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Europe User Conference: Albemarle FCC-SIM calibration best practices

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KBC (A Yokogawa Company)
KBC (A Yokogawa Company)

Presentation from downstream track at KBC Europe Software User Conference June 2018

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Proprietary Information of Albemarle Corporation. How Can I Use FCC-SIM to Monitor My FCC Unit Regularly? Alan Kramer Global FCC Modeling Specialist KBC Software User Group Conference 2018 London
Proprietary Information of Albemarle Corporation. The Questions 2 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
Proprietary Information of Albemarle Corporation. The Questions 3 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
Proprietary Information of Albemarle Corporation. What are the important calibration factors?
Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? 5 π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’
Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’π‘₯π‘˜π‘’π‘7 Kinetic Coke Make π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘14 Wet Gas Yield
Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? 7 π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’π‘₯π‘˜π‘’π‘7 Kinetic Coke Make π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘22 Reaction Rate Distribution π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘22 Reaction Rate Distribution π‘₯π‘˜π‘’π‘14 Wet Gas Yield
Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… 7 Kinetic Coke Make Regenerator Temperature 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke 9 Conversion Kinetic Conversion 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses 22 Reaction Rate Distribution LCO/Bottoms Ratio 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity 8
Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… 7 Kinetic Coke Make Regenerator Temperature 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke 9 Conversion Kinetic Conversion 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses 22 Reaction Rate Distribution LCO/Bottoms Ratio 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities 9
Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… Affected by Cat Formulation? 7 Kinetic Coke Make Regenerator Temperature Yes 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes 9 Conversion Kinetic Conversion Yes 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes 22 Reaction Rate Distribution LCO/Bottoms Ratio Yes 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) No* 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) No* 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes 10 * Yes for combustion promoter
Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Affected by Cat Formulation? How Catalyst Affects this Factor 7 Kinetic Coke Make Yes Coke selectivity of base catalyst 13 Contaminant Coke Factor Yes Metals (Nickel) passivation technologies; ADM-60 9 Conversion Kinetic Yes Activity / CTO 14 C1-C4 Gas Yield Yes ZSM-5 Usage, Bottoms Cracking 22 Reaction Rate Distribution Yes Bottoms Cracking / High Matrix; ADM-20; ADM-30 179 Hydrothermal Deactivation Yes RE/Z, Other Stabilizers; Z/M; Binding Technology; GRANITETM 11 Heat of Cracking Ratio Yes Rare earth on zeolite 1 / 93 Regen Coke Burn Rate No* Extreme overpromoting or underpromoting 2 / 94 Regen CO/CO2 Rate No* Extreme overpromoting or underpromoting 15-21 190-3 C2-C4 Individual Gas Yields Yes Re/Z; ACTIONTM; ZSM-5 Usage 11 * Yes for combustion promoter
Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… Affected by Cat Formulation? Typical Value 7 Kinetic Coke Make Regenerator Temperature Yes 0.1 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes 1.0 9 Conversion Kinetic Conversion Yes 1.0 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes 1.0 22 Reaction Rate Distribution LCO/Bottoms Ratio Yes 1.0 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes - 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes 1.0 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) No* 1.0 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) No* 1.0 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes - 12 * Yes for combustion promoter
Proprietary Information of Albemarle Corporation. Are my calibration factors good?
Proprietary Information of Albemarle Corporation. Are My Calibration Factors Any Good? 14 β€’ Correlate back to calibration input data β€’ Correct data or eliminate case β€’ Check for coincidence with catalyst change β€’ Correlate back to calibration input data β€’ Theoretically these should be flat with little variation β€’ Correlate back to calibration input data β€’ Use best judgment on input data
Proprietary Information of Albemarle Corporation. Variability in Calibration Factors 15
Proprietary Information of Albemarle Corporation. Variability in Calibration Factors 16
Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 17
Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 18 CORREL function vs Calibration Input Rows =ABS(CORREL(range1,range2))
Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 19
Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #2 20
Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #2 21
Proprietary Information of Albemarle Corporation. What calibration cases should I use?
Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 23
Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 24
Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 25 β€’As many as possible β€’Always consider catalyst formulation β€’Averaging calibration factors dampens variation effects β€’Superday / single-day use may amplify variations Which Cases Should I Use? β€’Significantly different feed rate β€’Different combustion mode β€’Catalyst transition β€’Different catalyst Which cases should I avoid?
Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 26 β€’ FCC-SIM Experiment β€’ 22 cases (weekly averages) β€’ Questionable daily data removed 1. Calibrate model for all 22 cases 2. Predict 22 cases Β» Independent variables = same for all, average for all 22 cases Β» Calibration factors = each cases’ individual 3. Predict 1 more case Β» Independent variables = same as above, average for all 22 cases Β» Calibration factors = average for all 22 cases 4. Analyze the variability in the predicted yields
Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 27 Wt% Yield Ranges Predicted with Case Calibration Factors Yield, wt% Min -1 sigma Average Calibration Factors +1 sigma Max H2 0.1 0.10 0.12 0.13 0.15 Dry Gas 2.12 2.23 2.36 2.50 2.64 LPG 16.55 17.30 18.14 18.98 19.73 C5 – 430F C5 – 221C 47.06 47.97 49.19 50.41 51.77 430-650F 221-343C 14.61 15.80 16.64 17.48 17.87 650F+ 343C+ 5.11 5.86 6.5 7.14 7.55 Regen Temp F Regen Temp C 1270 688 1296 703 1313 712 1330 721 1336 724
Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 28 Delta wt% From Yields Predicted with Average Calibration Factors Yield, wt% Min -1 sigma Average Calibration Factors +1 sigma Max H2 -0.02 -0.014 0.014 0.03 Dry Gas -0.24 -0.13 0.13 0.28 LPG -1.59 -0.84 0.84 1.59 C5 – 430F C5 – 221C -2.13 -1.22 1.22 2.58 430-650F 221-343C -2.03 -0.84 0.84 1.23 650F+ 343C+ -1.39 -0.64 0.64 1.05 Regen Temp F Regen Temp C -43F -24C -17F -9C 17F 9C 23 13C
Proprietary Information of Albemarle Corporation. Calibration Summary β€’ Focus on the key calibration factors. β€’ Trendplot key calibration factors always after calibrating. β€’ Calibration factor trendplots should be flat over time. β€’ Fix flyers & variability. Understand the reason for trends. β€’ Use the CORREL function to help relate calibration factors to calibration inputs. β€’ When choosing calibration cases to average: – Use as many as possible. – Consider the base catalyst, feed rate, combustion mode. β€’ Don’t use superdays. 29
Proprietary Information of Albemarle Corporation. Revisit The Questions 30 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
Proprietary Information of Albemarle Corporation.

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  • 1. Proprietary Information of Albemarle Corporation. How Can I Use FCC-SIM to Monitor My FCC Unit Regularly? Alan Kramer Global FCC Modeling Specialist KBC Software User Group Conference 2018 London
  • 2. Proprietary Information of Albemarle Corporation. The Questions 2 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
  • 3. Proprietary Information of Albemarle Corporation. The Questions 3 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
  • 4. Proprietary Information of Albemarle Corporation. What are the important calibration factors?
