1 Cracker RTO Approach
Presented by : Velagala V Reddy November 2019 Team: Wasique Khan, Velagala V Reddy, Viknesh Raja, Fareed Khan DISCLAIMER
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3 Content
Reliance Industries Limited – Overview
APC - RTOs at Reliance
Cracker RTO Scope
In - House Furnace Model
CKR RTO - Model Features
Benefits and Timeline
Forward Path 4 Reliance Industries Market cap of ~$ 125 billion
Introduction & Financials
Introduction & Financials
5 © Reliance Industries Ltd., 2019 India’s Most Profitable Company Today
A market leader across energy and materials value chain (E&P, R&M, Petchem) and in consumer businesses (Digital Services and Retail)
• Most profitable company for the year 2018-19. Recorded a net income of US$ 5.7 billion • Revenue of US$ 90.1 billion, PBDIT of US$ 13.4 billion. Market cap of ~$ 125 billion
Energy Value Chain Consumer-centric Businesses
Refining and Marketing Reliance Retail ◼ Largest, most complex single site refinery with 1.24 ◼ India’s largest retailer by revenue ($18.9 bn) mb/d capacity ◼ 10,415 stores with 22 MM sq.ft. space ◼ Consistently outperforming regional margins ◼ Presence across 6,600+ cities ◼ ~58% volumes placed in international markets ◼ One of the world’s fastest store expansion – added Petrochemicals ~10 stores a day in last 2 years ◼ Ranked Top 10 globally in key products Introduction ◼& 2ndFinancials largest producer of polyester fibre/yarn globally Reliance Jio ◼ FY19 Production: 37.7 MMT ◼ All IP-data network with latest 4G LTE technology ◼ India’s largest wireless data subscriber base : 306.7 Exploration and Production Mn with net adds of 120 Mn in FY19 ◼ Significant expertise in deep-water operations ◼ ~10.9 GB per user per month ◼ Substantial exposure in US Shale ◼ Carrying 71% of the total industry’s 4G data traffic ◼ R-Cluster first gas expected in 2H FY2021 (CY18) 6 © Reliance Industries Ltd., 2019 US$1 = INR 69.155 Forty Years of Phenomenal Growth
• Polyester expansion commissioned (PFY, PET, • Jamnagar refinery & PTA and PX) petrochemical complex – 2 • Elastomers (PBR,SBR) • KG-D6 production commissioned • Jamnagar Integrated • US Shale gas JVs • Ethane project, ROGC refinery and petrochemical commissioned • Cracker and Polymers @ complex • Partnership with BP • Acquired spectrum in Hazira • KG-D6 discovery • BWA spectrum 800/1800 MHz band • Fiber Intermediates @ • IPCL acquisition • Launched biggest ever Hazira hydrocarbon capex • JIO crosses 300 mn • Foray into organized retail subscriber milestone • Upstream – PMT program • IPO • Recron Malaysia • CBM production • GDR Issue • Innovative financing – • Polyester @ • Fortune Global 500 perpetual bond, • Gasification under • 50/100 Years Yankee Patalganga EXIM facilities stabilization Bond 1977-87 1987-97 1997-2007 2007-12 2012-19 7 © Reliance Industries Ltd., 2019 Reliance APC-RTOs at a glance
APC/RTO Coverage
✓ CDU/VDU ✓ FCC ✓ Reformer ✓ Alkylation Refinery ✓ Hydrocracker ✓ Cracker ✓ Hydrotreaters ✓ Butadiene ✓ Coker ✓ Aromatics ✓ CPP ✓ MEG Petrochemical ✓ Sulphur/Amine ✓ PTA ✓ VCM/PVC ✓ ACN ✓ CP Polymers ✓ LLDPE
✓ Endpoints ✓ RVP/ Flash Inferential ✓ Conversion ✓ CDU/VDU ✓ FCC/VGOHT RTO ✓ Coker ✓ Cracker ✓ Aromatics
8 Cracker Control Hierarchy
Planning
Scheduling
ROMeo Optimization
CLP
APC
Furnace Cold CGC & Quench Hot Hydrogenation FM_C2C3
DCS
9 Cracker RTO Scope
Cracker Block Diagram
Feed Handling Furnace & Dilution steam Demethanizer and and Cold Quench Tower CGC TLEs generation chilling Train Recovery Unit
C2R C3R
Acetylene Ethylene Deethanizer hydrogenation Fractionator
Propylene MAPD Steam Depropanizer CW Network Splitter Hydrogenation Network
Gas Customization Debutanizer MVC Block fractionator & Hx-Linkers
10 In-house Cracker Reactor Model - Milano
Fortran code for 133 Reactions,13 free radicals and 19 molecules. Total 32 components
Approach towards tuning – 7 kinetic Categories
Fortran dll used in excel for initial tuning of reactors.
