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[File Name or Event]Emerson Confidential27-Jun-01, Slide 2
© 2015 Page 2
PresentersPresenters
� Dr. Didier Lambert: Dr. Didier Lambert earned his PhD in Chemistry from 1984 at Paris Pierre and Marie Curie University. He worked for more than 16 years for BP where he invented solutions for real time Quality control for Oil & Gas industry. He has more than 30 patents in the field and was awarded with Engineer Award in 1989 for his invention. He bought out the business he developed in BP and set up Topnir Systems in early 2005.
� Patrick Truesdale: Mr. Truesdale is a Principal Consultant with Emerson Process Management. He started his career with duPont . He has over 40 years worldwide consulting experience in optimization and control and specializes in blending and petroleum and chemical logistics operations and automation. He has a BSEE from North Carolina State University in Raleigh, NC and is a Registered Professional Engineer.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 3
© 2015 Page 3
ContentContent
� Introduction – Challenges vs Opportunities
� Three Step Solution
� Example Results
� Benefit Overview
[File Name or Event]Emerson Confidential27-Jun-01, Slide 4
© 2015 Page 4
The Crude Unit: Gateway to RefiningThe Crude Unit: Gateway to Refining
� Every refinery has a crude unit– Common size for a single train: 120,000 bpd
� As crude feedstock broaden to include shale and opportunity crudes, this unit’s performance becomes critical to flexibility and profitability
[File Name or Event]Emerson Confidential27-Jun-01, Slide 5
© 2015 Page 5
Business ChallengesBusiness Challenges
� Crude operations require process flexibility– Response to market demands for products
– Must be capable of processing varying grades of crude
– Good response to crude switches and operating mode changes
CRUDETANK
CRUDEPIPELINE
DOWNSTREAM PROCESSES
[File Name or Event]Emerson Confidential27-Jun-01, Slide 6
© 2015 Page 6
Process ChallengesProcess Challenges
� Energy efficiency – Heat transfer efficiency loss drives energy costs up
� Crude unit utilization – Sub-optimal temperature control decreases product quality
– Poor fractionator control lower separation efficiency
� Reliability of field assets– Unplanned slowdowns and shutdowns are often caused by failure
of rotating and fixed plant assets
� Safety, Health & Environmental concerns– Fines, personnel issues plague refinery operations worldwide
[File Name or Event]Emerson Confidential27-Jun-01, Slide 7
© 2015 Page 7
Worldwide Assessed Basins Shale Oil/Gas Formation: May 2013Worldwide Assessed Basins Shale Oil/Gas Formation: May 2013
[File Name or Event]Emerson Confidential27-Jun-01, Slide 8
© 2015 Page 8
Energy Research Policy Foundation Inc.
6
USA-Canada Crude Typical PropertiesUSA-Canada Crude Typical Properties
[File Name or Event]Emerson Confidential27-Jun-01, Slide 9
© 2015 Page 9
Crude Unit Utilization: ChallengesCrude Unit Utilization: Challenges
� Frequent crude switching negatively impacts quality
� Corrosion of the overhead condenser and piping
� Plugging and fouling of crude preheat exchangers
[File Name or Event]Emerson Confidential27-Jun-01, Slide 10
© 2015 Page 10
Crude Unit Control & OptimizationCrude Unit Control & Optimization
Vacuum TowerAtmospheric
Tower
Crude Feed
Naphtha
Kerosene
Lt Diesel
Diesel
AGO
Stripping Tower
Steam
Steam
Steam
Steam
Steam
T
T
T
T
T
F
F
F
F
F
F
F
F
F
F
T
T
F
F
F
F
FL
L
L
L
FBP
IBP FBP
IBP
Cong.D360
T P
Flood
O Flash
Gas
F F
D360
O2
HV
Fuel
F
Air
F
CO
T
Fired Heaters
T
P
P
T-7
NaphthaStabilizerSmartProcess™ Fractionation
SmartProcess™ Heater
SmartProcess™ Distillation
F
F
Crude
A
Crude
B
Crude Blender
SmartProcess™ Blend
FTIR/TopNir Crude Characterization
Properties& Targets
Q’s
F
Q’s
Ratio
[File Name or Event]Emerson Confidential27-Jun-01, Slide 11
© 2015 Page 11
Step 1: Crude Feed Online AnalysisStep 1: Crude Feed Online Analysis
Real time Monitoring of Crude transition
[File Name or Event]Emerson Confidential27-Jun-01, Slide 12
© 2015 Page 12
NIR Spectrum
Intensity = Io Intensity = I
NIR Source
Detector
Measurement
Cell
Fourier
Transform
NIR Spectroscopy – Basic PrinciplesNIR Spectroscopy – Basic Principles
� Each NIR Spectrum is unique for each Product
� It is the DNA of the sample
KEY ISSUE in NIR is MODELING !
