Application of visbreaker analysis tools to optimize performance
View Patent ↗A system and method are outlined for controlling and optimizing chemical injection into a process unit to control fouling. The method uses an optical device to measure the fouling propensity of the process fluid at various points within the process unit. The measurements are compared with one another and prediction methods are used to evaluate the fouling potential within the unit, and determine the proper chemical dosage. Antifoulant chemical is then introduced into the unit to control the rate of fouling. The method and application continue on a frequent basis to maintain optimal fouling control within the unit.
1. A method to reduce and optimize the fouling rate in a process unit comprising the steps of:
estimating a concentration of foulant materials contained within a fluid of the process unit;
determining the fouling potential based on said concentration;
determining the impact of antifoulant chemical on the fouling potential within the unit;
determining an acceptable baseline fouling potential;
comparing said baseline parameter to said concentration of foulant materials measured during subsequent unit operations; and
regulating input of said anti-fouling chemical into said process unit during running of unit operations based on said comparison so as to achieve one or more unit goals.
2. A method to reduce and optimize the fouling rate in a process unit comprising the steps of:
estimating a concentration of foulant materials contained within a fluid of the process unit;
determining the fouling potential based on said concentration;
determining the impact of antifoulant chemical on the fouling potential within the unit;
determining an acceptable baseline fouling potential;
comparing said acceptable baseline fouling potential to said fouling potential determined from said concentration of foulant materials measured during subsequent unit operations; and
regulating input of said anti-fouling chemical into said process unit during running of unit operations based on said comparison and said impact of antifoulant chemical on said fouling potential so as to achieve one or more unit goals.
3. The method of claim 2 , wherein said unit goals include improved yield, improved quality, and reduced fouling related maintenance.
4. The method of claim 3 , wherein said estimating step includes estimating a distribution of foulant materials contained within said fluid; and said fouling potential is determined by said concentration and said distribution.
5. The method of claim 4 , wherein said regulating step includes selecting and controlling the type or quantity of said anti-fouling chemical being input into the unit.
6. The method of claim 5 , further comprising the step of improving run-lengths compared to previous un-treated conditions.
7. The method of claim 6 further comprising the use of predictive modeling to derive the impact of chemical on the fouling rate, and the amount of necessary chemical to provide adequate run length, according to planned maintenance schedules.
8. The method of claim 7 , further comprising the use of multiple measurements, either within the unit or its feed steams, to determine the impact of introduced chemical upon foulant concentrations; wherein the impact of introduced chemical upon foulant concentrations is used to determine the impact of introduced chemical upon fouling potential.
9. The method of claim 8 , further comprising the use of multiple chemical injection locations inside and/or outside unit boundaries.
10. The method of claim 2 , wherein said estimating step is performed using an apparatus comprising:
an optical lens system comprising a stage adapted to receive a sample of fluid;
a light sources for focusing a beam of light onto said sample;
means of directing said light beam along a plurality of path lengths within a predetermined area of said sample;
means of detecting light transmitted through said sample along each path length;
means for quantifying an intensity of said transmitted light; and
means for correlating said quantified transmitted light to a concentration of said foulant particles in said samples.
11. The method of claim 10 , further comprising means for determining the type or quantity of antifouling chemical injected into the process unit.
12. The method of claim 10 , further comprising means for estimating the impact of injected anti-fouling chemical on foulant particles and run length predictions.
13. The method of claim 10 , further comprising the usage of measured data to generate predictive models for use in controlling chemical injection.
14. The method of claim 10 , further comprising the usage of multiple chemical injection locations inside and/or outside the units boundaries.
15. A method to improve a hydrocarbon fluid stream in a refinery comprising the steps of:
estimating a concentration of foulant materials contained within a hydrocarbon fluid stream in a refinery;
determining the fouling potential based on said concentration;
determining the impact of antifoulant chemical on the foulant materials;
determining an acceptable baseline fouling potential;
comparing said baseline parameter to said concentration of foulant materials measured during subsequent refinery operations; and
regulating input of said anti-fouling chemical into said fluid stream during running of refinery operations based on said comparison so as to achieve one or more refinery goals.
16. A method to improve a hydrocarbon fluid stream in a refinery comprising the steps of:
estimating a concentration of foulant materials contained within a hydrocarbon fluid stream in a refinery;
determining the fouling potential based on said concentration;
determining the impact of antifoulant chemical on the fouling potential;
determining an acceptable baseline fouling potential;
comparing said acceptable baseline fouling potential to said fouling potential determined from said concentration of foulant materials measured during subsequent refinery operations; and
regulating input of said anti-fouling chemical into said fluid stream during running of refinery operations based on said comparison and said impact of antifoulant chemical on said fouling potential so as to achieve one or more refinery goals.
17. The method of claim 16 , wherein said refinery goals include improved yield, improved quality, improved run-lengths, and reduced fouling related maintenance.
18. The method of claim 17 , wherein said estimating step includes estimating a distribution of foulant materials contained within said fluid; and said fouling potential is determined by said concentration and said distribution.
19. The method of claim 18 , wherein said regulating step includes selecting and controlling the type or quantity of said anti-fouling chemical being input into the fluid stream.
20. The method of claim 19 further comprising the use of predictive modeling to derive the impact of chemical on the fouling rate, and the amount of necessary chemical to provide adequate run length, according to planned maintenance schedules.
21. The method of claim 20 , further comprising: the use of multiple measurements, either within the refinery or its feed steams, to determine the impact of introduced chemical upon foulant concentrations, wherein the impact of introduced chemical upon foulant concentrations is used to determine the impact of introduced chemical upon fouling potential; and the use of multiple chemical injection locations.
22. The method of claim 21 , wherein said estimating step is performed using an apparatus comprising:
an optical lens system comprising a stage adapted to receive a sample of fluid;
a light sources for focusing a beam of light onto said sample;
means of directing said light beam along a plurality of path lengths within a predetermined area of said sample;
means of detecting light transmitted through said sample along each path length;
means for quantifying an intensity of said transmitted light; and
means for correlating said quantified transmitted light to a concentration of said foulant particles in said samples.