Spectroscopic Analyzer Control of Hydrotreating and FCC Properties
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Solution Overview
Problem
Current systems for monitoring and controlling hydrotreater and fluid catalytic cracking (FCC) processes face challenges due to delayed and inaccurate information acquisition, leading to inefficiencies and suboptimal production of FCC-related products that fail to meet industry standards.
Innovation Solution
The implementation of spectroscopic analyzers calibrated to generate standardized spectral responses, which condition and analyze hydrocarbon feedstocks and CFH unit materials to predict properties and control the processes in real-time, enabling prescriptive control of hydrotreater and FCC operations to achieve target properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional laboratory analysis is used to monitor hydrocarbon feeds and process materials, then comprehensive material characterization is achieved, but response time is excessively long (hours to weeks)
Solution Approach 1:
The patent replaces conventional mechanical/chemical laboratory analysis methods with spectroscopic analysis (NIR, MIR, Raman). This substitution enables real-time or near-real-time monitoring of hydrocarbon feed properties and process materials, reducing analysis time from hours to seconds while maintaining sufficient measurement precision for process control applications.
Solution Approach 2:
The patent introduces spectroscopic analyzers as intermediary devices between the process materials and the control system. These analyzers provide continuous spectral data that serves as an intermediate representation of material properties, enabling rapid feedback for process optimization without the time delays of traditional laboratory methods.
2Loss of time
If spectroscopic analyzers are implemented for real-time monitoring, then response time is reduced, but measurement accuracy and reliability may be compromised
Solution Approach 1:
The patent implements comprehensive calibration procedures before deploying spectroscopic analyzers for real-time monitoring. Standard reference materials are analyzed to establish spectral signatures and calibration models, ensuring that the analyzers provide accurate measurements from the outset. This preliminary action guarantees measurement precision while enabling immediate real-time monitoring capabilities.
Solution Approach 2:
The patent establishes feedback loops where spectroscopic analyzer measurements are continuously compared against expected values and process data. This feedback mechanism allows for real-time validation of measurement accuracy and enables corrective actions if drift or errors are detected, maintaining reliability throughout continuous operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for more accurate and responsive monitoring and control of hydrotreater and FCC processes, resulting in the production of FCC-related products with desired characteristics and properties in a more efficient and economically viable manner.
Implementation Method 1
analyzing the hydrocarbon feedstock sample via a first spectroscopic analyzer to provide hydrocarbon feedstock sample spectra
Data Source
AI summary
Assemblies and methods to enhance hydrotreating and fluid catalytic cracking (FCC) processes associated with a refining operation, during the processes, may include supplying a hydrocarbon feedstock to a cat feed hydrotreater (CFH) processing unit to produce CFH unit materials. The assemblies and methods also may include conditioning material samples, and analyzing the samples via one or more spectroscopic analyzers. The assemblies and methods further may include prescriptively controlling, via one or more FCC process controllers, based at least in part on the material properties, a FCC processing assembly, so that the prescriptively controlling results in causing the processes to produce CFH materials, intermediate materials, the unit materials, and/or the downstream materials having properties within selected ranges of target properties, thereby to cause the processes to achieve material outputs that more accurately and responsively converge on one or more of the target properties.