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Using Engineering Simulations to Sustain

Refining Profit Margins


Gautam Pradhan, Sr. Principal Business Consultant

Agenda
Why use Engineering Simulations in Refining?
What is HYSYS Petroleum Refining?

Improved Components

Petroleum Properties

Assay Management

Reactors

Refinery Wide Models

Planning and Scheduling Support

Benefits of Refinery Wide Models

Success Stories

Demos

Crude distillation with improved properties and assays

Refinery Reactors (FCC, Reformer)

Refinery Wide Models

Planning and Scheduling Support


2015 Aspen Technology, Inc. All rights reserved.

Why Use Engineering Simulations in Refining?


What do you tell the refinery manager in one minute?
How does it make money for the refining owner/operator?

Engineering simulations are used to predict yields and properties


Predicts how to turn crude oil into products which is the main business of refining
If you dont use simulations, you are guessing about key decisions for feed stocks and operating
conditions
Simulations can play a key role in refinery profit margin analysis

2015 Aspen Technology, Inc. All rights reserved.

How to Use Engineering Simulations


Planning and scheduling support (Aspen PIMS and Aspen Petroleum Scheduler)
Shared assays allow Engineering models to validate PIMS predictions of CDU performance
Engineering simulations improve PIMS assay table and reactor submodel accuracy
Refinery wide engineering model partners with PIMS for more accurate decisions

Standalone unit models (crude distillation and reactors)


Predict changing feed stocks
Predict changing catalysts (FCC, semi-regen reformer)
Optimize plant set points
reactor temperatures, column cut points
Equipment revamp studies

Multi-unit and refinery wide models


Predict gasoline or diesel production train

Predict new refinery configurations

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aspenONE Engineering
focused on process engineering and optimization

The refining branch


HYSYS Petroleum Refining
focused on margin analysis

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Refining Features Predict Yields and Properties

Aspen
HYSYS
Petroleum
Refining
(RefSYS)

Refining Components
Petroleum Properties

Assay Management
Refinery Reactors

Multi-unit Simulation
PIMS & APS Support

Aspen HYSYS

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Traditional Hypos (Pseudo-components)


Produced by HYSYS Oil Manager
Crude - 1

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

Crude Feed after


Mixer

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

Crude Oil Mixer

Crude - 2

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

Each feed has a separate set of hypos


Flowsheet stream compositions are awkward
combination of all feed hypos
Hard to manage yields and properties across the
flowsheet
Hypo properties cannot change in flowsheet

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Aspen HYSYS Petroleum Refining Hypos


Produced by Assay Manager
Crude - 1

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

Crude Feed after


Mixer

Crude Oil Mixer

Crude - 2

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

Feed share the same hypos

Flowsheet uses a single set of hypos

Easier to manage yields and properties across


flowsheet

Hypo properties change in the flowsheet.

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Petroleum Properties
A Complete Set is Available for Hypos and Streams

Over 50 Petroleum Properties

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How Can AspenTech Help Refineries Maximize Profits?


Maximize Profit Margins from rigorous
profit margin analysis.

Sustain Profit Margins by ensuring


planning models are up to date.

Integration of Aspen PIMS and Aspen HYSYS allows

Quick development of an Easy to Use Refinery Wide Process Model for


Margin Analysis

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Easier updates of Aspen PIMS Planning Models using Aspen HYSYS

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Aspen Assay Manager


Process Engineers and Planners Share Assays

Components for Aspen


HYSYS Petroleum Refining

Assay Manager

Lab Data

Share
Assays
with
.AFAM
file

Main and Swing Cuts for


Aspen PIMS
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Crude Distillation Model Support


HYSYS Petroleum Refining used to Calibrate Assay Manager Fractionation Effects

HYSYS Petroleum
Refining Model

Plant
data

PIMS Assay Manager


Main and Swing Cuts
Fractionation
Effects
Cut points and
Fractionation
Factors
(SI Factors)

Accurate representation of non-ideal


separation achieved through integration of
Engineering and Planning Distillation Models
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PIMS Assay Table

Crude Distillation (CDU) Support: Two Steps


Step 1: Yields (Cut Points)
Use HYSYS Petroleum Refining model to get product cut points
Cut points define the yields used in PIMS Assay Tables

Step 2: Properties (SI Factors)


Use HYSYS Petroleum Refining model to get fractionation factors (SI factors) that match plant
product overlaps
Use fractionation factors to improve property predictions that are sensitive to fractionator overlap
like cloud point and sulfur.

