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Europe User Conference: ADNOC predictive model of gas oil hydrotreater unit for studying different feeds

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ABU DHABI NATIONAL OIL COMPANYADNOC REFINING
PREDICTIVE MODEL OF GAS
OIL HYDROTREATER UNIT FOR
STUDYING DIFFERENT FEEDS
HA...

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PRESENTATION OUTLINE
2
• Introduction: ADNOC,ADNOC Refining & ADNOC Refining Research Centre
• Project Background
• Unit D...

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ADNOC – GROUP OF COMPANIES
3
Refining
Crude
Gas
Final Products

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Europe User Conference: ADNOC predictive model of gas oil hydrotreater unit for studying different feeds

  1. 1. ABU DHABI NATIONAL OIL COMPANYADNOC REFINING PREDICTIVE MODEL OF GAS OIL HYDROTREATER UNIT FOR STUDYING DIFFERENT FEEDS HALA KELANI PROCESS SIMULATION ENGINEER
  2. 2. PRESENTATION OUTLINE 2 • Introduction: ADNOC,ADNOC Refining & ADNOC Refining Research Centre • Project Background • Unit Description • Model Development • Model Applications • Conclusions
  3. 3. ADNOC – GROUP OF COMPANIES 3 Refining Crude Gas Final Products
  4. 4. ADNOC REFINING 4
  5. 5. ADNOC REFINING REFINERIES 5
  6. 6. ADNOC REFINING RESEARCH CENTRE 6 2006: ADNOC’s vision that the technology and innovation supported by scientific research are essential to its strategy. 2009: ADNOC Refining Research Centre (ARRC) started its research activities to be the first applied entity with UAE in the field of oil and gas. 2011: ADNOC Refining Research Centre was officially inaugurated
  7. 7. ADNOC REFINING RESEARCH CENTRE 7
  8. 8. ORGANIZATION OF ARRC 8
  9. 9. PROCESS MODELING & SIMULATION AT ARRC 9 Department Manager Process Modeling & Simulation Section Head Sr. Process Simulation Engineer Process Simulation Engineer Process Simulation Engineer Sr. CFD Engineer Sr. Modeling Engineer
  10. 10. PROCESS MODELING & SIMULATION AT ARRC 10 PM&S First Principles Modeling Computer Aided Engineering Process Simulation
  11. 11. PROCESS MODELING & SIMULATION AT ARRC 11
  12. 12. PROCESS MODELING & SIMULATION AT ARRC 12 PM&S First Principles Modeling Computer Aided Engineering Process Simulation • Unit-level process improvement. • Units performance monitoring • Energy optimization. • Refinery-wide simulation. Process Simulation
  13. 13. PROCESS MODELING & SIMULATION AT ARRC 13 PM&S First Principles Modeling Computer Aided Engineering Process Simulation • CFD studies to troubleshoot and optimize plant operations. • FEA studies for Fitness for Service and Remaining Life analysis. Computer Aided Engineering
  14. 14. PROCESS MODELING & SIMULATION AT ARRC 14 PM&S First Principles Modeling Computer Aided Engineering Process Simulation Support other Sections at ARRC, and Perform Vital Functions in Research & Technology Development Provide Modeling Support to ADNOC Refining Refineries and Supply Division to achieve Operational Excellence, and Improve Profit Margins Provide Modeling Support to ADNOC Refining Refineries for Operations Optimization, Troubleshooting and Conduct Asset Integrity Studies
  15. 15. PROJECT BACKGROUND 15 • Process Modeling & LP Modeling: One of the focus areas of Operational Excellence activities at ADNOC Refining. • Objective of Focus Area: • Establish Modeling Awareness across ADNOC Refining • Establish industrial best practices in modeling across ADNOC Refining • Establish coordination and alignment for modeling activities in ADNOC Refining • Monitor Modeling & Simulation software usage and ensure maximum utilization in ADNOC Refining • Develop UAE nationals as modeling experts and leaders
  16. 16. Project Workflow 16 ARRC ARRC
  17. 17. PROJECT GOALS 17 Objective: • Develop a Steady State Model of a Gas Oil Hydrotreater Unit in ADNOC Refining Refinery. • Utilize the model to support production modeling team and refinery process engineers for optimization studies. Scope: • Utilize the model to generate data for LP (Linear Programming) base and delta vectors generation for production planning. • Utilize the model to conduct process parametric studies. • Predict unit performance for different types of feed to assist in production and operations planning. • Utilize the model to provide operational insight to refineries and suggest improvement opportunities.
