天津炼油厂催裂化装置计算机控制系统

前言由于催裂化装置有些参数不具备在线检测的条件,即使所有重要参数都能在线检测,没有一个最优控制的数学模型也是不行的,所以,很难在短期内实现全装置的最优闭环控制,因此,可以采用不同层次逐步实现最终目标,第一步实现数据采集和过程管理;第二步实现监测预报;第三步实现开环指导,之后实现某些回路的在线控制,最终实现优化闭环控制。最大程度的获得催化裂化装置的利润,必须要迅速准确地测出操作参数,原料量等值。

催裂化装置计算机模拟优化控制应用系统设计

根据原油精炼的实际情况,本论文给出了一个在催裂化装置中使用微机的具体方法.通过把一台微机同一个协处理器相联结.这个方法可以提高优化计算的速度,将这种方法推广到其它工厂是很有益的.

Influence of Design Margin on Operation Optimization and Control Performance of Chemical Processes

Operation optimization is an effective method to explore potential economic benefits for existing plants. The m.aximum potential benefit from operationoptimization is determined by the distances between current operating point and process constraints, which is related to the margins of design variables. Because of various ciisturbances in chemical processes, some distances must be reserved for fluctuations of process variables and the optimum operating point is not on some process constraints. Thus the benefit of steady-state optimization can not be fully achied（ed while that of dynamic optimization can be really achieved. In this study, the steady-state optimizationand dynamic optimization are used, and the potential benefit-is divided into achievable benefit for profit and unachievable benefit for control. The fluid catalytic cracking unit （FCCU） is used for case study. With the analysis on how the margins of design variables influence the economic benefit and control performance, the bottlenecks of process design are found and appropriate control structure can be selected.

A Novel Close-loop Strategy for Integrating Process Operations of Fluidized Catalytic Cracking Unit with Production Planning Optimization

Production planning models generated by common modeling systems do not involve constraints for process operations, and a solution optimized by these models is called a quasi-optimal plan. The quasi-optimal plan cannot be executed in practice some time for no corresponding operating conditions. In order to determine a practi- cally feasible optimal plan and corresponding operating conditions of fluidized catalytic cracking unit （FCCU）, a novel close-loop integrated strategy, including determination of a quasi-optimal plan, search of operating conditions of FCCU and revision of the production planning model, was proposed in this article. In the strategy, a generalized genetic algorithm （GA） coupled with a sequential process simulator of FCCU was applied to search operating conditions implementing the quasi-optimal plan of FCCU and output the optimal individual in the GA search as a final genetic individual. When no corresponding operating conditions were found, the final genetic individual based correction （FGIC） method was presented to revise the production planning model, and then a new quasi-optimal production plan was determined. The above steps were repeated until a practically feasible optimal plan and corresponding operating conditions of FCCU were obtained. The close-loop integrated strategy was validated by two cases, and it was indicated that the strategy was efficient in determining a practically executed optimal plan and corresponding operating conditions of FCCU.

A Novel Systematic Method of Quality Monitoring and Prediction Based on FDA and Kernel Regression

A novel systematic quality monitoring and prediction method based on Fisher discriminant analysis (FDA) and kernel regression is proposed. The FDA method is first used for quality monitoring. If the process is un-der normal condition, then kernel regression is further used for quality prediction and estimation. If faults have oc-curred, the contribution plot in the fault feature direction is used for fault diagnosis. The proposed method can ef-fectively detect the fault and has better ability to predict the response variables than principle component regression (PCR) and partial least squares (PLS). Application results to the industrial fluid catalytic cracking unit (FCCU) show the effectiveness of the proposed method.

Soft Sensor for Inputs and Parameters Using Nonlinear Singular State Observer in Chemical Processes

Chemical processes are usually nonlinear singular systems.In this study,a soft sensor using nonlinear singular state observer is established for unknown inputs and uncertain model parameters in chemical processes,which are augmented as state variables.Based on the observability of the singular system,this paper presents a simplified observability criterion under certain conditions for unknown inputs and uncertain model parameters.When the observability is satisfied,the unknown inputs and the uncertain model parameters are estimated online by the soft sensor using augmented nonlinear singular state observer.The riser reactor of fluid catalytic cracking unit is used as an example for analysis and simulation.With the catalyst circulation rate as the only unknown input without model error,one temperature sensor at the riser reactor outlet will ensure the correct estimation for the catalyst circulation rate.However,when uncertain model parameters also exist,additional temperature sensors must be used to ensure correct estimation for unknown inputs and uncertain model parameters of chemical processes.