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Aspen HYSYS Petroleum Refining Model for Cut


Points and SI Factors
Blend CDU products

to get crude assay

PIMS LP crude
model in HYSYS
Petroleum Refining
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Fractionation Model Provides Fractionation Factors (SI


Factors) for Product Overlaps

SI Factors for PIMS Main


and Swing Cuts

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Cut points and SI Factors In PIMS Assay Manager


Used to Cut New Main and Swing Cuts

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Aspen HYSYS Petroleum Refining Reactors

Naphtha Hydrotreater

Atmospheric Distillation

Kerosene Hydrotreater

Diesel Hydrotreater

GasOil Hydrotreater

Vacuum Distillation

Resid Hydrotreater

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Alkylation

Fluid Catalytic
Cracking (FCC)

Cat. Gas. Hydrotreater


Di-Olefin HDTR

Selective HDS

Delayed Coker
Visbreaker

Catalytic Reformer

Isomerization

Hydrocracker

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Product Blending

Gas Processing

Aspen HYSYS Petroleum Refining Reactors


Fluid Catalytic Cracking (FCC)

Select FCC from palette and place on flowsheet.


Model is reactor and regenerator with heat balance.

Feed and reactions based on 21 lumps.


Reactor can be one or two risers with dilute phase.
Regenerator can be one or two stage.

Model contains calibration for matching plant data.

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Aspen HYSYS Petroleum Refining Reactors


Naphtha Reforming (Reformer)

Select Reformer from palette and place on flowsheet.


Model is reactor beds and recycle gas system.

Feed and reactions based on 50 lumps.


Reactor can be three to six beds.
Model options include semi-regenerative and continuous.

Model contains calibration for matching plant data.

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Aspen HYSYS Petroleum Refining Reactors


Isomerization (C4/C5/C6)

Select Isomerization from palette and place on


flowsheet.
Model is standalone reactor bed. Use two reactors for
lead and lag reactor systems.

Feed and reactions based on 50 lumps.


Supports C4/C5/C6 isomerization.
Normally used in flowsheet with reformer.

Default kinetics may need manual calibration to match


plant.

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Aspen HYSYS Petroleum Refining Reactors


Heavy Oil Hydroprocessing (HYSYS Hydrocracker)

Select Hydrocracker from palette and place on flowsheet.

Model is reactors and recycle gas system.


Feed and reactions based on 97 lumps.
Each reactor can be one to six beds.

Hydrotreating and hydrocracking are modelled.


Feeds can be distillate, gas oils or resids.
Model contains calibration for matching plant data.

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Aspen HYSYS Petroleum Refining Reactors


Naphtha (Light Oil) Hydroprocessing (NHT and CGH)

Select hydrotreater from palette and place on flowsheet.


Three reactors are available.
1.

NHT reactor is for treating reformer feed

2.

Cat Gas SHU is for FCC naphtha selective hydrotreating

3.

Cat Gas HDS is for FCC naphtha desulfurization

Each reactor is a standalone bed

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Aspen HYSYS Petroleum Refining Reactors


Thermal Cracking (Delayed Coker and Visbreaker)

Select from palette and place on flowsheet.

Feed and reactions based on 37 lumps.


Coker is feed heater with drum.
Visbreaker is feed heater with optional soaker.

Model contains calibration for matching plant data.

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Aspen HYSYS Petroleum Refining Reactors


Alkylation (H2SO4 and HF)

Select from palette and place on flowsheet.


Feed and reactions based on 49 lumps.
Models for H2SO4 and HF.
Models are standalone reactors.

User adds IC4 recycle and fractionation system.


Model contains calibration for matching plant data.

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Aspen HYSYS Petroleum Refining Reactors


Short Cut Reactor (PIMS Reactor LP Submodel)

Select from palette and place on flowsheet.