  • 5. Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? 5 π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’
  • 6. Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’π‘₯π‘˜π‘’π‘7 Kinetic Coke Make π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘14 Wet Gas Yield
  • 7. Proprietary Information of Albemarle Corporation. β€’ Important equations inside FCC-SIM – Rate of coking – Rate of cracking – Rate of C1-C4 gas production What are the Important Calibration Factors? 7 π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ 𝐢/𝑂 β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’ π‘Ÿπ‘”π‘Žπ‘  = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘Ÿπ‘π‘Ÿπ‘Žπ‘π‘˜ π‘Ÿπ‘π‘œπ‘˜π‘’ = π‘Ÿπ‘₯ π‘π‘œπ‘›π‘ π‘‘ β€’ π‘π‘Žπ‘Ÿπ‘π‘œπ‘› β€’ π‘‘π‘–π‘šπ‘’ β€’ π‘‘π‘’π‘šπ‘ β€’ π‘Žπ‘π‘‘π‘–π‘£π‘–π‘‘π‘¦ β€’ 𝑓𝑒𝑒𝑑 β€’ π‘π‘Ÿπ‘’π‘ π‘ π‘’π‘Ÿπ‘’π‘₯π‘˜π‘’π‘7 Kinetic Coke Make π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘22 Reaction Rate Distribution π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘179 Hydrothermal Deactivation π‘₯π‘˜π‘’π‘13 Contaminant Coke Factor π‘₯π‘˜π‘’π‘9 Conversion Kinetic π‘₯π‘˜π‘’π‘22 Reaction Rate Distribution π‘₯π‘˜π‘’π‘14 Wet Gas Yield
  • 8. Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… 7 Kinetic Coke Make Regenerator Temperature 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke 9 Conversion Kinetic Conversion 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses 22 Reaction Rate Distribution LCO/Bottoms Ratio 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity 8
  • 9. Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… 7 Kinetic Coke Make Regenerator Temperature 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke 9 Conversion Kinetic Conversion 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses 22 Reaction Rate Distribution LCO/Bottoms Ratio 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities 9
  • 10. Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… Affected by Cat Formulation? 7 Kinetic Coke Make Regenerator Temperature Yes 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes 9 Conversion Kinetic Conversion Yes 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes 22 Reaction Rate Distribution LCO/Bottoms Ratio Yes 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) No* 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) No* 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes 10 * Yes for combustion promoter
  • 11. Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Affected by Cat Formulation? How Catalyst Affects this Factor 7 Kinetic Coke Make Yes Coke selectivity of base catalyst 13 Contaminant Coke Factor Yes Metals (Nickel) passivation technologies; ADM-60 9 Conversion Kinetic Yes Activity / CTO 14 C1-C4 Gas Yield Yes ZSM-5 Usage, Bottoms Cracking 22 Reaction Rate Distribution Yes Bottoms Cracking / High Matrix; ADM-20; ADM-30 179 Hydrothermal Deactivation Yes RE/Z, Other Stabilizers; Z/M; Binding Technology; GRANITETM 11 Heat of Cracking Ratio Yes Rare earth on zeolite 1 / 93 Regen Coke Burn Rate No* Extreme overpromoting or underpromoting 2 / 94 Regen CO/CO2 Rate No* Extreme overpromoting or underpromoting 15-21 190-3 C2-C4 Individual Gas Yields Yes Re/Z; ACTIONTM; ZSM-5 Usage 11 * Yes for combustion promoter
  • 12. Proprietary Information of Albemarle Corporation. Important Calibration Factors Calibration Factor Factor Pertains To… Affected by Cat Formulation? Typical Value 7 Kinetic Coke Make Regenerator Temperature Yes 0.1 13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes 1.0 9 Conversion Kinetic Conversion Yes 1.0 14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes 1.0 22 Reaction Rate Distribution LCO/Bottoms Ratio Yes 1.0 179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes - 11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes 1.0 1 / 93 Regen Coke Burn Rate C οƒ  CO in Regenerator (dense bed) No* 1.0 2 / 94 Regen CO/CO2 Rate CO οƒ  CO2 in Regenerator (dilute bed) No* 1.0 15-21 190-3 C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes - 12 * Yes for combustion promoter
  • 13. Proprietary Information of Albemarle Corporation. Are my calibration factors good?
