Inline Crude Oil Analysis for Refinery Switchover
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Solution Overview
Problem
Current refinery automation systems face challenges in seamlessly processing different types and qualities of crude oil due to offline analysis of crude oil composition and consistency, leading to time delays and potential errors during switchover operations.
Innovation Solution
Implementing an inline analysis system that measures crude oil properties such as density, viscosity, and sulfur content in real-time, translating these measurements into process and control parameters to automatically adjust refining equipment, enabling efficient processing and quick switchovers between crude oil types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline analysis of crude oil composition and consistency is used, then measurement precision is achieved, but loss of time occurs during switchover operations
Solution Approach 1:
The patent replaces offline laboratory analysis (mechanical/chemical process) with online instrumental analysis using devices such as NMR spectrometers, mass spectrometers, and infrared spectrometers. This substitution enables real-time measurement of crude oil composition and consistency, eliminating the time delay inherent in offline analysis while maintaining measurement precision.
Solution Approach 2:
The system performs preliminary analysis of crude oil properties before switchover operations are initiated. By having the online analysis system ready and continuously monitoring crude oil characteristics, the refinery can determine optimal switchover timing in advance, reducing actual switchover execution time and improving operational efficiency.
2Ease of operation
If manual monitoring and adjustment of refining equipment is used, then operational flexibility is maintained, but productivity decreases due to delayed responses
Solution Approach 1:
The patent implements a closed-loop feedback system where online analysis instruments continuously measure crude oil properties, the data is processed by a control system, and adjustments are automatically made to refining equipment parameters. This feedback mechanism maintains operational flexibility while significantly improving productivity by eliminating manual monitoring delays and enabling real-time process optimization.
Solution Approach 2:
The refining system performs self-adjustment based on online analysis data. The control system automatically modifies operating parameters of distillation columns, reactors, and other equipment according to real-time crude oil composition measurements, eliminating the need for continuous manual intervention while maintaining optimal processing conditions and high productivity.
3Adaptability or versatility
If frequent switchover operations between different crude oil types are performed manually, then adaptability is achieved, but loss of time and potential errors increase
Solution Approach 1:
The patent replaces manual switchover operations with automated control based on online analysis. The system automatically determines when switchover is needed based on real-time crude oil composition data and executes the switchover sequence, reducing both time and human error while maintaining full adaptability to handle various crude oil types.
Solution Approach 2:
The system performs preliminary assessment of incoming crude oil properties using online analysis instruments before switchover is initiated. This allows the control system to prepare appropriate processing parameters in advance, execute switchover more quickly, and minimize disruption to refinery operations, thereby reducing switchover time while maintaining adaptability.
Data Source
AI summary
An apparatus includes at least one processor configured to obtain inline measurements of one or more properties of crude oil, translate the measurements into a set of process and control parameters, and apply the process and control parameters to process equipment. The process and control parameters configure the process equipment to process the crude oil having the one or more properties. The one or more properties of the crude oil may include at least one of: density, specific gravity, viscosity, carbon residue, and sulfur content of the crude oil. The process and control parameters could be applied to one or more controllers associated with a blending unit in a refinery or to one or more controllers associated with a crude oil distillation column in the refinery.