[File Name or Event]Emerson Confidential27-Jun-01, Slide 13
© 2015 Page 13
TOPNIR™ Database for ModellingTOPNIR™ Database for Modelling
� 20 samples required for calibration
� Densification methodology to maintain the accuracy
� Creation of virtual samples – linear and non-linear mixing rules
[File Name or Event]Emerson Confidential27-Jun-01, Slide 14
© 2015 Page 14
TOPNIR™ Basic Postulate: Pattern RecognitionTOPNIR™ Basic Postulate: Pattern Recognition
Abs. 1Abs. 2
.
.Abs. n
Abs. 1Abs. 2
.
.Abs. n
Spectra A
Prop. 1Prop. 2
..Prop. m
Prop. 1Prop. 2
.Prop. m
Sample
A
Sample
B
Same spectra �������� Same sample Same spectra �������� Same sample
Same sample �������� Same propertiesSame sample �������� Same properties
SameSame
Modeling achieved from Reference DatabaseModeling achieved from Reference Database
SameSame
Spectra B
[File Name or Event]Emerson Confidential27-Jun-01, Slide 15
© 2015 Page 15
TOPNIR™ Pattern Recognition TechnologyTOPNIR™ Pattern Recognition Technology
Properties X = f ( Prop[S1, S2, S3, S4, S5, S6] )Properties X = f ( Prop[S1, S2, S3, S4, S5, S6] )
New Sample X
S1S1
S2S2
S4S4S6S6
S5S5
S3S3
NO MODEL TO MAINTAIN EASY MAINTENANCE
All Properties from one Reference Database
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
© 2015 Page 16
TOPNIR™ SummaryTOPNIR™ Summary
� Patented technology
� Uses only a reference database to predict and calculate sample properties;
� Update is easily done only by adding new sample in the database, with both NIR Spectra and conventional analysis.
� Self-learning method without necessity of remodelling.
� When new sample is added, it is taken into account by Topnir™.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 17
© 2015 Page 17
Provides Properties of Crude OilProvides Properties of Crude Oil
Property Accuracy per ASTM
TBP curve +
API +
Sulphur, % +
Assays Yield, % +
TAN +
Crude Assays +
GOR +
Carbon-Hydrogen ratio +
Asphaltenes +
RVP +
others
[File Name or Event]Emerson Confidential27-Jun-01, Slide 18
© 2015 Page 18
Asphaltene Stability Index (ASI) for Crude OilsAsphaltene Stability Index (ASI) for Crude Oils
Asphaltene Stability (Crude Compatibility) Index is a function of:
� Asphaltene / Resin ratio
� Saturates / Aromatics ratio
� Light Fraction yield
� API Gravity
� Viscosity
Dispersion of Asphaltene in Crude Oils Asphaltene Equilibrium
[File Name or Event]Emerson Confidential27-Jun-01, Slide 19
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Step 2: Optimum Crude BlendStep 2: Optimum Crude BlendFTIR Analyzers/TOPNIRSmartProcess Blend
TankCrude A
TankCrude B
TankCrude C
TankCrude n
TCAC
AC
Pass 1
Pass 2
Pass 3
Pass 4
TI
TI
TI
TI
TI
FC
FC
FC
FC
FC
Total Charge
Flow
TC
Coil Outlet
FC
TI
TI
TI
TI
FI
AI
Fuel
PC
PC
[File Name or Event]Emerson Confidential27-Jun-01, Slide 20
© 2015 Page 20
Step 3: Smart Refining – Crude HeaterStep 3: Smart Refining – Crude Heater� Control total process flow to target
� Control outlet temperature
� Pass Balancing
� Adjust inlet air and draft dampers to minimize excess air
� Stabilize heater against changes in fuel gas and feed temperature
� Combustion control including fuel/ air cross limiting
� Operate within all heater constraints
� Heater efficiencies are calculated as well as estimated stack gas compositions and emissions
[File Name or Event]Emerson Confidential27-Jun-01, Slide 21
© 2015 Page 21
Step 3: Smart Refining FractionatorStep 3: Smart Refining Fractionator
Fired Heater
Vacuum Tower
Atmospheric Tower
Crude Feed
Naphtha
Kerosene
Lt Diesel
Diesel
AGO
To Vacuum System
LVGO
HVGO
Residue
Stripping Tower
Steam
Steam
Steam
Steam
Steam
Steam
T
T
T
T
T
F
F
F
F
F
F
F
F
F
F
T
T
FuelF
HV
F
F
T
T
F
F
F
T
T
O2
F
F
T
T
F
F
F
F
T
T
T
TF
F
F
F
FL
L
L
L
FBP
IBP FBP
IBP
