How to get the best of the daily mass balance system operation

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1 How to get the best of the daily mass balance system operation Oscar Rotava Process System Engr. PhD. Petrobras Alexandre Almeida Campos Chemical Engr. MSc. Soteica

2 Agenda The Companies PETROBRAS and SOTEICA Presentation objectives Why to implement mass balance Generating reconciled data Using reconciled data: benefits and profits Perspectives and future applications 2

3 The Companies PETROBRAS HIGHLIGTS Headquarters in Rio de Janeiro Brazil US$ 80 billion net income /US$ 13 billion net profit /US$ 17 billion investment ,920,000 bpd oil/lng and 370,000 bpd of nat.gas production 1,872,000 bpd refining capacity 11 refineries in Brazil and 4 abroad (3 in Argentina/1 in USA) SOTEICA A consultancy Company Main activity: Modeling of IT Systems oriented to Process Eng. Founded 22 years ago Employees: 51 Projects developed in Germany, Argentina, Belgian, Brazil, Chile, Equador, Spain, USA, France, England, Mexico, Venezuela 3

4 The Companies Refineries with SIGMAFINE operational REPLAN (SOTEICA) REVAP (SOTEICA) RLAM (SOTEICA) RECAP RLAM (SOTEICA) REGAP REMAN LUBNOR REDUC (SOTEICA) REFINERIES IN BRAZIL 4

5 Presentation objectives To show the usage of SIGMAFINE in the generation of reconciled data in many different tasks in oil refineries improving data quality optimizing refinery operation, resulting in profits Hard work and perseverance 5

6 Why to implement mass balance FW Management Operations Ltd (1995) Petrobras needs to get the refineries to carry out a daily mass balance in order to establish accurately the FUEL & LOSS... This will then give a good indication of the areas for improvements in the management of the oil within the refinery, and will indicate the economic justification for improvements. 6

7 FW Management Operations Ltd The most important KPI used in the international oil refining industry is not measured in both refineries. Oil is money. IF IT IS NOT MEASURED, IT CANNOT BE CONTROLLED. 7

8 Why to implement mass balance SIGMAFINE IN PETROBRAS 2000 Bid to buy mass balance system (won by SOTEICA an OSI partner) 6 turn key projects 5 in house projects 2 3 projects every year 2003 Decision made to hire SOTEICA to operate the system at some refineries June 2004/April 2005/March 2007 Mass Balance Workshops 8

9 Why to implement mass balance There are no facts, only interpretations. Friedrich Nietzsche 9

10 ESA61 Generating reconciled data PI Process data Tank transactions Constraints Constraints Sigmafine ESA63 Reconciled data 10

11 Slide 10 ESA61 reduction of the execution time: calculation of the value of simultaneous transactions in runing tanks density integration in the tanks capture of inconsistent density 0.5<d<1.5 transaction time Oscar Rotava, 7/25/2007 ESA63 Observation of kpis (DX) zeroeing flows that should be zero Oscar Rotava, 7/25/2007

12 Using reconciled data Oil loss accountability Determination of fuel consumption KPI Production accountability support (financial) Maintenance support Production accountability support (mass balance) Test run data reconciliation Refinery KPIs follow up Team training Optimization group support Inventory monitoring Production Planning Reconciled data can be used in many daily activities of the refinery staff 11

13 Using reconciled data: benefits and profits Data quality improvement: benefits Mass Balance before Sigmafine Feb/01 Jan/02 (Loss % Cumulative = 1.09%) Loss Accountability 10.0% 8.0% 6.0% 4.0% 2.0% 0.0% 2.0% 4.0% 6.0% (%) Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Loss % 3 Month Rolling Loss % Cumulative 3 jan 04 mar 04 mai 04 jul 04 sep 04 nov 04 jan 05 mar 05 mai 05 jul 05 sep 05 nov 05 jan 06 mar 06 mai 06 Gross error detection Regular improvements Optimization SF Losses jul 06 Solution 0.48 sep 06 nov 06 Loss Accountability Oil Sigmafine loss figures available after Sigmafine implementation Benchmark jan 07 mar 07 mai Jun/02 Jul/02 Aug/02 Sep/02 Oct/02 Nov/ % SF montly SF cumulative 12