Short cut reactor model based on PIMS reactor LP
submodel.
Uses Base & Delta LP method
Reduces complexity in multi-unit or refinery wide models
by replacing rigorous reactor models

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Reactor Support
Process Data from Aspen HYSYS Petroleum Refining Drives Aspen PIMS Submodel Coefficient Formulas

Process data table drives submodel


coefficients
Case Study Output from HYSYS
Petroleum Refining transfers to
PIMS Submodel sheet

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Refineries Run on Tight Profit Margins

Profit Margin Analysis is CRUCIAL

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Challenge with rigorous refinery wide model


Very Cumbersome Models

Long Time to Develop

Long Run Time to Converge


Demands High Expertise to
Develop and Use Models
Keeps Refineries DEPENDENT on Expensive Consultants to Make and Use these Models

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Aspen Techs Solution


Leverage the Integration between Aspen PIMS & Aspen HYSYS to

Reproduce the
refinery wide
PIMS Model in
Aspen HYSYS

Selectively
upgrade rigorous
sub model units

Use the Refinery


wide Model to find
ways to boost
profit

A Refinery wide model that is a mix of shortcut and rigorous sub-models keeps it

Manageable and Accurate!


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Refinery wide model can be used to

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Pin down specific process areas for profit improvement

Come out with alternative improvement plans

Predict impact of each alternative on refinery profit

2015 Aspen Technology, Inc. All rights reserved.

So the gist of it is.


Refineries can maximize profits from analysis using refinery wide process model.

We can Deliver a Refinery wide model which is


Easier and faster to develop
Accurate
Much faster to run
when compared to our competitors.
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CASE STUDY: Taiyo Oil Company Ltd.

Refinery margin improvement


Business Challenge & Objective

Results & Benefits

The complex business and operational challenges for


refinery planning and scheduling.
Improving the accuracy of yield in scheduling.
Understanding RFCC behavior for improving operational
constraints.

Data available in timely manner improves crude selection.


Model enabled profitable operation from the startup.
Continuous review and update of the RefSYS/LP model increased profitability.
A 12.7% profit increase reported for the refinery.

Solution Overview

Aspen HYSYS Petroleum Refining (RefSYS) to model


multiple units including crude distillation and reactor units.
Aspen HYSYS (RefSYS) Reformer model improved LP
models for Aspen PIMS and Aspen Petroleum Scheduler
(Orion).
Aspen HYSYS (RefSYS) CatCracker model helped to plan
plant operating strategy and update the RefSYS/LP model.
Aspen HYSYS Petroleum Refining (RefSYS) incorporates
plant data to calibrate reactor models.
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Ref: Koichi Takeda, Taiyo Oil Co. Ltd.,


AspenTech Global Conference: OPTIMIZE 2011,
Washington, D.C., May 2011

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CASE STUDY: BP
Hydrocracking model to support crude selection process
Business Challenge & Objective

Results & Benefits

Update refinery site heat and mass balance.


Unit health monitoring of yields and catalyst bed activity.
Production and planning support for crude selection.
Identifying Hydrocracking model uncertainties and
performance gaps.

Crude Selection: Model used to assess


alternative crudes at a BP site for
benefits of $20+ million by processing
these opportunity crudes

Planning Support: Margin improvements


from LP submodel updates and other
process changes:

Solution Overview

Aspen HYSYS Petroleum Refining used to simulate the entire


complex.
Aspen HYSYS Hydrocracker to simulate multiple reactor
units.
Aspen Simulation Workbook (ASW) for input data and link to
BPs Excel-based LP vector generation tool (Autovec) for
Aspen PIMS.
Uncertainty analysis performed with Deterministic Equivalent
Modeling Method (DEMM).
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$71,000 per day summer

$57,000 per day winter

Other process modeling projects to


support operations.

Refinery heat and weight balances

Unit health monitoring

Revamps and new unit evaluation

2015 Aspen Technology, Inc. All rights reserved.

Ref: Bruce Briggs, et. al., BP


Refining Technology,
AspenTech Global
Conference: OPTIMIZE
2011,Washington, D.C., May
2011; and AspenTech
Webinar: Improve Refinery
Margins with
Hydroprocessing Models, Jan
2012.

