Advanced Chemical
Engineering
Overview and Capabilities
© 2009 KBR. All Rights Reserved.
Presentation Outline
♦
♦
♦
♦
♦
Portfolio Overview
Areas of Applications
Applications Benefits
Why KBR?
Overview
 Dynamic Simulation
 OTS
 APC
♦ Summary
© 2009 KBR. All Rights Reserved.
Portfolio Overview
Technology Operations
Advanced Chemical Engineering
Advanced Services
Advanced Solutions
Dynamic Simulation
Operator Training Simulator
Computation Fluid Dynamics
Advanced Process Control
Logistics Simulation
Real-Time Optimization
Liquid Transient Analysis
Alarm Rationalization
Technical Data Support
Manufacturing Execution Systems
© 2009 KBR. All Rights Reserved.
Areas of Applications
Troubleshooting
Front End
Design
Commissioning
& Startup
EPC
Dynamic Simulation
Liquid Transient Analysis
CFD
Pinch Analysis
Operation &
Maintenance
Operator Training Simulators
Advanced Process Control
Alarm Rationalization
Real Time Optimization
© 2009 KBR. All Rights Reserved.
Applications Benefits
♦
Resolution of complex design & field problems
♦
Provides hands-on training for smooth startup, shutdown and normal
operation
♦
Faster plant commissioning
♦
Ensures safe operations
♦
Increased plant reliability & availability
♦
Optimizes operations – production, energy use, emissions
♦
Minimize CAPEX & OPEX
1 day to 1 week production gain per year
($0.5MM - $10MM)
© 2009 KBR. All Rights Reserved.
Why KBR?
♦ Intimate knowledge of process and operations
♦ Specialized and experienced execution team
♦ Depth of talent pool within the organization
 plant services, start-up/commissioning teams, machinery, etc
♦ Attention to detail and quality
♦ Open and transparent communication channel
♦ One stop solution provider
© 2009 KBR. All Rights Reserved.
Advanced Chemical Engineering
Dynamic Simulation
© 2009 KBR. All Rights Reserved.
What is Dynamic Simulation?
Dynamic Simulation
(Movie)
Steady State Simulation
(Picture)
Dynamic Simulation tracks the real behaviour of a
process or whole plant over time.
© 2009 KBR. All Rights Reserved.
Why Dynamic Simulation?
♦ Robust Design for the Full Range of Operation
 Startup, shutdown, restart, load variation and other nonsteady state operations
 Minimize design margins
 Verify control systems
♦ Driven by Industry Demand
 Larger and complex systems
 Reliability, availability, operability and performance
optimization
 Optimal design of flare and relief systems
 Improve on past experience
© 2009 KBR. All Rights Reserved.
Dynamic Simulation Applications in KBR
♦ Ammonia
 Utilities – Flare and
Steam
 Control System
♦ Ethylene
 Furnace Control
 Utilities – Flare, Steam
and Fuel Gas
 Compressors
♦ Petro-Chemicals
 Reactor Depressuring
♦ Refining Facilities
 Utilities – Flare, Steam
and Fuel Gas
♦ LNG and Offshore
 Compressor Studies
 Control System
Verification
 Utilities – Flare, Steam,
Fuel Gas
♦ Equipment Specific
 Heat Exchangers
 Vessels
© 2009 KBR. All Rights Reserved.
Dynamic Simulation – Model Validation
Deviation from SCL
0.6
 Surge control
0.4
0.2
DEV.V
♦ Refrigeration
Compressors
0.0
-0.2
-0.4
Simulation
-0.6
Plant data
-0.8
-1.0
0
5
10
15
20
25
30
35
40
45
50
55
time, seconds
01FI3001C
Plant
Model
670000
 Plant Turndown
650000
640000
Mass Flow (kg/hr)
♦ Overall Process
Responses
660000
630000
620000
610000
600000
590000
580000
570000
560000
550000
12:00
13:00
14:00
15:00
16:00
Time
© 2009 KBR. All Rights Reserved.
17:00
18:00
19:00
What Does a Dynamic Model Look Like?
Flue Gas Treating
Flue Gas Cooler
(Rigorous)
Stm Drum
(Rigorous)
Steam/
Condensate
Distillate/Stripper
(Simplified)
Catalyst Feed
System
Converter
(Semi-Rigorous)
PQE
(Rigorous)
Oil Quench Tower
(Semi-Rigorous)
PGC 1st & 2nd
Stages
(Rigorous)
Fuel Oil
Surge Drum
(Rigorous)
Catalyst Filters
Oily Water
Stripper
(Simplified)
Process Feed
System
(Rigorous)
Gasoline
DEA Stripping
(30 trays)
(Simplified)
DEA/HC Stripping
(packing)
(Simplified)
O2 Removal
(Simplified/SemiRigorous)
DEA Tower
(33 trays)
(Semi-Rigorous)
Caustic Tower
(45 trays)
(Rigorous)
Wast Water
Air Feed System
(Rigorous)
Condensate
Core Exchange (Rigorous)
SCC Deprop. Twr
(46 trays)
(Rigorous)
Dryers
(Simplified)
C4 Product to C4
CATPoly
Demeth Twr
(20 trays)
(Rigorous)
Deeth Twr
(38 trays)
(Rigorous)
C2 Splitter
(76 trays)
(Rigorous)
FT DepropTwr
(56 trays)
(Rigorous)
C3 Splitter
(180 trays)
(Rigorous)
PR
(Rigorous)
SASOL SUPERFLEX
Simplified BFD of OTS Scope
© 2009 KBR. All Rights Reserved.