Analysis on Causes of Scaling in Flue Gas Turbine of FCCU and Countermeasures

Causes of scale deposition in flue gas turbine expander of FCCU were analyzed based on some aspects,including the types and operating conditions of flue gas turbines,properties and composition of feedstocks and catalysts,and operating conditions of the reactor and regenerator.Some countermeasures were proposed for preventing scale deposition in flue gas turbine of FCCU.

Study on Commercial Application of FP-DSN Sulfur Transfer Additive in FCC Unit

The FCC unit with addition of various inventories of the FP-DSN type sulfur transfer additive was tested in a commercial scale. The effect of the sulfur transfer additive was analyzed by investigating the indicators related with the regenerator flue gas composition,the dry gas composition before desulfurization,the LPG composition before desulfurization,the acid gas,and the yield of gasoline and diesel. The test results indicated that the sulfur was trans ferred from the feed stream into the dry gas,LPG and acid gas,and the sulfur transfer effect was obvious only when the inventory of sulfur transfer additive exceeded over 2.0% of total FCC catalyst inventory.

Study on Reaction Mechanism for Cracking FCC Gasoline on Acid Catalyst

This article is based on the experimental data on reaction of FCC naphtha in the presence of acid catalysts. The data published in the literature were reprocessed and compared with experimental data and the relationship of hydrogen and methane contained in the dry gas with the conversion rate was identified.The similarity between the route for cracking of olefin enriched FCC gasoline and the route for reaction of individual hydrocarbons was deduced, while the route for formation of ethylene in dry gas was also proposed to identify the relationship between the reaction path for formation of ethylene and the conversion rate.

A Novel Strategy for Simulating the Main Fractionator of Delayed Cokers by Separating the De-superheating Process

Delayed coking is an important process in refinery to convert heavy residue oils from crude distillation units （CDUs） and fluid catalytic cracking units （FCCUs） into dry gas, liquefied petroleum gas （LPG）, gasoline, die- sel, gas oils and cokes. The main fractionator, separating superheating reaction vapors from the coke drums into lighter oil products, involves a de-superheating section and a rectifying section, and couldn＇t be simulated as a whole column directly because of non-eouilibrium in the de-suoerheatine section. It is verv imoortant to correctlv simulate the main fractionator for operational parameter and energy-use optimization of delayed cokers. This paper discusses the principle of de-superheating processes, and then proposes a new simulation strategy. Some key issues such as composition prediction of the reaction vapors, selection of thermodynamic methods, estimation of tray efficiency, etc. are discussed. The proposed simulation approach is applied to two industrial delayed cokers with typical technological processes in a Chinese refinery by using PRO/II. The simulation results obtained are well consistent with the actual operation data, which indicates that the presented approach is suitable to simulate the main fraction- ators of delayed cokers or other distillation columns consisting of de-superheating sections and rectifying sections.

Modeling and optimum operating conditions for FCCU using artificial neural network

A self-organizing radial basis function(RBF) neural network(SODM-RBFNN) was presented for predicting the production yields and operating optimization. Gradient descent algorithm was used to optimize the widths of RBF neural network with the initial parameters obtained by k-means learning method. During the iteration procedure of the algorithm, the centers of the neural network were optimized by using the gradient method with these optimized width values. The computational efficiency was maintained by using the multi-threading technique. SODM-RBFNN consists of two RBF neural network models: one is a running model used to predict the product yields of fluid catalytic cracking unit(FCCU) and optimize its operating parameters; the other is a learning model applied to construct or correct a RBF neural network. The running model can be updated by the learning model according to an accuracy criterion. The simulation results of a five-lump kinetic model exhibit its accuracy and generalization capabilities, and practical application in FCCU illustrates its effectiveness.

7-lump kinetic model for residual oil catalytic cracking

In this paper a novel 7-lump kinetic model is proposed to describe residual oil catalytic cracking, in which coke is lumped separately for accurate prediction. The reactor block is modeled as a combination of an ideal pipe flow reactor (PFR) and a continuously stirred tank reactor (CSTR). Unit factors are designed to correct the deviation between model predictions and practical plant data and tuned by modified Levenberg-Marquardt algorithm. The parameters estimated are reliable and good agreement between the model predictions and plant observations is observed. The model helps us get good insight into the per- formance of an industrial riser reactor that would be useful for optimization of residual oil catalytic cracking.