Success Story : GS Caltex


Applications of CCR Models
Notes:
This was molecular management project to introduce molecules into PIMS to drive
feedstock selection for BTX production
Old PIMS used reformer shift vectors like N=2A
New PIMS used reformer shift vectors based on BTX precursors like MCP.
These molecules were added to PIMS assay tables to drive shift vectors in four reformer
submodels for the four reformers in the plant
RefSYS reformer was used to develop the submodel data for all four reformers.

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GS Caltex
Planning and scheduling model updates
Challenge

Solution

Result

Objective: Improve refinery


margins
Improve planning model for
increased planning accuracy of
aromatics complex
Better prediction of aromatic yields

Ref: Y-J Shin, GS Caltex,


AspenTech User Conference, Berlin, April 2008
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2015 Aspen Technology, Inc. All rights reserved.

GS Caltex
Planning and scheduling model updates
Challenge

Result

Solution

Aspen HYSYS Petroleum Refining,


Crude Manager (for assays),
Reformer model, ASW (with link to
Aspen PIMS)

Aspen HYSYS Petroleum Refining


model of 4 crude units and 4
catalytic reformers

Ref: Y-J Shin, GS Caltex,


AspenTech User Conference, Berlin, April 2008
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2015 Aspen Technology, Inc. All rights reserved.

GS Caltex
Planning and scheduling model updates
Challenge

Result

Solution

Significantly improved predictive


capability
Model now predicts more accurate
yields (within 99% accuracy vs.
97.5% before)
Better visibility into feedstock
selection options

Optimized product quality for units


downstream of reformer
Ref: Y-J Shin, GS Caltex,
AspenTech User Conference, Berlin, April 2008
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2015 Aspen Technology, Inc. All rights reserved.

CEPSA
Rigorous reactor modeling for operations and capital projects
Challenge

Solution

Quick and accurate assessment of


opportunities to improve FCC
performance and refinery margins:
Revamps and other capital
projects
New catalyst selection
New feedstock scenario

LP planning model updates

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Result

CEPSA
Rigorous reactor modeling for operations and capital projects
Challenge

Result

Solution

Aspen HYSYS Petroleum Refining


Aspen HYSYS CatCracker
AspenTech services

Ref: Modesto Miranda, CEPSA,


AspenTech User Conference, Berlin, April 2008
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2015 Aspen Technology, Inc. All rights reserved.

CEPSA
Rigorous reactor modeling for operations and capital projects
Challenge

Result

Solution

Unit revamps and new catalyst


selection increased profit by 18,000
/day
Other lifecycle applications of the
unit model for:
Feedstock optimization for 8,000
/day improved margin

Improved LP model for FCC


planning and scheduling
purposes
Ref: Modesto Miranda, CEPSA,
AspenTech User Conference, Berlin, April 2008
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2015 Aspen Technology, Inc. All rights reserved.

Valero
CDU Unit Model
Note :

This refinery is in New Jersey and is now owned by PBF.


Valero used this model to evaluate crude switches on the CDU.
When crude mix changed, they ran model to predict product rates to give the operators
guidance on where to set APC targets
Also, they checked key constraints like ovhd reflux pump HP to make sure they did not
blow this constraint.
If the HP was too high, they would change the cutpoint spec to reduce flow and not cut the
feedrate.

Management did not care about the overhead 95% point but they did care about unit feed
rate.
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Valero
Deploy models to operations
Challenge

Solution

Detect and troubleshoot problems


early
Reduce operating costs by better
insight into the impact of crude
blend changes on operating
conditions
Enable operations to perform whatif scenarios and increase agility in
decision making
Make faster and better operating
decisions in response to disruptions
or changes
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Result

Valero
Deploy models to operations
Challenge

Result

Solution

Deploy engineering models in


operations in an MS Excel
environment
Aspen Simulation Workbook (ASW)
interface driven by Aspen HYSYSbased model

Ref: David Schumann & Gregory Davis, Valero,


NPRA Annual Meeting, March 2009 and AspenTech User
Conference, Houston, May 2009
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Valero
Deploy models to operations
Challenge

Result

Solution

Analysis times for new feedstock


and operating scenarios reduced
from days to minutes
Robust models used by operating
personnel through Excel interface
to improve decision making

Ref: David Schumann & Gregory Davis, Valero,


NPRA Annual Meeting, March 2009 and AspenTech User
Conference, Houston, May 2009
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2015 Aspen Technology, Inc. All rights reserved.

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