  18. 18. HYDROTREATING 18 • A fixed bed catalytic process in the presence of large amount of hydrogen for hydrotreating a wide range of feedstock. • It is designed primarily to: • Remove organic sulfur, oxygen and nitrogen compounds contained in the hydrocarbon. • Saturates the olefinic/aromatic compounds.
  19. 19. HYDROTREATING REACTIONS 19
  20. 20. HYDROTREATING REACTIONS 20
  21. 21. UNIT SCHEMATIC 21
  22. 22. MODEL DEVELOPMENT 22 Information required for Model Development • Process and design information • PI data ( Process operation data) • Lab analysis for feed and the products • DCS Snapshots • Unit PFD • DHTR-SIM Module of Petro-SIM software by KBC used to develop the model of the Gas Oil Hydrotreater Unit. Petro-SIM v6.0
  23. 23. MODEL DEVELOPMENT 23
  24. 24. MODEL DEVELOPMENT 24
  25. 25. MODEL TUNING 25 • Differences: • Off gases flow rates • Bottom sulfur content
  26. 26. MODEL TUNING 26
  27. 27. MODEL RESULTS – Back Prediction 27 • DHTR-SIM is operated in calibration mode, thereby generating reaction kinetics parameters, yield factors and reaction extent factors. • Back-prediction of the base case data is then executed and is in excellent agreement.
  28. 28. MODEL RESULTS – Model Validation 28 • DHTR-SIM is operated in calibration mode, thereby generating reaction kinetics parameters, yield factors and reaction extent factors. • Prediction using the another set of input data is then executed and the predictions again show excellent agreement.
  29. 29. MODEL APPLICATIONS: PARAMETRIC STUDIES 29 “Predict” function is used to investigate model response at various Parametric Scenarios: 1. LHSV 2. S.G of the feed 3. Make up hydrogen purity 4. Reactors Inlet temperatures 5. Product sulfur content
  30. 30. MODEL STEP-OUT CASES 30
  31. 31. MODEL APPLICATION: FEED VARIATIONS 31 • The validated model was utilized to predict unit performance. • Three cases were predicted: • 15% LVGO with 85% HGO • 20% LVGO with 80% HGO • 30% LVGO with 70% HGO
  32. 32. MODEL APPLICATION 32
  33. 33. MODEL APPLICATION 33
  34. 34. MODEL APPLICATION 34 8,600 8,800 9,000 9,200 9,400 9,600 9,800 0% 5% 10% 15% 20% 25% 30% 35% H2MakeupFlowRate(Nm3/hr) LVGO Percentage in the Feed H2 Make Up Flow Rate
  35. 35. MODEL APPLICATION 35 0.96 0.98 1 1.02 1.04 1.06 1.08 0% 5% 10% 15% 20% 25% 30% 35% DeactivationRate(°C/(m3/kg)) LVGO Percentage in the Feed Deactivation Rate
  36. 36. MODEL APPLICATION 36 76 77 78 79 80 81 82 83 84 85 86 87 0% 5% 10% 15% 20% 25% 30% 35% ChemicalH2Consumption(Nm3/m3) LVGO Percentage in the Feed Chemical H2 Consumption
  37. 37. MODEL APPLICATION 37 60 61 62 63 64 65 66 67 68 69 0% 5% 10% 15% 20% 25% 30% 35% TotalDeltaTemperature(°C) LVGO Percentage in the Feed Total Delta Temperature
  38. 38. MODEL APPLICATION 38 3.5 3.6 3.7 3.8 3.9 4 4.1 4.2 0% 5% 10% 15% 20% 25% 30% 35% RemainingCatalystLife(yrs) LVGO Percentage in the Feed Remaining Catalyst Life
  39. 39. DATA FOR LP VECTORS 39 Data from model step-out cases is provided to production planning for LP Vectors generation
  40. 40. MODEL UTILIZATION & BENEFITS 40 SD – Data for LP Model • Increase Refinery Throughput • Improve Refinery Yields • Investigate flexibility to process Gas Oil feed from different sources Process Improvement • Process Monitoring • Improve Hydrogen Management • Increase ability to react to market changes Refinery-wide Simulation • Monitor impact of unit changes in a global picture
  41. 41. CONCLUSIONS 41 • A steady-state process model of a Gas Oil Hydrotreater unit has been developed and calibrated for plant operating conditions • The model has been used for LP vectors (Base and Delta vectors) generation for input to Production Planning model for profit improvement • The model has been used for parametric studies and predicting unit performance using different feeds to support refinery operations • Path forward: • Develop models of all units in ADNOC Refining • Update refinery-wide model with updated / new unit models 41 RR ARRC ADNOC RefiningSD
  42. 42. ADNOC REFINING THANK YOU

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