Blendingwith DeltaV
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This document discusses blending processes and how DeltaV can help with blending control and optimization. It begins with defining blending as the uniform mixing of three or more streams to produce a product with specific properties. It then discusses challenges with blending like flow constraints and accuracy. The document outlines the history of blending moving from mostly sequential to more inline blending. It also discusses who uses blenders like refineries and chemical plants. It then covers the benefits of improved blending like reduced costs and inventory. The final sections discuss DeltaV's blending control strategy and modular design. It provides overviews of ratio control, quality control, optimization capabilities, and the operator interface for blending control and optimization.
Blendingwith DeltaV
- 1. Digital InlineDigital Inline Blending with DeltaVBlending with DeltaV by Emerson Process Management @Copyrights
- 2. Emerson Process Management Confidential AgendaAgenda What is Blending? How do we do it? Blend Ratio Control Blend Quality Control & Optimization Conclusions
- 3. Emerson Process Management Confidential What is BlendingWhat is Blending Definition – Uniform mixing of 3 or more different streams to produce a product with specific properties Problems: Flow Constraints Inventory Constraints Accuracy & Precision Poor Mixing (Tank stratification) Approaches Sequential Blending Continuous Inline Blending
- 4. Emerson Process Management Confidential History of BlendingHistory of Blending Prior to 1990 Most blending is sequential 1990 – 2000 Most refinery (gasoline & diesel) blenders upgraded to inline blending Some chemical blending converted to inline 2000+ Gasoline blenders forced to consider optimization Most remaining sequential blenders upgrade to inline
- 5. Emerson Process Management Confidential Who Uses BlendersWho Uses Blenders Refineries Gasoline Diesel Distillates, Solvents, Fuel Oils Lube Oils Asphalt Chemical Plants Other Baby Formula The blender is the cash register of the refinery
- 6. Emerson Process Management Confidential Blender’s Operating ProblemsBlender’s Operating Problems Make more grades with more specifications using many more components Make the grade on-spec with minimum giveaway, but don’t use too much of any one component Don’t contaminate any finished product tanks because of bad line-ups, line fill, leaks, etc. This is a manually intensive operation but doing it right is key to the refinery’s profitability Increase capacity Blend Operator
- 7. Emerson Process Management Confidential Improved Blending BenefitsImproved Blending Benefits Reduced “Giveaway” - Produce closer to specification, reduced cost of producing average blend Reduced Off-spec and co-mingled material Reduced Reblending - increased capacity on blenders Reduced Component and Product Inventory - reduced working capital Reduced Blend period – Blend is on-spec from start to finish Estimated benefits $0.05 to $0.10 per barrel of gasoline blended
- 8. Emerson Process Management Confidential Sequential Vs. Ratio BlendingSequential Vs. Ratio Blending One Component at a time Economical Method (Lower Installation Cost) Line Flush required for proper product quality Blend Accuracy assured only for completed batches Large volume blends will require long periods of mixing In-line or all at same time Requires meter and valve for each stream Precise control of blending Instantaneous alarms on blend available Blend quality assured on aborted blends
- 9. Emerson Process Management Confidential An Integrated Application SolutionAn Integrated Application Solution Consulting High Performance Field Instrumentation Control Valves Flowmeters On-Line Analyzers Conventional Analyzers (GC’s, NIR, etc) Neural Network based inferential sensors DeltaV Controller w/ Proven Configuration & Algorithms Blend Quality Control, Optimization & Scheduling Turnkey Skid Installation, Start-up & Training Financing
- 10. Emerson Process Management Confidential FC Component Ratio Control FI AI Blend Quality Controller On-Line Blend Optimization Ratio Targets Component Ratio & Quality Targets Component Qualities & Limits Desired Rundown Rate & Flow Limits Blend Planning LP Prices Batches Target Recipes Target Inventories Heel Information Component Quality & Availability Blend Start/Stop FC FC FC DeltaV Blend DeltaV Blend Control StrategyDeltaV Blend Control Strategy
- 11. Emerson Process Management Confidential Modular DesignModular Design Continuous or Batch (Tank) In-Line Digital Blending Recipe Control 30 recipes with 80 configurable parameters each Start/Hold/Resume/Complete logic Blend Reports Component & Additive Ratio Control Pacing (Instantaneous ratio control) Memory (Total ratio control) Ramp up/down Dual Analyzer Trim Control Decoupling