Cong.D360
T
T
P
P
Flood
O Flash
Flood
T P
Gas
F F
D360
O2
O2
HV Fuel
F
Ai
r
F
CO
CO
T
Fired Heaters
F
HV Fuel
T
P
P
T-7NaphthaStabilizer
SmartProcess™ Fractionation
[File Name or Event]Emerson Confidential27-Jun-01, Slide 22
© 2015 Page 22
Step 3: Smart Refining - DistillationStep 3: Smart Refining - Distillation
FT
LC
FC
QR
LC
Feed Flow
TI
FC
QR
75# Steam
Reflux
Control Temp
Propane Product
Butane Product
PC
C4’s
C3’s
PredictPro
CV
CV MV MVMV
MV
SmartProcess™ Distillation
[File Name or Event]Emerson Confidential27-Jun-01, Slide 23
© 2015 Page 23
Crude Value Added Benefit ChainCrude Value Added Benefit Chain
Suboptimum
Blending
Optimum
Blending
CrudeMixing Penalty
[File Name or Event]Emerson Confidential27-Jun-01, Slide 24
© 2015 Page 24
TOPNIR™ Crude DistillationAramco, Yanbu, Saudi ArabiaTOPNIR™ Crude DistillationAramco, Yanbu, Saudi Arabia� 200,000 BPD refinery
� 9 Streams – Crude, LSRN, HSRN, CDU HSRN, KERO, LDO, ADO, HDO, RCO
� On-line analysis 117 Properties
� Analyzer integrated in a shelter
[File Name or Event]Emerson Confidential27-Jun-01, Slide 25
© 2015 Page 25
Example Results: Raw Crude CharacterizationExample Results: Raw Crude Characterization
Family 4
Family 3
Family 1
Family 2
Property min max units
TAN 0.2 3.7 mg KOH/gTotal Sulfur 0.02 4.9 wt%Gravity, API 18.8 66.4 deg
More than 70 Crude Oils
[File Name or Event]Emerson Confidential27-Jun-01, Slide 26
© 2015 Page 26
Example Results:TBP Curve Comparison with LabExample Results:TBP Curve Comparison with Lab
2
Crude Oil 1
[File Name or Event]Emerson Confidential27-Jun-01, Slide 27
© 2015 Page 27
TOPNIR™ Crude Oil Ecopetrol, ColombiaTOPNIR™ Crude Oil Ecopetrol, Colombia
� Crude Pipeline Transportation Optimization
– >140 Crude; Blend in Pipeline 3 to 40 Crudes
– Crude Composition Known
– Blend Ratio Unknown
– Five Pumping Stations; Two Refineries -Barrancabermeja & Cartagena
� Scope
– Crude Identification and Characterization
� Project Completed in 9 months
� ROI less than 6 Months
EMPRESA COLOMBIANA
DE PETRÓLEOS
[File Name or Event]Emerson Confidential27-Jun-01, Slide 28
© 2015 Page 28
FTIR + TOPNIR™: On-line Crude SolutionFTIR + TOPNIR™: On-line Crude Solution
� Better Crude Allocation and Segregation
� Crude Blending Optimization
� Crude Switch Optimization
� Distillation Curve (TBP) Continually Available
� Crude Stability Index
� Feed Preparation Giving Greater Stability
� Feed Optimized for Different CDU Modes
� Crude Throughput Increase
Benefits: $2-3 Million/year
[File Name or Event]Emerson Confidential27-Jun-01, Slide 29
© 2015 Page 29
Example Results:Fractionator Control PerformanceExample Results:Fractionator Control Performance
CV
SP
MV
Lab
Spec
Controller ON
Naphtha
Kero AGO
Hvy Kero
Crude Change
[File Name or Event]Emerson Confidential27-Jun-01, Slide 30
© 2015 Page 30
SummarySummary
� Refineries have unique challenges that significantly impact their economic operating margin;
� Shale (LTO) and other unconventional heavy crudes provide significant advantages to optimize crude feed
� Emerson Process Management and TopNir Systems offer new technology and application packages that provide high performance while substantially reducing both implementation costs and maintenance/support costs. These include:– TOPNIR™ Crude Characterization using Online FTIR– SmartProcess ™ Blending– SmartProcess™ Fractionation– SmartProcess™ Heaters– SmartProcess™ Distillation
[File Name or Event]Emerson Confidential27-Jun-01, Slide 31
© 2015 Page 31
Where to get more information?Where to get more information?
� To discuss your specific requirements
� Contact: • Patrick Truesdale (Patrick.Truesdale@Emerson.com)
• Didier Lambert (Didier.Lambert@TopNir.com)
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