FCC Optimization 101: The Path From Process Knowledge to Real Time Optimization via Basic Process Control and APC
Optimization, FCC
Facilitator:
Atique Malik, AIControl LLC
Speakers:
Darin Foote, CHS Inc.
Chuck Johnston, Marathon Petroleum Corporation LP
Vidyashankar Kuppuraj, Marathon Petroleum Corporation
Johnny Serafin, Phillips 66
Nic Tognetti, CHS Inc.
Advanced process control (APC) has been employed in FCC applications for 40 years. Despite the similarities of FCC Technology and APC platforms the success of these applications varies widely. In this session we will discuss common threads that lead to poor outcomes and how to build a successful APC program on a modern FCC.
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Topic
Refinery Wastewater Upset Lessons Learned: Maintaining Production and Avoiding Negative Environmental Impacts
Environmental, Sustainability
The oil refining process generates a significant volume of wastewater that contains a suite of challenging contaminants, from hydrocarbons to heavy metals and organic compounds. Oil production at a refinery relies on efficient and reliable wastewater treatment as it is impossible for the facility to operate without treating its effluent. Issues with the wastewater treatment systems can result in production limitations, as well as significant environmental impacts and violations. These systems can be complex, and they are sensitive to upset conditions due to poor feed quality, unexpected contaminants, or equipment breakdown.
This presentation will discuss a significant upset condition that impacted both the primary and secondary wastewater treatment system at a large West Coast refinery. We will present the processes that allowed for detection of the upset, and the steps taken by the operations group, technical team, and vendor support that helped maintain target production rates and avoid any environmental violations or impacts. The mitigation steps allowed for storage and post-upset treatment of the problematic effluent streams. The technical team evaluated options for treatment and environmental compliance, and the water treatment vendor supplied specialty biological treatment technology to get the system back online as quickly as possible. All of this contributed to a successful upset response and the implementation of best practices that can help all refineries facing a wastewater oil contamination.
Moderator:
Dan Harbs, Veolia
Speakers:
Angela Wharton, Chevron U.S.A. Inc.
Kai Zhang, Chevron U.S.A. Inc.
Speakers
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AI Plant Control: A Reinforcement Learning Approach to Process Optimization
Artificial Intelligence, Optimization
In this session we will discuss in detail the continuous improvement in plant profitability achieved by having a holistic approach for advanced automation where applications such as procedural automation, Artificial Intelligence Plant Control (AIPC), control strategy in distributed control system and safety instrumented system all work together in harmony. AIPC, leveraging Reinforcement Learning (RL), offers a transformative approach to process plant optimization, addressing key limitations of traditional Model Predictive Control (MPC).
While MPC has been a cornerstone of advanced process control for decades, its reliance on linear models and manual tuning often struggles to effectively handle complex, nonlinear process dynamics, particularly in scenarios with frequent disturbances or changing operating conditions. AIPC overcomes these limitations by continuously learning and adapting to the plant's behavior. We will share our motivation to develop this product in-house and how easy it is to maintain the application and sustain the benefits by existing operations staff without the need of any AI or MPC expertise.
Participants will:
- Understand the benefits of using AIPC over conventional MPC
- Learn how Linde has successfully implemented AIPC on their Air Separation Units that include cryogenic distillation and very complex heat integration and recovery process.
- Realize the importance of embracing this cutting-edge technology for improving profitability and safety of their plant and also for their personal and professional growth.
Moderator:
Atique Malik, AIControl LLC
Presenters:
Rajeev Limaye, Linde Advanced Operations Services
Lena Tetampel, Linde Engineering Munich Germany
Speakers
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Process Controls 101: Back to the Basics
Optimization
What is basic process control?
How is it done? Why is it important for the refinery engineer to be familiar with the basics?
In this foundational session, the discussion will focus on the workings of everyday loops and instrumentation that a refinery engineer is likely to encounter.
Moderator:
Sriram Ramaganesan, Phillips 66
Speakers:
Joe Boyce, Marathon Petroleum Corporation
Scott Flanagan, Marathon Petroleum Corporation
Tim Olsen, Emerson Automation Solutions
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Closed-Loop Optimization: Old School vs. New School
Optimization
This session covers the complete spectrum of process optimization methods at a refinery or petrochemical plant. From models predictive control to real time optimization via process models and onto machine learning methods via neural networks. The attendee will gain an understanding of when to apply these methods in practice and the organizational support needed to succeed long term.
Moderator:
Patrick Robinson, PBF Energy Inc.
Speakers:
GT McDaniel, Marathon Petroleum Corporation
Chuck Johnston, Marathon Petroleum Corporation
Sriram Ramaganesan, Phillips 66
Abhay Singh, Motiva Enterprises LLC
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Unlocking the Future of Refining: The Transformative Power of Perchloroethylene (PCE or PERC) – Regulations, Safety, and Sustainability
Gasoline Processes, Environmental
The intersection of refining and petrochemical manufacturing has never been more significant as industries navigate the dual challenges of efficiency and sustainability. This session will explore the critical role of Perchloroethylene (PERC) in modern refining processes while also highlighting its applications in petrochemical production.
PERC is recognized as one of the safest catalyst activators during normal operations, as well as a regenerator for spent catalysts. Utilizing less efficient materials can necessitate larger quantities of hazardous substances being kept onsite, thus increasing exposure risks. Other chlorinating agents are either restricted by the EPA or are inherently more hazardous, making PERC a preferable option.
Attendees will gain insights into how PERC enhances refining technologies through processes such as isomerization and catalytic reforming, which help ensure compliance with environmental regulations. Industry experts will discuss the extensive benefits of utilizing PERC, emphasizing innovations that contribute to both safety and operational efficiency.
Moreover, we will review advancements in safety protocols that facilitate the effective handling of PERC, ensuring minimal exposure and adherence to rigorous regulatory standards. By fostering dialogue among leaders in refining and petrochemical manufacturing, this session aims to identify collective strategies for driving innovation and achieving sustainability goals within the industry.
Moderator:
Alex Kniuksta, Honeywell UOP
Speaker:
Scott Wozniak, Honeywell UOP
Speakers
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