- 12. Emerson Process Management Confidential OptionsOptions Basic Customization Add/Delete streams Custom graphics Customer Tags Define I/O Add/Delete recipes/parameters Optimization Low level optimization in Analyzer control strategies High level optimization integration (OPC) Master Blend Control Coordination of multiple blend headers Integration of header and pipeline control (OM&S)
- 13. Emerson Process Management Confidential OptionsOptions Simulation Training Testing Custom Interfaces (analyzers, optimizers, etc) Special Calculations & Functions Special equipment scheduling and blend line-ups based on production rates, equipment availability, etc Derived Quality Calculations Blend grade transition and Tank heel accounting Tank Farm Management Component, additive & product compatibility checking Scheduling and Time-to-completion calculations
- 14. Emerson Process Management Confidential Standard DeltaV Blender AlgorithmsStandard DeltaV Blender Algorithms Blend Ratio Control Streams 12 main component flows 4 additive flows 2 Analyzer trim controllers with decoupling (Optional) Start/Stop Control Sequential blender pump and valve line-ups 1 pump, 1 control valve, 1 flow transmitter per stream Delay Sequences, ramping up/down Analog & Discrete controls and monitoring of auxiliary equipment Feed and Product tank level Monitoring Header pressure & temperature control
- 15. Emerson Process Management Confidential Blend Start/Stop ControlBlend Start/Stop Control Startup Sequencing Load Blend Order to on-line system Log starting conditions to Blend Order DB Flush lines Zero totalizers Select, Line-up, & Start pumps Ramp valves open and put FC’s into control Start ratio control, ramp to target rate Shutdown Sequencing Ramp down blend rate to minimum Place FC’s in manual and close valves Shutdown pumps Log final blend results to Blend Order DB
- 16. Emerson Process Management Confidential Operator InterfaceOperator Interface Primary Operating Displays Blend Setup Blend Overview Graphic Component & Additive loops Analyzer Trim Control Interlock/Permissive Status Displays Active/Bypassed Recipe management Displays –Load recipes –Modify recipes –Save recipes Support Displays –Trends –Alarm management –Reports
- 17. Emerson Process Management Confidential Primary User ViewsPrimary User Views Blend Control Recipe Management Blend Setup Blend Components
- 18. Emerson Process Management Confidential FC Component Ratio Control FI AI Blend Quality Controller On-Line Blend Optimization Ratio Targets Component Ratio & Quality Targets Component Qualities & Limits Desired Rundown Rate & Flow Limits Blend Planning LP Prices Batches Target Recipes Target Inventories Heel Information Component Quality & Availability Blend Start/Stop FC FC FC DeltaV Blend Blend Quality Control & OptimizationBlend Quality Control & Optimization
- 19. Emerson Process Management Confidential US Gasoline Regulatory Time LineUS Gasoline Regulatory Time Line 20052004200320022001200019991998199719961995 CARB CBG EPA RFG Phase ll EPA Low Sulfur Gasoline EPA RFG Complex Model CARB MTBE Phase Out EPA RFG Simple Model Each New Regulation Means More Complicated Blending 199419931992 Mandated Oxygenates
- 20. Emerson Process Management Confidential Complicated Gasoline SpecificationsComplicated Gasoline Specifications Parameter Current California Specification Octane Per Grade RVP 7.0 psi max Sulfur 80 ppm max 30 ppm av T50 220 F max 170 F min 200 F av T90 330 F max 290 F av Olefins 10 vol % max 4 vol % av Aromatics 30 vol % max 22 vol % av Oxygen 2.7 wt % max 1.8 wt % min To meet these specifications is a complicated multivariable control problem
- 21. Emerson Process Management Confidential Longer term coordination Production Planning Medium term definition of activities Production Scheduling Blend Control Real-time regulatory control & optimization Initial ConditionsPlanned production and/or material and resource constraints Current Status and PerformanceTargets and recipes Interactions between Planning,Interactions between Planning, Scheduling, and ControlScheduling, and Control
- 22. Emerson Process Management Confidential So why isn’t recipe control enough for blending? Production PlanningProduction Planning Linear Program (LP) Run monthly (weekly?) with average product demand Selects crudes, intermediates, and product purchases for future period (one to three months) to meet demand at maximum profit Sets average blend recipes for period (assumed component quantities and qualities)
- 23. Emerson Process Management Confidential ProblemsProblems Simplified LP models Crude assay database Component properties are different than that assumed by Planning LP Crudes are run individually or in blends different from average resulting from the Planning LP Specific batches of gasoline have to be produced to a specific grade with the stocks on hand How can we help solve these problems?
