Romeo Pdvsa

REFINERIA ISLA (CURAZAO) S.A.
Crude Unit Optimization at Refineria Isla, Curacao
A ROMeo Case Study
S. Ranganathan , A. Offerman and J. Cijntje

Refineria ISLA, Curacao
R. C. McFarlane, V. Lough
Invensys Production Management
F:\Isla General Presentation 2001.ppt

Talk Outline
Project overview/scope
ROMeo overview
Process MRA overview
CD3 Crude Unit Case Study
Conclusions

Overview: Refineria Isla
Refineria Isla (Curacao) S. A.

Curacao, Netherland Antilles
Affiliate of PDVSA, Venezuela
Crude Distillation Unit-3 capacity : 180,000 bbls/day
26-30 API; switch every 2-3 days
Scope of CD3 optimization model

Atmospheric unit
Vacuum unit
Preheat train including furnaces
Gas plant

Overview: Highlights
Real-time Optimization: ROMeo

State-of-the-art equation-based modeling/real-time
optimization package
Enhanced usability features for faster implementation/
ease of maintenance
Invensys Process MRA
Reliable, robust online NMR technology
Crude, kerosene and naphtha stream analysis for
improved APC and optimizer performance
Project executed by refinery staff

1.5 refinery engineers
0.25 Invensys engineer (consulting only)

Overview: Milestones
MRA Analyzer
Test Installation Nov 2000
Final Installation including Crude August 2001
ROMeo
Started June 2001
Model building/application configuration performed entirely
by refinery staff; consulting from Invensys
Online, open-loop since Jan, 2002
Optimization moves reviewed before being implemented by
operations staff
Online, closed-loop since March, 2002
Optimization moves transmitted to DCS and implemented
automatically

ROMeo Overview
ROMeo: Rigorous On-line Modeling and Equation-based

Optimization
Joint development project between Invensys/SimSci and Shell

U.S.A
Implemented worldwide in FCCUs, Hydrotreaters/Hydrocrackers,
Crude units, Ethylene crackers
Common look/feel for all stages of model configuration,
implementation, maintenance and off-line studies
Enhanced usability features cut down implementation time,
improve maintainability
Refinery engineers required only three days of training to carry out
most of the configuration tasks

What are the Process MRA
Features ?
Minimum temperature and no

chemical pre-conditioning
Sampling is non invasive and
simple in design
Structural Groups have their own
domains (orthogonal)
Energy absorption is Linear
across the spectral range
Short track execution, with
conceptual study, basic design
and reduced client risk
Robust, less noisy measurement
-->significant benefit to APC &
Optimization 60 M Hz
8 7 6 5 4 3 2 1 0 -1
Methyl Paraffinic
Aromatic Olefinic Water Oxygenate Aromatic

CD3 Crude Unit

Case Study

Real-time Optimization Objectives
How to maximize most valuable products like kerosene,

heavy gasoil, LPG?
How should circulating reflux flows be adjusted to maximize

heat integration with the gas section?
How to adjust the crude and vacuum furnace duties?
Can column pressure, reboiler and reflux in gas section be

adjusted to minimize fuel gas?
Can we achieve uniform operating philosophy acceptable to

all shifts?

System Overview
Economics.XLS Blend.XLS
ROMeo
Limits ProcessModel DataRec

(MS ACCESS)
Optimization
Lab
LIMS
TARGETS
PI System
MRA DCS
PLANT

Problem Size, Platform and
Performance
Size
252 Measurements
26,000 Equations
Degrees of Freedom
170 in Data Reconciliation (tuning parameters)
31 in Optimization (targets to APC/DCS)
Platform
Dell PC with dual 1-GHz CPUs , 2 GB RAM.
Windows NT Enterprise server
Networked to Foxboro I/A, PI, LIMS.
Performance
Reconciliation: 10 minutes
Optimization: 5 minutes

On-line MRA data
MRA supplies real-time measurements to APC and ROMeo

Optimizer
ROMeo:
Crude: 5 pt TBP
improves feed characterization during data
reconciliation
ROMeo, APC:
Kero: freeze point, flash point
Naptha: end point
closer operation to constraints by APC and ROMeo
improved benefits

