07 - Benefits of Rapid Deployment of Refinery Wide Model - Gautam

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
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
aspenONE Engineering
focused on process engineering and optimization
The refining branch

HYSYS Petroleum Refining
focused on margin analysis
Refining Features Predict Yields and Properties
Aspen
HYSYS
Petroleum
Refining
(RefSYS)
Refining Components
Assay Management
Refinery Reactors
Multi-unit Simulation
PIMS & APS Support
Aspen HYSYS
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
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.
A Complete Set is Available for Hypos and Streams
Over 50 Petroleum Properties
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
10
Easier updates of Aspen PIMS Planning Models using Aspen HYSYS
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
11
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
12
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.
13
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
14
Fractionation Model Provides Fractionation Factors (SI

Factors) for Product Overlaps
SI Factors for PIMS Main

and Swing Cuts
15
Cut points and SI Factors In PIMS Assay Manager

Used to Cut New Main and Swing Cuts
16
Aspen HYSYS Petroleum Refining Reactors
Naphtha Hydrotreater
Atmospheric Distillation
Kerosene Hydrotreater
Diesel Hydrotreater
GasOil Hydrotreater
Vacuum Distillation
Resid Hydrotreater
17
Alkylation
Fluid Catalytic
Cracking (FCC)
Cat. Gas. Hydrotreater

Di-Olefin HDTR
Selective HDS
Delayed Coker
Visbreaker
Catalytic Reformer
Isomerization
Hydrocracker
Product Blending
Gas Processing

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.
18

Naphtha Reforming (Reformer)
Select Reformer from palette and place on flowsheet.

Model is reactor beds and recycle gas system.

Reactor can be three to six beds.
Model options include semi-regenerative and continuous.
19

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.

Supports C4/C5/C6 isomerization.
Normally used in flowsheet with reformer.
Default kinetics may need manual calibration to match

plant.
20

Heavy Oil Hydroprocessing (HYSYS Hydrocracker)
Select Hydrocracker from palette and place on flowsheet.
Model is reactors and recycle gas system.

Each reactor can be one to six beds.
Hydrotreating and hydrocracking are modelled.

Feeds can be distillate, gas oils or resids.
21

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
22

Thermal Cracking (Delayed Coker and Visbreaker)
Select from palette and place on flowsheet.

Coker is feed heater with drum.
Visbreaker is feed heater with optional soaker.
23

Alkylation (H2SO4 and HF)

Models for H2SO4 and HF.
Models are standalone reactors.
User adds IC4 recycle and fractionation system.

24

Short Cut Reactor (PIMS Reactor LP Submodel)

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
25
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
26
Refineries Run on Tight Profit Margins
Profit Margin Analysis is CRUCIAL
27
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
28
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!

29
Refinery wide model can be used to
30
Pin down specific process areas for profit improvement
Come out with alternative improvement plans
Predict impact of each alternative on refinery profit
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.
31
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.
32
Ref: Koichi Takeda, Taiyo Oil Co. Ltd.,

AspenTech Global Conference: OPTIMIZE 2011,
Washington, D.C., May 2011
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).
33
$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
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.
34
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
35
GS Caltex
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

36
GS Caltex
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
37
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
38
Result
CEPSA
Challenge
Result
Solution
Aspen HYSYS Petroleum Refining

Aspen HYSYS CatCracker
AspenTech services
Ref: Modesto Miranda, CEPSA,

39
CEPSA
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,
40
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.
41
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
42
Result
Valero
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
43
Valero
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
44
Thank You
AspenTech is ranked as a top
innovative growth company

07 - Benefits of Rapid Deployment of Refinery Wide Model - Gautam

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Using Engineering Simulations to Sustain

Refining Profit Margins

Refinery Wide Models

Planning and Scheduling Support

Benefits of Refinery Wide Models

Crude distillation with improved properties and assays

Refinery Reactors (FCC, Reformer)

Refinery Wide Models

Planning and Scheduling Support

Why Use Engineering Simulations in Refining?

Engineering simulations are used to predict yields and properties

2015 Aspen Technology, Inc. All rights reserved.

How to Use Engineering Simulations

Standalone unit models (crude distillation and reactors)

Multi-unit and refinery wide models

Predict new refinery configurations

2015 Aspen Technology, Inc. All rights reserved.

The refining branch

2015 Aspen Technology, Inc. All rights reserved.

Refining Features Predict Yields and Properties

2015 Aspen Technology, Inc. All rights reserved.

Traditional Hypos (Pseudo-components)

Crude Feed after

Crude Oil Mixer

Each feed has a separate set of hypos

2015 Aspen Technology, Inc. All rights reserved.

Aspen HYSYS Petroleum Refining Hypos

Crude Feed after

Crude Oil Mixer

Feed share the same hypos

Flowsheet uses a single set of hypos

Easier to manage yields and properties across

Hypo properties change in the flowsheet.

2015 Aspen Technology, Inc. All rights reserved.

Over 50 Petroleum Properties

2015 Aspen Technology, Inc. All rights reserved.

How Can AspenTech Help Refineries Maximize Profits?

Sustain Profit Margins by ensuring

Integration of Aspen PIMS and Aspen HYSYS allows

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

Easier updates of Aspen PIMS Planning Models using Aspen HYSYS

2015 Aspen Technology, Inc. All rights reserved.

Aspen Assay Manager

Components for Aspen

Main and Swing Cuts for

2015 Aspen Technology, Inc. All rights reserved.

Crude Distillation Model Support

PIMS Assay Manager

Accurate representation of non-ideal

2015 Aspen Technology, Inc. All rights reserved.

PIMS Assay Table

Crude Distillation (CDU) Support: Two Steps

Step 2: Properties (SI Factors)

2015 Aspen Technology, Inc. All rights reserved.

Aspen HYSYS Petroleum Refining Model for Cut

to get crude assay

2015 Aspen Technology, Inc. All rights reserved.

Fractionation Model Provides Fractionation Factors (SI

SI Factors for PIMS Main

2015 Aspen Technology, Inc. All rights reserved.

Cut points and SI Factors In PIMS Assay Manager

2015 Aspen Technology, Inc. All rights reserved.

Aspen HYSYS Petroleum Refining Reactors