- 24. Emerson Process Management Confidential Multi-Period Blend Planning LPMulti-Period Blend Planning LP Multi-period, multi-blend, executed daily or weekly Linearized blend models (recursive LP) Determines optimum blends required to meet specific batches of product demands Integrated with refinery planning LP Inputs: Product shipments, prices Starting inventories Projected component rates & qualities Target ending inventories Outputs: Finished product batches Target recipes for each batch Target ending inventories for each period (products and components)
- 25. Emerson Process Management Confidential Traditional Blend Control ArchitectureTraditional Blend Control Architecture Blend Models AI FC FC FC FC FC AI MPC Dynamic Models Ratio Controls (Ramping & Pacing) Flow Targets Blend Property Control Ratio Targets Blend Scheduling Target Recipe & Availability Blend Models Blend Optimization Product Quality Targets Component Flows
- 26. Emerson Process Management Confidential Blend Order Management System Blend Order ManagementBlend Order Management Blend Order Database Blend Start/Stop Blend Order Execution MMI Blend Reports Blend Reporting Blend Optimizer
- 27. Emerson Process Management Confidential Blend Order ManagementBlend Order Management User Interface to Blend Order Database Security functions User authority changes with order status Order Entry Load from past orders Order Management Tracks orders through phases Confirms required data input before changing phases Approvals Data validation Blend Reporting
- 28. Emerson Process Management Confidential Blend Order Data ObjectBlend Order Data Object Blend Order • Blend Order ID • Blended Product Name • Blender ID • Order Status • Planned start/end time • Target Quantity • Product Quality Targets & Limits (up to 25 qualities) • Components and target quantities (up to 15 components) • Additives and target quantities (up to 10 additives) • Special instructions • Actual time for each status change • Final blend results • Operator comments
- 29. Emerson Process Management Confidential Blend Order PhasesBlend Order Phases Planned Approved Selected Starting Active Stopping Complete Hold Blend Planner in Control Operator in Control
- 30. Emerson Process Management Confidential Offline Blend OptimizationOffline Blend Optimization File based Load inputs from stored blend orders Alternative objective functions Correct for heel User can modify all inputs Inputs: Target recipe Desired finished batch size Finished product quality specs Component qualities and availability Heel quantity and qualities Outputs: Optimal blend qualities Optimal recipe Final batch size
- 31. Emerson Process Management Confidential Blend OptimizationBlend Optimization • Optimum recipe • Component usage • Predicted qualities Results RTO+ Real-Time Optimization Engine Inputs • Prices • Target Recipe • Product Specs • Component Availability • Current Heel Quantity & Quality Objective Function • Maximize Profit • Minimize Deviation from Target Recipe • Min/Max use of Specific Component Blend Models
- 32. Emerson Process Management Confidential • Total Blended Amount • Predicted Density • Predicted Qualities Outputs Blend ModelsBlend Models • Component Name • Amount to be blended • Density • Qualities • Component Name • Amount to be blended • Density • Qualities Components • Component Name • Amount to be blended • Density • Qualities Heel • Product Name • Amount • Density • Qualities Blend Models Blend Quality Library • Density • Sulfur • Octane • ASTM Distillation • Aromatics • Olefins • Benzene • RVP...
- 33. Emerson Process Management Confidential Inputs • Prices • Target Recipe • Product Specs • Component Availability • Current Heel Quantity & Quality RTO+ Real-Time Optimization Engine Objective Function • Maximize Profit • Minimize Deviation from Target Recipe • Min/Max use of Specific Component Blend Models • Optimum recipe • Component usage • Predicted qualities Results Off-Line Optimizer Multiple Optimizer ApplicationsMultiple Optimizer Applications Real-Time Database Inputs • Prices • Target Recipe • Product Specs • Component Availability • Current Heel Quantity & Quality RTO+ Real-Time Optimization Engine Objective Function • Maximize Profit • Minimize Deviation from Target Recipe • Min/Max use of Specific Component Blend Models • Optimum recipe • Component usage • Predicted qualities Results On-Line Optimizer Blend Order Database Inputs • Prices • Target Recipe • Product Specs • Component Availability • Current Heel Quantity & Quality RTO+ Real-Time Optimization Engine Objective Function • Maximize Profit • Minimize Deviation from Target Recipe • Min/Max use of Specific Component Blend Models • Optimum recipe • Component usage • Predicted qualities Results Blend Quality Control
- 34. Emerson Process Management Confidential Online Blend OptimizationOnline Blend Optimization Executes every 5-15 minutes Runs for blend orders that are “Active” Operator selects objective function Outputs recommended results even in open-loop Handles reduced degrees of freedom (e.g. 1 or more controllers in Auto) Accommodates actual component qualities and blend model update from analyzers or lab Inputs: Automatically loaded from RT database and blend order system Outputs: Optimal instantaneous quality targets Optimal recipe Target batch size
- 35. Emerson Process Management Confidential Components Product Tankage Total Blend On-Spec Heel Components Product In-Line Each Part of Blend On-Spec Online Analyzers Blend Property Control Online Blend Optimization Product Certification Two Basic Types of BlendingTwo Basic Types of Blending
