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

1. FCC-SIM model usage
Esa Tamminen
Senior Process Specialist
Operations, Porvoo Refinery, Neste Oyj
KBC User Group Conference, June 2018, London

2. • Based Finland
• Two conventional Refineries = 15 Mt/a
• Porvoo and Naantali
• Two NEXBTL-refineries + 2 units in Porvoo = 2,6 Mt/a
• Singapore and Rotterdam
• 76 % of the feedstock is waste or residue
• 24 % palm oil
• Porvoo is complex refinery
• CDU, VDU, REF, HCR, FCC, ALKY, RHCR, SDA, H2
• Several HDTRs, Gaso Isom, MTBE, TAME, …
Neste Oyj
Esa Tamminen / Neste Oyj, Operations2

3. • Flow correction, mass balance accuracy
• Problems with data
• LP example
• Model as a source of process data for equipment monitoring
• From FCC-SIM model to an OTS
• Organisation culture
Contents
Esa Tamminen / Neste Oyj, Operations3

4. • Monitor (test run) once a week
• Neste uses mass flow based reporting
• Most flow meters are orifices
• Temperature compensation is done in DCS
è Reconstruct the compensation (density)
• Density correction based on samples
• Distillation curve and SPGR
• Temperature seen by the meter
èUse Petro-SIM to calculate actual density
Flow correction, mass balance accuracy
Esa Tamminen / Neste Oyj, Operations4

5. • Correct all mass flows in Excel (prior FCC-SIM)
Flow correction, mass balance accuracy
Esa Tamminen / Neste Oyj, Operations5

6. • Problems in
slurry line flow
meter causes a
systematic error
in mass balance
• By cleaning the
line & meter,
good accuracy
was achieved.
Flow correction, mass balance accuracy
Esa Tamminen / Neste Oyj, Operations6

7. • Light gas sample location
• C3 recycle via storage
• HGaso Flow meters
• LCO runs
• Combined feed(s) vs
separate feed flows
• CO used as pump
sealing liquid
Problems with data
Esa Tamminen / Neste Oyj, Operations7

8. • Heat losses
• Originally FCC-SIM guideline
• Calculations
è more accurate value
è locations of losses
• Afterburn
(post regenerator)
• Light gas composition
– partial fix
• Introduce interior balances
• Instrument purges
with fuel gas
Problems with data
Esa Tamminen / Neste Oyj, Operations8

9. • Significant shifts in some yields
• Partly due to newly introduced operating
parameters (cut points)
• Gasoline and Kero flow changes up to 8 t/h
• Discovered sulphur balance problem
• A notable change in refinery LP model
result
• Shifts in feed stock purchase and gasoline
blending
• Approx. 10 M$/year change in profit
LP example
Esa Tamminen / Neste Oyj, Operations9

10. • Regenerator is at the end of its life cycle
• Licensor requires valid process data
• Licensor reports using desired conventions
• Wet gas compressor renewal
• Use detailed model to obtain process data
• Catalyst selection process
• Absorber-Stripper
capacity study
Model as process data source
Esa Tamminen / Neste Oyj, Operations10

11. • OTS uses hypo components
è detailed chemical composition is not there
• FCC reaction chemistry is very complex
è accurate modelling requires hundreds of components
è reaction network must be calibrated against plant data
FCC-SIM model as a basis for an OTS
Esa Tamminen / Neste Oyj, Operations11
Do these requirements
ring a bell ?

12. • Do we really need complex reaction network ?
• LP vectors capture changes in yield
• OTS has yield shift reactor model
è Use FCC-SIM to create yield shift vectors
è Input the vectors into OTS
è ”Changes” in OTS ~ ”Drivers” in LP
FCC-SIM model as a basis for an OTS
Esa Tamminen / Neste Oyj, Operations12

13. • Neste FCC OTS (built by Neste Engineering Services)
FCC-SIM model as a basis for an OTS
Esa Tamminen / Neste Oyj, Operations13

14. • Understanding of catalyst behaviour and
circulation in FCC
• https://napcongames.com/
FCC-SIM model as a basis for an OTS
Esa Tamminen / Neste Oyj, Operations14

15. • Successful test run requires everyone
• Sampling
• in time
• representative
• Lab analysis – analyze all
• Steady state
Organisation culture
Esa Tamminen / Neste Oyj, Operations15

16. • Plant engineer’s
• Responsibilities
• Tools
Organisation culture
Esa Tamminen / Neste Oyj, Operations16

17. • Flow correction, mass balance accuracy
• Problems with data
• LP example
• Model as a source of process data for equipment monitoring
• From FCC-SIM model to an OTS
• Organisation culture
Summary
Esa Tamminen / Neste Oyj, Operations17
Thank you