Crude Overhead Predictive Control for Salting and Corrosion
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Solution Overview
Problem
Hydrocarbon refining processes face challenges in maximizing distillate production while minimizing operating risks due to salting and corrosion issues in crude unit overhead systems, particularly with unmonitored distillate maximization leading to severe corrosion and equipment failure.
Innovation Solution
The implementation of predictive analytics to dynamically manage hydrogen chloride and amine conditions in the overhead crude section of hydrocarbon refining processes, simulating variations in operating conditions to determine risk indicators and provide recommended changes that adhere to constraints such as salting temperature, water dew point, and tower top temperature, thereby optimizing operation and reducing corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tower top temperature is lowered to increase distillate production, then productivity increases, but corrosion risk increases due to salt deposition
Solution Approach 1:
The system performs preliminary calculations to determine the salt point temperature before it becomes a problem. By continuously monitoring operating conditions and calculating when salt deposition is likely to occur, the system can take preventive action (adjusting temperatures, adding inhibitors) before corrosion damage happens, thus allowing higher distillate production without the harmful corrosion effects
Solution Approach 2:
The system implements continuous feedback by monitoring operating conditions (temperatures, pressures, flow rates) and using this data to recalculate salt point temperature in real-time. This feedback loop allows the system to dynamically adjust operations to maintain distillate maximization while preventing corrosion by keeping the salt point below critical temperatures
2Object-affected harmful factors
If neutralizer is added to control pH and reduce corrosion, then corrosion resistance improves, but salt deposition temperature increases causing new corrosion problems
Solution Approach 1:
The system changes parameters dynamically by continuously calculating the salt point temperature based on current neutralizer concentration and operating conditions. When the salt point rises due to neutralizer addition, the system adjusts other parameters (temperature, pressure, flow rates) to compensate and keep the salt deposition temperature below critical levels, thus maintaining corrosion protection without creating new problems
Solution Approach 2:
The system makes the neutralizer dosage dynamic rather than static. By continuously monitoring operating conditions and recalculating the salt point, the system adjusts neutralizer addition in real-time to maintain optimal pH for corrosion protection while ensuring the salt point remains low enough to prevent deposition. This dynamic approach allows the system to adapt to changing conditions and balance the two competing requirements
3Object-affected harmful factors
If water wash is used to remove salts from overhead system, then salt deposition decreases, but additional equipment and operational complexity are required
Solution Approach 1:
The system replaces the mechanical water wash system with a predictive analytics approach. Instead of using physical water injection and wash equipment to remove salts, the system uses continuous calculation of salt point temperature and predictive modeling to prevent salt deposition in the first place. This substitution eliminates or reduces the need for complex water wash equipment while achieving the same protective effect
Solution Approach 2:
The system enables the overhead system to protect itself through continuous self-monitoring and self-adjustment. By continuously calculating salt point temperature based on real-time operating conditions and automatically adjusting operations or neutralizer dosage, the system makes the corrosion protection self-regulating without requiring external water wash intervention, thus reducing equipment complexity
Data Source
AI summary
Described herein are systems and methods for control of an overhead crude section of a hydrocarbon refining process. In one aspect, the method comprises monitoring a plurality of operating conditions of an overhead crude section of a refinery; determining hydrogen chloride and amine conditions of the overhead crude section of the refinery at current operating conditions of the overhead crude section; determining a plurality of fields of action by simulating a variation of one or more of the plurality of conditions; determining a risk indicator of salting for each of the plurality of fields of action; and providing a recommended change in operation of the overhead crude section to one of the plurality of fields of action while adhering to one or more constraints.