- 36. Emerson Process Management Confidential Accelerated Heel CorrectionAccelerated Heel Correction Final Target Percent of Blend Octane 0% 100% Heel Current Tank Quality Blend header target adjusted to meet final target Current Blend Header Target
- 37. Emerson Process Management Confidential Blend ExecutionBlend Execution FC Component Ratio Control FI AI Blend Quality Controller Ratio Targets Component Qualities & Limits Desired Rundown Rate, Header Pressure, Flow and Valve Limits FC FC FC PI Product Quality Targets
- 38. Emerson Process Management Confidential Blend Quality ControlBlend Quality Control RTO+ Real-Time Optimization Engine Blend Models • Executes 1-2 minutes • Specifications can be: - Target - Range - Max or min Real-TimeDatabase • Current Blend Quality Targets & Specs • Current Component Ratios • Blend Quality Analyzers • Component Limits & Qualities • Component ratio targets • Predicted qualities Objective Function • Primary: Meet Quality Specs • Secondary: Minimize Deviation from Current Recipe
- 39. Emerson Process Management Confidential SummarySummary Pre-engineered proven application Reduced risk Leading Technology hardware platform Non-proprietary Longest Life Expectancy Easily customized and extended Integrate virtually any feature or function as required Complete Engineering support from start to finish Consultation Main Automation Contractor The Global Industry Leader
- 40. Emerson Process Management Confidential Technical AdvantagesTechnical Advantages Integrated suite of applications on DeltaV Scaleable, Modular Automated Startup/Shutdown No need for multivariable control layer Dynamics are trivial No step tests required Incorporates non-linearity Simplifies architecture Integrated set of blend models used by all applications Non-linear Biased by lab or analyzer data Incorporate RFG simple and complex models Integrated blend order management & reports
- 41. Emerson Process Management Confidential Moving ForwardMoving Forward Complete Blend Optimization Modules Parallel Effort to Develop Movements & Inventory Solution Leverage Terminal Automation Solution
Editor's Notes
- #6: Virtually every liquid refinery product is blended to spec prior to sale. More attention has been given to the “ProcessUnits”, but poor blending can eat away at margins as fast as anything. We have a solution to help you reduce reblending and giveaways.
- #9: Most blending is performed in-line today. It avoids the need for extra tankage and mixing and generally provides a more uniform product when dealing with large quantities characteristic of most refineries. In-line blending requires proper instrumentation and controls.
- #10: Our Digital Blending Package is an application solution which incorporates many potential products and services from Emerson/Fisher-Rosemount. This list of elements is explained in more detail in later slides. Not every project will require every element, we have can provide any and all of these and more if required.
- #12: Again, these are standard capabilities, not limits. Pacing is an important requirement for digital blending and keeps the blend components in ratio even if one of the component streams becomes flow limited or constrained. It allows the blend rate to be set by recipe or by component availability. We also keep track during the blend so if there is any discrepancy, it is blended out over the remainder of the blend. Naturally, we include the ability to ramp up and down for the beginning and end of a blend. It is also possible to stop and restart or resume blending if necessary.
- #13: The blend algorithms can be modified in virtually any way necessary to achieve the customer’s objectives. Basic customization is actually built into the cost of the product. Other functions can be provided as required.
- #14: This slide shows even more options. DeltaV allows essentially unlimited calculational and reporting capabilities. We can even add Batch software with S88 recipe management for complex applications like lube oils or high performance specialty/racing fuels.
- #15: This product should handle all but the most complex blending applications, but adding even more streams is easy. An example of the decoupling routine would be octane and RVP control. Components used to control octane (eg MTBE) and RVP (Butane) will affect both octane and RVP. The basic recipe will provide a coarse control, but analyzers can be used to trim octane and RVP. The decoupler overcomes the problem of interaction with the trim control using those components. The other features should be fairly obvious and are covered in more detail in the functional description. Note: I have updated this slide 3/27/00 to show 16 components and 8 additives as standard. Some of the other pieces including the functional description may not yet be updated.
- #18: This is the most visible part of the package from the oerator’s perspective. We have designed the OI for ease of use leveraging the features of DeltaV and our experience with blending.
- #41: In summary…. We can help identify potential savings and deliver a system to maximize those savings over time with a solution that offers the fastest payback and lowest risk possible. And after the new blender controls are up and running, our tools and services will ensure sustained performance over the lifetime of the system. We can easily adapt our solution to meet your special and unique requirements. With our resources and position as a global leader in this business, you can count on us to deliver results from start to finish!