catcracking seminar düsseldorf, october 17-21, 2011 · 2017-08-03 · catcracking seminar...
TRANSCRIPT
CatCracking SeminargDüsseldorf, October 17-21, 2011
Online, Non-intrusive Trouble Shooting and Process Characterization of FCCU's using Gamma Ray and Tracer Technology
Presented by:Lee Robins and Andrew Shaw
Presentation Format
Introduction to Tracerco Process Diagnostics™ The Technology
Applications of the Technology for FCC Diagnostics pp gy g
Case Studies
Conclusion and Questions Conclusion and Questions
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Tracerco, who are we?
Tracerco: Part of Johnson Matthey Plc …leaders in environmental catalytic solutions, preciousin environmental catalytic solutions, precious metals and process technology
• Founded in London almost 200 years ago• Publicly listed FTSE 100 Company• Turnover excess $10bn • 10,000 employees in 50 countries
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Tracerco – Markets Served
Upstream Oil & Gas - Reservoir to Refinery
• Separator Studies• Flow Assurance• Pig Tracking
I t it A t
Downstream Industry – Refineries to Polymers
• Integrity Assessment• Flow Rate Studies
y y• Distillation Column Studies• Reactor system trouble shooting & vessel inspection• Heat Exchanger Leak TestHeat Exchanger Leak Test• FCC Unit Studies• Flow Assurance• Integrity Assessment
Pi li A• Pipeline Assurance
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The CompanyTracerco – Global Support
World leading technology specialists in radioisotope technology,
chemical tracers, measurement & instrumentation
R&D Centre at HQ plus science institutes worldwide
350+ qualified scientists, engineers and technologists
Winner Queen’s Award for Enterprise: Innovation 2003 and 2009
Winner Queen’s Award for Enterprise: International Trade 2005
ISO 9001:2000 certified
HQ - Billingham, UK, Aberdeen (Scotland)Argentina – Buenos Aires
ISO 9001:2000 certified
SCC 2006 certified
Australia – PerthAzerbaijan – BakuBrazil – Rio de JaneiroBelgium – BrusselsCanada – Sarnia, ON; Edmonton, ABGermany – OldenburgGermany OldenburgIndonesia – JakartaItaly – Vaprio d’Adda (MI)Malaysia – Kuala LumpurNetherlands – RotterdamNorway – BergenSingaporeThailand – BangkokUSA – Pasadena, TX; Corpus Christi, TX; Fresno, CA; West Valley City, UT; Merrillville, IN; Newark, DE; Baton Rouge, LA
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The Technology
P id di ti i t h l t i d i li t
Pioneers in radioisotope science…• Provide diagnostic scanning technology, tracer services, and specialist
nucleonic instrumentation to the Oil, Gas and Process Industries to enhance process plant performance
• Experts at seeing inside process plant to verify real time process conditions andExperts at seeing inside process plant to verify real time process conditions and equipment integrity - Online and non-intrusive : Insight Onsite
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The Technology – Gamma Ray Scan
• Gamma Scanning using sources and detectors to non-intrusively scan through vessels and pipelines to obtain accurate density/
I = IO e -μρxintegrity measurements
O
ρ
IO Iρ
GAMMA RAY μGAMMA RAY μ
x7
The Technology – Tracer Injection
• Tracer Injection using Unsealed Isotopes for tracking the different phases present in a particular process
• Gas, liquid, or solid form (individually measure hydrocarbon, steam and catalyst)• Follows process material into which it is injected
M it d b t ll t d d t t
Condition 1 HP Flare Normal Purge
• Monitored by externally mounted detectors• Process parameters can be measured
Condition 1 - HP Flare Normal Purge
8001000120014001600
Res
pons
e
Applications:• Flow Rate Measurements• Distribution Studies• Residence Times
0200400600800
0 2 4 6 8 10 12 14 16 18 21 23 25 27 29 31 33 35 37 39 41
