX operation

Heavy Naphtha Feed

-PIONA, T95, RVP

Reformate Product Rundown

- RON, benzene, aromatics, RVP

© ABB – Analytical Measurement Group February 25, 2015 | Slide 13

Refinery Process UnitsISOM – Naphtha Isomerisation Unit

Improve ISOM unit operation and flexibility,

maximise isomerate yield and quality, for better

supply of gasoline blending feedstock

Rapid detection of naphtha feed quality changes

due to CDU swop-over and cut-point variation

Light Naphtha Feed

-PIONA, T95, RVP

Isomerate Product Rundown

- RON, RVP

Refinery Process UnitsNaphtha Steam Cracker – Olefins Unit

Natural naphtha feed variation in quality

Often blended on-line, various sources

(CDU, NG condensate etc)

Feed mixed with steam and briefly cracked

at 850degC

Very high speed, high temperature process

Huge downstream compressor requirement

Light / Heavy naphtha transitions can

impact coking rate or flood downstream

compressors / de-methaniser

Very energy-intensive: heat-recovery and

steam production important

PyGas by-product

as Petrochems Feed

© ABB – Analytical Measurement Group February 25, 2015 | Slide 15

Refinery Process UnitsNaphtha Steam Cracker – Olefins Unit

Steam-Cracking Optimisation

Real-time fast analysis of steam cracker

naphtha feed

Provides PIONA, %Distillation and C-number

breakdown analyses

Enables efficient use of SPYRO feed-forward

optimiser for management of COT control

Minimise coil coking, side-products

Correctly manage cracking severity to match

downstream volumetric flow (compressor)

constraints

Maintain optimal P/E ratios in response to feed

quality variation

PIONA estimation by FT-NIR

P

N

O A (low)

A (high)I

C-number Breakdown for SPYRO Optimiser

iC6 v%

R2 = 0.96

SECV=0.26

8

9

10

11

12

13

8 9 10 11 12 13

pC6 v%

R2 = 0.98

SECV=0.21

7

8

9

10

11

12

13

14

7 8 9 10 11 12 13 14

-

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

PC4PC5

PC6PC7

PC8

Tot Para

ffin

IC4

IC5

IC6

IC7

IC8

Tot i-P

araffi

n

Tot Ole

finNC8

Tot Cyclo

paraffi

n

Tot Aro

matic

s

vol % FTIR

Actual

C-number estimation by FT-NIR

iC6 v%

R2 = 0.96

SECV=0.26

8

9

10

11

12

13

8 9 10 11 12 13

pC6 v%

R2 = 0.98

SECV=0.21

7

8

9

10

11

12

13

14

7 8 9 10 11 12 13 14

pC8 v%

R2 = 0.98

SECV=0.25

0

1

2

3

4

5

6

7

8

0 2 4 6 8

iC8 v%

R2 = 0.99

SECV=0.28

2

4

6

8

10

12

2 4 6 8 10 12

PIONA estimation by FT-NIR on-line data (w/w%)

0

10

20

30

40

50

60

70

80

n-Paraffins

iso-Paraffins

Olefins

Naphthenes

Aromatics

Total C4

T10

T30

T50

Example LPG analysis iC5 in C3/C4 stream

Example – discrimination of c6 isomers in naphtha

FT-NIR spectra of

2,3-dimethylbutane

2-methylpentane

3-methylpentane

n-hexane

methyl-cyclopentane

FT-NIR spectra of

analysed samples

for calibration set

Example – discrimination of c6 isomers in naphtha

© ABB – Analytical Measurement Group February 25, 2015 | Slide 23

Introducing Talys ASP400 Ex Process FTNIR AnalyzerCome and see Talys at IFPAC booth 204