Commercial Application of the MIP-CGP Technology for Olefin Reduction in FCC Unit

The refinery of Yanshan Petrochemical Company has twice retrofitted a 2.0-Mt/a RFCC unit with the MIP-CGP technology aimed at maximization of isoparaffins/clean gasoline and increased output of propylene. By modifying the riser reactor with addition of the second reaction zone coupled with an added external catalyst cooler outside the regenerator and adoption of the CGP catalyst to control the cracking depth the refiners have realized the target of reducing olefin content in gasoline and increasing the yield of LPG. The results of retrofitting the RFCC unit have revealed that after revamp of FCC unit the yield of LPG was increased by 7.31%, the conversion rate was increased by 9.06%, and the total liquid yield was decreased by 0.3%. After revamp of the RFCC unit the olefin content in gasoline was reduced by 19.5 v%, and the RON rating of gasoline was increased by 0.7 units to meet the demand of Beijing municipality for manufacture of the Olympic clean gasoline.

Decoupling Control of Fluid Catalytic Cracking Unit

This study presents a decoupling control scheme of fluid catalytic cracking unit to account for the high interaction between two temperature control loops. The feed flow rate load disturbance is introduced to test the proposed decoupling control scheme. Through simulation study shown that the decoupling is effective, stable and it presents advantage over controller without decoupler. Also, this scheme is able to offer good dynamic performance for most disturbances.

Investigate the Parameters Effect on Thermogravimetry Analysis （TGA） Performance for SOx Additive in FCC Units

Although the FCC process has been used for more than halfa century, new and important developments continue to be made in several areas. Some of these new developments are a direct response to environmental regulation. Sulfur oxides （SOx-SO2＋SO3） emitted from fluid catalytic cracking units （FCCU） are one of the most hazardous atmospheric pollutants, which may cause serious environmental problems such as the formation of acid rain and the destruction of the ozone layer. Thus, great attention has been focused on the SOx removal from FCC in last few years. The present papers will focus on the spinel material studies include three samples they were prepared by acidic method, solid solution MgAl2O4, solid solution with cerium10%Ce/MgAl2O4, iron mixed spinel with cerium 10%Ce/MgAl2-xFeO4.MgO and two samples solid solution with cerium introduce by vanadium as second co-catalyst prepared by basic method, 1% V/10%Ce/MgAl2O4.MgO were tested in TGA for oxidation half cycle to study some parameters effect on performance of SOx additives in TGA under condition similar to those of FCC units. Thermogravimetry analysis experiments have been used to demonstrate the pick-up and release of sulfur oxides in the development of additives for SOx control in the FCCU.

Simulating the Effect of Propylene Promoter on Product Yield with FCC Mechanism Model

A FCC mechanism model was used to predict the effects of propylene promoter in a 3.0 Mt/a FCCU. The FCC mechanism model was developed based on one set of commercial FCC data without using the promoter, and was modified by using another set of commercial FCC data with 3m% promoter in the catalyst inventory, and the calculations by means of this simulation model were performed to predict the data of the FCC unit containing 4m% promoter in the catalyst inventory. The test results showed that the calculated values agreed well with the data obtained from the commercial FCC unit, in which the deviations of calculated product yields versus the actual product yields at the commercial FCC unit were equal to 1.74 percentage points for gasoline, 2.59 percentage points for diesel, 1.50 percentage points for dry gas and LPG, and 0.28 percentage points for coke. The proposed method regarding the development of a simulation model and modifications to the model for commercial FCC unit was feasible.

Molecular-Based Simulation of Feedstock Properties for Complex Reaction System

The kinetics of complex reaction systems were studied on molecular level with the combined method of Monte Carlo simulation and Structural Oriented Lumping by focusing on deep catalytic cracking （DCC） process, the model parameters were optimized by means of routine analytic data of a DCC unit. A model was established to transform the feedstock of the complex reaction systems such as DCC to 1000-10000 pseudo-molecules with the Monte Carlo simulation and every molecule was expressed by 19 attributes. The results of model simulation showed that these pseudo-molecules reflected the characteristics of feedstock very well and their average properties gave a good agreement with the plant data.

Effects of Light Olefins Formation during Catalytic Pyrolysis of n-Heptane

The influence of zeolite structure and process parameters (including reaction temperature and catalyst/oil ratio) on rules for formation of ethylene and propylene in the course of catalytic pyrolysis of n-heptane was studied in a small- scale fixed fluid catalytic cracking unit. Test results have revealed that compared to the USY zeolite and Beta zeolite, the catalytic pyrolysis of n-heptane in the presence of the ZRP zeolite catalyst can result in higher yield and selectivity of ethyl- ene and propylene, while a higher reaction temperature and a higher catalyst/oil ratio can promote the formation of ethylene and propylene during catalytic pyrolysis of n-heptane. The ethylene formation reaction is more sensitive to the changes in reaction temperature, whereas the changes in catalyst/oil ratio are more influential to the propylene formation reaction. This paper has made a preliminary exploration into the different reaction pathways for formation of ethylene and propylene on zeolites with different structures.