Time after Initial Injection (seconds)
Det
ecto
r R • Residence Times• Leak Detection / Bypassing• Carryover• FCCU Efficiency Studies
Run 1 Run 2 Run 3
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Applications of the Technology – FCCU’s
Improving profitability, increasing yields and reducing downtime are all key parameters for any FCCU. Tracerco Diagnostic Solutions
th l t h i il bl t ff ti l ‘l k i id ’ kiare the only techniques available to effectively ‘look inside’ a working FCCU to accurately measure:
·feed and catalyst distribution in the riser feedfeed and catalyst distribution in the riser feed zone
·catalyst and vapour traffic velocities and slip through the riser
·determination of efficiency of the riser termination device
·flow distribution through the reactor and stripper
·cyclone distribution/operating characteristics
·reactor/stripper residence times
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Applications of the Technology – FCCU’s
Technology used in 5 keysections of FCC unit:• Riser
Di t Ch b• Disengagement Chamber• Stripper• RegeneratorRegenerator• Stand-pipe
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Applications of the Technology – FCCU’s
• When is the technology used?When is the technology used?• Trouble-shooting exercises
• Fast responsep• Process optimisation trials
• Immediate results• Pre-shutdown investigations
• No effect on processC i i i t i l• Commissioning trials
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Applications of the Technology – FCCU’s
BenefitsBenefits• Minimise shut down time• Increase production capacityp p y• Reduce operating costs
• Minimise raw materials• Reduce utilities• Identify catalyst losses
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Applications – Riser Study
C t l t D it P fil• Catalyst Density Profile• Coke Deposits• Velocity slip ratios• Velocity - slip ratios• Residence times• Distribution of feed, ,
steam & catalyst
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Applications – Cyclones and Disengagement Chamber
R id ti• Residence times• Distribution• Cyclone blockages• Cyclone blockages• Cyclone efficiency• Vapour underflowp• Carryover
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Applications – Stripper Section
R id ti• Residence times• Velocities• Distribution• Distribution• Steam underflow• Catalyst Bed y
Level• Dip-Leg Catalyst
L lLevels
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Applications – Regenerator and Stand Pipe
Ai di t ib ti• Air distribution • Cyclone efficiency• Catalyst distribution• Catalyst distribution• Carryover
• Stratification of catalyst• Slugginggg g• Catalyst Flow Patterns• Catalyst Density Profiles
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CFD vs Real time data
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Case Studies – Regenerator Bed Level Scans
Th diff t ti• Three different operatinglevels of the Regenerator
• Gamma Scan at each condition to optimize the bed level and reducebed level and reduce catalyst carryover.
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1000 10000
Case Studies – Scan of Internal Cyclones to locate Blocked Cyclone
2’
4’
Exte
0’
6’
8’
10’
rnal Lining0
12’
14’
16’
18’
20’
Plugged Cyclone Dipleg
Bracing
22’
24’
26’
Flapper Valve
Manway
26
28’
30’
Catalyst
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Case Studies – Scan of Internal Cyclones to locate Blocked Cyclone – example 2
• Cyclone A was blocked.
TRACERCO Diagnostics FCCU StudyCyclone Scan
Cyclone A was blocked. • The blockage
commenced at elevation 500mm, in the narrow ,part of the cyclone, but the catalyst had backed up to elevation 6300mm.
• Above elevation 6300mm, the blockage cleared and the scan profile from that point upwards is identical to that of Cyclone B.