Dynamic Simulation of Ethylene Furnace
OUTLET DAMPER
SPEED RESET
Flue Gas to Stack
ID FAN
COT RESET
Feed "A"
LC
FC
STEAM
DRUM
FC
FPI "B"
FPI "A"
Decoke Air
BFW
W=k
FC
Blow Down
QL = fn(QTLE)
Decoke Steam
FPII "B"
FPII "A"
FC
FC
LP BFW
Dilution Steam "A"
OPEN FOR SWD
DS "A"
DS "B"
UMF "A"
UMF "B"
COT RESET
FC
FC
FEED "B"
Dilution Steam "B"
M
CG to Transfer Line
P=k
CSSH
M
Attemperating BFW
FI
TC
HSSH
TLE
"A"
TLE
"B"
TL "A"
TL "B"
COT
"A"
COT
"B"
RAD
"A"
RAD
"B"
YLD
"A"
YLD
"B"
HP Steam Export
P=k
Different
Feedstock
MF "A"
MF "B"
MFS "A"
MFS "B"
DRAFT
O2 Resets P
PC
AO2
XOV "A"
fn(XOT)
Decoke Effluent
P = fn(W)
Pass-by-Pass Variation
Steam Decoke
ARCH
XOV "B"
QW
fn(XOT)
fn(DUTY)
VENTURI
Yield Model from
Team Ethylene
Pre-cracking in Cross-Over
PC
Fuel
Two-Phase Heat Transfer
& Pressure Drop
ADJUSTABLE FOR SWD
W = fn(DUTY)
1° Combustion Air
COMB
W = fn(dP)
2° Combustion Air
Flue Gas - Control of Firing, Excess Oxygen, ID Fan
© 2009 KBR. All Rights Reserved.
Dynamic Simulation - Relief & Flare Systems
♦ Refinery Expansion
V-3
Crossover
800,000
0.5
0.4
0.3
0.2
0.1
0
600,000
400,000
200,000
0
0
V-6
Flare B
Unit B-1
Unit D-1
48"
10
15
20
Tim e, m in
HP Header
LP Header
Flare A
5
Back
Pressure,
barg
Total Relief
Flow, lb/h
V-1
Flare Relief Profiles
Total Relief Flow
Back Pressure Profile
V-7
54"
Unit Reliefs
Unit A-1
36"
Unit Relief, lb/h
Unit C-1
Unit H-1
(new unit)
Unit H-2
42"
54"
200,000
150,000
100,000
50,000
0
0
 Adequacy of relief & flare system design
 Relieving sequence
 HIIPS Validation
© 2009 KBR. All Rights Reserved.
5
10
15
Tim e, m in
Unit 1 Flow
Unit 2 Flow
Unit 3 Flow
20
Advanced Chemical Engineering
Operator Training Simulator
© 2009 KBR. All Rights Reserved.
What is OTS?
Plant
Dynamic Model of the Plant
DCS Consoles
© 2009 KBR. All Rights Reserved.
Advanced Automation Examples
Advanced Process Control
© 2009 KBR. All Rights Reserved.
What is Advanced Process Control?
Original Setpoint
New Setpoint
$$$
Product Specification
Poor Control
(without APC)
Better Control
(with APC)
Optimized
Setpoint
♦
STABILIZE unit operation - minimize variability of key process variables
♦
PUSH to constraints - reach closer to the product quality and equipment
limitations
♦
OPTIMIZE - minimize energy consumption or maximize plant throughput
© 2009 KBR. All Rights Reserved.
Advanced Process Control - Ammonia
In general, the benefits of implementing a APC system in an ammonia
plant are: an increase in the ammonia throughput by 1 to 4%, decrease
in the energy consumption by 1 to 3%
© 2009 KBR. All Rights Reserved.
Advanced Process Control - Ethylene
BEFORE
AFTER
observation
( Ethane ppm)
range
© 2009 KBR. All Rights Reserved.
Advanced Process Control - Benefits
% change
♦ FCC Unit (Mexico)
20
 Improvement in
converter operation
from
15
10
• Better conversion
• Closer operation to
constraints
5
0
-5
 Benefits of over
$1,000,000 / year from
increase in production
of higher value
products
-10
-15
-20
C3=
© 2009 KBR. All Rights Reserved.
C4
C5
Gasoline
LCO
Slurry
Summary
KBR Technology
Proprietary
Technologies
Advanced Services
& Solutions
© 2009 KBR. All Rights Reserved.
Client Support
Services
Thank you very much…
Questions?
© 2009 KBR. All Rights Reserved.