Feed Characterization
Crude Tank
Composition
Crude Book
Blend Select Tank

Assay Data
Components Lineup
Plant
Reconciliation NMR TBP Data
Measurements
Lab Data
Reconciled Crude Assay
Legend:
Real Time
Daily

On-line Feed Characterization
with MRA
Crude Adjustment
100
90
80
70
60
WT% Yield
Before
50
After
40 NMR
30
20
10
0
-150 50 250 450 650 850 1050
CutPoint Deg C

Benefits
Online:
Preliminary benefit estimate: 7-12 K $US/Day
benefits derived primarily from:
kero maximization
improved heat integration
Off line:
Several circulating reflux flows were moved from their
traditional operating levels
Avoided unnecessary opening of columns and
exchangers during short turn around
Understand the impact of crude switch on downstream
units

Conclusions
The usability features of ROMeo allowed application to be

configured by plant engineers on time (4 months) and
within budget
On-line optimization provides a set of operating guidelines

to capture the benefit in real time instead of running the unit
on preset operating guidelines that may be suboptimal
Process MRA provides valuable real-time measurements to

enhance APC and ROMeo performance

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REFINERIA ISLA (CURAZAO) S.A.

Crude Unit Optimization at Refineria Isla, Curacao

A ROMeo Case Study

S. Ranganathan , A. Offerman and J. Cijntje

F:\Isla General Presentation 2001.ppt

 Process MRA overview

 CD3 Crude Unit Case Study

F:\Isla General Presentation 2001.ppt

 Refineria Isla (Curacao) S. A.

 Scope of CD3 optimization model

F:\Isla General Presentation 2001.ppt

 Real-time Optimization: ROMeo

 Project executed by refinery staff

F:\Isla General Presentation 2001.ppt

F:\Isla General Presentation 2001.ppt

 ROMeo: Rigorous On-line Modeling and Equation-based

 Joint development project between Invensys/SimSci and Shell

F:\Isla General Presentation 2001.ppt

 Minimum temperature and no

F:\Isla General Presentation 2001.ppt

CD3 Crude Unit

F:\Isla General Presentation 2001.ppt

Real-time Optimization Objectives

 How to maximize most valuable products like kerosene,

 How should circulating reflux flows be adjusted to maximize

 How to adjust the crude and vacuum furnace duties?

 Can column pressure, reboiler and reflux in gas section be

 Can we achieve uniform operating philosophy acceptable to

F:\Isla General Presentation 2001.ppt

Limits ProcessModel DataRec

F:\Isla General Presentation 2001.ppt

F:\Isla General Presentation 2001.ppt

On-line MRA data

 MRA supplies real-time measurements to APC and ROMeo

F:\Isla General Presentation 2001.ppt

Blend Select Tank

Reconciled Crude Assay

F:\Isla General Presentation 2001.ppt

F:\Isla General Presentation 2001.ppt

 improved heat integration

F:\Isla General Presentation 2001.ppt

 The usability features of ROMeo allowed application to be

 On-line optimization provides a set of operating guidelines

 Process MRA provides valuable real-time measurements to

F:\Isla General Presentation 2001.ppt

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Process MRA overview

CD3 Crude Unit Case Study

Refineria Isla (Curacao) S. A.

Scope of CD3 optimization model

Real-time Optimization: ROMeo

Project executed by refinery staff

ROMeo: Rigorous On-line Modeling and Equation-based

Joint development project between Invensys/SimSci and Shell

Minimum temperature and no

How to maximize most valuable products like kerosene,

How should circulating reflux flows be adjusted to maximize

How to adjust the crude and vacuum furnace duties?

Can column pressure, reboiler and reflux in gas section be

Can we achieve uniform operating philosophy acceptable to

MRA supplies real-time measurements to APC and ROMeo

improved heat integration

The usability features of ROMeo allowed application to be

On-line optimization provides a set of operating guidelines

Process MRA provides valuable real-time measurements to