ROMeo provides two options either OE code in Milano or CE black box models R*+R’*→R’’ Chain termination Geometry exposed to GUI, can input any coil configuration R→R’+R’’ reactions Purely molecular reactions Temperature Profile is estimated approximately along the tube length R*+R’→R= Radical Addition reactions to Pressure Profile is calculated along the tube length. R*→R’* Unsaturated molecules Radical isomerisation R*→R’+R’’ reactions Radical Decomposition Reactions R*+R’→R+R’’ Furnace Hydrogen Abstraction Reaction R→R* Yield
Chain Initiation Reaction 11 In-house Cracker Reactor Model - Milano
12 Cracker Reactor Model and Design Yield Comparison
Ethane Cracking Propane Cracking
13 In-house Cracker Reactor Model - Milano
Online tuning parameters on the Furnace model to match plant yields
Feed Distribution to different zones and modes of Furnace operations done by Switching Macros
Customized fire Box model as Radiation section
17 Furnace zone is modeled with each zone as single reactor.
Multiple Hx-Linker for convection Section
Faster and robust execution
TMT, CPR and Run-length constraints are approximated by regressed equations.
14 CKR Model Features
Multiple Hx-Linkers are used for Pressure drop equations are tuned cold box modeling in data reconciliation at high volumetric flowrate zones
C2R, C3R & CGC Compressors Valve output Constraints are also included using modeled using performance curves the simple gain module and Hydrogenation reactors are approximated using Conversion reactor
Configured Close loop Steam, BFW APC MVs as optimization variable & and Refrigeration circuits CVs as Constraints. APC calculated variables are included in the model through calculation blocks
15 CKR Model Implementation Features
APC Limits Plant values that are outside APC Limits are NOT pushed further during Optimization by considering them as Relaxed bounds Equipment performance Report also contains detailed Furnace yields, column efficiency, heat exchanger Execution Logics U and Compressor efficiency. Ramper Logic for ETs - Smoother APC movement. Performance Index Unified Performance Index to track RTO benefits and its run time Reports Automated Shift and Daily Reports to Operations, CTS and RTO Engineers
16 Benefits and Timeline
Kick off meeting
Online: Offline: FDS sign off 1 months • Furnace load distribution • Shift wise Top five profit • Furnace conversion improvement opportunities Subflowsheet review Building • Dilution Steam Ratio 7 months • Recovery vs Energy • Offline case scenarios testing, DBN Testing, Plant • Hx and Compressors Integrating Troubleshooting, Equipment Monitoring Flowsheet performance monitoring 3 months Open loop testing & Close loop commissioning 3 months17 Forward Path
Repeat the success story at two other crackers
Graphical interface with RTO Target Historian
Advisory systems from Delta vectors for fouling prediction
Advisory Parallel run with engineering limit offline to evaluate maximum achievable profit
Ramper logic improvement
Hard limits in RTO to bring critical CVs within limits
Evaluation of better approach – All APC constraints vs accurate constraints
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