  • 14. Proprietary Information of Albemarle Corporation. Are My Calibration Factors Any Good? 14 β€’ Correlate back to calibration input data β€’ Correct data or eliminate case β€’ Check for coincidence with catalyst change β€’ Correlate back to calibration input data β€’ Theoretically these should be flat with little variation β€’ Correlate back to calibration input data β€’ Use best judgment on input data
  • 15. Proprietary Information of Albemarle Corporation. Variability in Calibration Factors 15
  • 16. Proprietary Information of Albemarle Corporation. Variability in Calibration Factors 16
  • 17. Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 17
  • 18. Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 18 CORREL function vs Calibration Input Rows =ABS(CORREL(range1,range2))
  • 19. Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #1 19
  • 20. Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #2 20
  • 21. Proprietary Information of Albemarle Corporation. Calibration Factor Trendplots – Flyers Example #2 21
  • 22. Proprietary Information of Albemarle Corporation. What calibration cases should I use?
  • 23. Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 23
  • 24. Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 24
  • 25. Proprietary Information of Albemarle Corporation. Which Calibration Cases to Use? 25 β€’As many as possible β€’Always consider catalyst formulation β€’Averaging calibration factors dampens variation effects β€’Superday / single-day use may amplify variations Which Cases Should I Use? β€’Significantly different feed rate β€’Different combustion mode β€’Catalyst transition β€’Different catalyst Which cases should I avoid?
  • 26. Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 26 β€’ FCC-SIM Experiment β€’ 22 cases (weekly averages) β€’ Questionable daily data removed 1. Calibrate model for all 22 cases 2. Predict 22 cases Β» Independent variables = same for all, average for all 22 cases Β» Calibration factors = each cases’ individual 3. Predict 1 more case Β» Independent variables = same as above, average for all 22 cases Β» Calibration factors = average for all 22 cases 4. Analyze the variability in the predicted yields
  • 27. Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 27 Wt% Yield Ranges Predicted with Case Calibration Factors Yield, wt% Min -1 sigma Average Calibration Factors +1 sigma Max H2 0.1 0.10 0.12 0.13 0.15 Dry Gas 2.12 2.23 2.36 2.50 2.64 LPG 16.55 17.30 18.14 18.98 19.73 C5 – 430F C5 – 221C 47.06 47.97 49.19 50.41 51.77 430-650F 221-343C 14.61 15.80 16.64 17.48 17.87 650F+ 343C+ 5.11 5.86 6.5 7.14 7.55 Regen Temp F Regen Temp C 1270 688 1296 703 1313 712 1330 721 1336 724
  • 28. Proprietary Information of Albemarle Corporation. Superday vs. Average Projection 28 Delta wt% From Yields Predicted with Average Calibration Factors Yield, wt% Min -1 sigma Average Calibration Factors +1 sigma Max H2 -0.02 -0.014 0.014 0.03 Dry Gas -0.24 -0.13 0.13 0.28 LPG -1.59 -0.84 0.84 1.59 C5 – 430F C5 – 221C -2.13 -1.22 1.22 2.58 430-650F 221-343C -2.03 -0.84 0.84 1.23 650F+ 343C+ -1.39 -0.64 0.64 1.05 Regen Temp F Regen Temp C -43F -24C -17F -9C 17F 9C 23 13C
  • 29. Proprietary Information of Albemarle Corporation. Calibration Summary β€’ Focus on the key calibration factors. β€’ Trendplot key calibration factors always after calibrating. β€’ Calibration factor trendplots should be flat over time. β€’ Fix flyers & variability. Understand the reason for trends. β€’ Use the CORREL function to help relate calibration factors to calibration inputs. β€’ When choosing calibration cases to average: – Use as many as possible. – Consider the base catalyst, feed rate, combustion mode. β€’ Don’t use superdays. 29
  • 30. Proprietary Information of Albemarle Corporation. Revisit The Questions 30 β€’What are the important calibration factors? β€’How does catalyst affect calibration factors? β€’How can I tell if my calibration factors are any good? β€’How should I select which cases’ calibration factors to use? Calibration β€’How can I tell if I need to manually tune the model? β€’How do I know what factor to adjust? Tuning
  • 31. Proprietary Information of Albemarle Corporation.