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Case Studies – Catalyst Distribution in Riser
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Case Studies (Tracer) - RTD Maldistribution
TRACERCO Diagnostics FCCU StudyRTD Vapour Inlet Distributionp
200
250
150
atio
n In
tens
ity
Pick-up fromOverheads Line
50
100
Rad
ia
040 42 44 46 48 50 52 54 56 58 60
Time (seconds)
RTD1 Inlet RTD2 Inlet RTD3 Inlet
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Case Studies (Tracer) – Vapour Underflow
TRACERCO Diagnostics FCCU StudyRTD Dip-leg Vapour Distributionp g p
30
35
300
350Vapour Returning up
Disengagement Chamberwith Stripping Steam
Pick-up fromOverheads Line
15
20
25
atio
n In
tens
ity
150
200
250
5
10
15
Radi
a
50
100
150
Vapour UnderflowResponse
040 60 80 100 120 140 160 180
Time (seconds)
0
RTD1 Dipleg Top RTD2 Dipleg Top RTD3 Dipleg Top Overheads 2 (2nd Y-axis)
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Case Studies (Tracer) – Cyclone Blockage
Results from distribution study
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Case Studies (Tracer) – Stripper Maldistribution
Gross maldistribution East/West maldistribution
East side maldistributionEast side maldistribution
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Case Studies – Stripper Upgrade
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Case Studies (Tracer) – Stripper Maldistribution
TRACERCO Diagnostics FCCU StudyStripping Steam Distribution
B f
1000
1200Before
600
800
diat
ion
Inte
nsity
200
400
Rad
030 32 34 36 38 40 42 44 46 48 50
Time (seconds)
Stripper Top N Stripper Top E Stripper Top S Stripper Top W
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Case Studies (Tracer) – Stripper Maldistribution
TRACERCO Diagnostics FCCU StudyStripper Steam Distribution - Top
Aft
160
180
200
6400
7200
8000After
80
100
120
140
iatio
n In
tens
ity
3200
4000
4800
5600
20
40
60
80
Radi
800
1600
2400
3200
025 35 45 55 65 75
Time (seconds)
0
Stripper Top N Stripper Top E Stripper Top S Stripper Top W Strip Steam In
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Case Studies – Effectiveness of Equipment Upgrades (e.g. RTD’s)
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Case Studies (Tracer) – Vapour Maldistribution in Dip Legs
Vapour Distribution in RTD Dip-Legs
160 40
100
120
140
ty 25
30
35
60
80
100
Rad
iatio
n In
tens
i
15
20
25
0
20
40
0
5
10
030 35 40 45 50 55 60 65 70 75 80
Time (seconds)
0
Riser 1 Dip-Leg Bot N Dip Leg Bot S
Detector DistributionDi L B tt N th 40%
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Dip-Leg Bottom North 40%Dip Leg Bottom South 60%
Case Studies (Tracer) – Vapour Distribution Above Air Grids
FCC Regenerator Air Grid DistributionLower Air Grid Injection
Position Percent Area
Air 1 14 4%Air 1 14.4%Air 2 13.4%Air 3 4.0%Air 4 6.0%Air 5 10.5%Ai 6 5 3%Air 6 5.3%Air 7 7.4%Air 8 10.6%Air 9 5.3%
Air 10 10.0%Ai 11 5 8%Air 11 5.8%Air 12 7.3%
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Case Studies (Tracer) – Vapour Distribution Cyclone Inlets
FCC Regenerator Cyclone DistributionLower Air Grid Injection
Position Percent Area
N Cyclone 12.3%NE Cyclone 14.9%
E Cyclone 12.7%SE Cyclone 10.9%y
S Cyclone 12.5%SW Cyclone 13.2%
W Cyclone 10.7%NW Cyclone 12 7%NW Cyclone 12.7%
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Example of Tracer Results - (Link to animation)
Conclusion
• Scanning and Tracer injection/detection are the only techniques that allow you to effectively ‘look inside’ your FCCU whilst in t at a o you to e ect e y oo s de you CCU stnormal operating conditions.
• The perfect technology to:• Troubleshoot operating problemsTroubleshoot operating problems• Carry out a Process Optimisation Study• Plan a Turnaround more efficiently
C t ‘b li ’ t d f th it d i C i i i• Carry out a ‘baseline’ study of the unit during Commissioning or after a Turnaround
• Measure Efficiency gains after a Retrofit• CFD modelling has limitations. Tracerco measurement data can
be used to complement/enhance CFD modelling for more accurate analysis.
Thank you and any [email protected] - [email protected]
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