14 Using reconciled data: benefits and profits Data quality improvement: benefits Tank density integration D ata 16/2/2007 T anque T Q 4726 D a ta 16 /2 / :0 0 T a nq u e T Q om siçã tanq ue (%) Difference = (Measured C o m p o siçã o Volume) d o tanq u e (% ) (Reconciled Value) Tank Tank composition Composition Fuel Diesel Oil 4% 7% 4 % 1% 10 % 00% % 0 0% % 0 % 9% 12% 10 % 16% 1 6 % 18% 0% 0% 0% 0% 4 m3 35 m3 0% 25% 30 % Density tank integration P ro d uto R V _ U 21 0 A R V _ U 21 0 R A T _ U 20 0A G O P _U G O P _U 9 8 0A D IL_ U 2 10 G P O roduto M _ U 98 0 O LR D IEH _ U 2D 20 T A 71 K D L_U 200A O LR D ISP _ U 2 20 O D E P_ IN U 2 20 G OD L L_U G OQ M IIN _ U 98 0 A O DN E A_ PE U 2 20 A G O L _U 9 8 0A 18% Q _U % O D E C _ U 2 10 O C E X 26 3 G O P _U 2 1 0A M F DDa ados s 13

15 Using reconciled data: benefits and profits Data quality improvement: benefits 25,00% LPG yield in Fluidized Catalytic Cracking Unit PI LPG yield 20,00% 15,00% 10,00% Before Sigmafine operation After Sigmafine operation 5,00% 0,00% 8/1/ /1/ /2/2005 9/3/ /3/ /4/2005 8/5/ /5/ /6/

16 Using reconciled data: benefits and profits Data quality improvement: benefits % LGN consume versus KPI Energy NG consumption versus Energy KPI KPI energy (%) % 98.00% 96.00% 94.00% 92.00% 90.00% 88.00% 86.00% KPI Target Consumption (ton (ton LGN NG per day) ** 20 ton of NG in a global refinery balance represent 0.04%, BUT they mean 1% in the energy KPI 15

17 Using reconciled data: benefits and profits Data quality improvement: profits Mass balance yield (%) Mass balance yield FCC (Fluidized Catalitic Cracking Unit) *Data reconciliation group identified LCO flow meter fault *During this period it was believed that LCO yield had decreased. It was eliminated loss corresponding to US$ 23.5 million per year Unit shut down Different catalyst loaded Date Flow meters maintenance required by reconciliation group **LCO flow meter repaired **Actual LCO yield equal to the value previously to the catalyst change **Lower light HC and more decanted oil produced = Less profits 16

18 Using reconciled data: benefits and profits Data quality improvement: profits Diesel batch production case Giveaway reduction 17

19 Tanque TQ 4722 Components volume (m 3 ) Components Histórico volume Volume (m3) Batch of diesel being sold Soma de Volume New batch of diesel Hydrotreated diesel $ Kerosene $ ,00 90,00 1/2/2007 2/2/2007 3/2/2007 4/2/2007 Média de Margem Lucro (US$/m3) 5/2/2007 6/2/2007 7/2/2007 8/2/2007 9/2/ /2/ /2/2007 Batch Profit (US$) Batch Profit fev/07 (US$) Mês Data 12/2/ /2/ /2/ /2/ /2/ /2/ ,00 70,00 60,00 50,00 Batch composition recipe defined by blending optimizer 40,00 30,00 20,00 10, US$/m 3 0,00 1/2/2007 2/2/2007 3/2/2007 4/2/2007 5/2/2007 6/2/2007 7/2/2007 8/2/2007 9/2/2007 fev/07 10/2/ /2/ /2/ /2/ /2/ /2/ /2/ /2/2007 Profit of new batch 18 (larger than previous one) Mês Data

20 Using reconciled data: benefits and profits Data quality improvement: profits Cost integration with reconciled data Optimizer result 62,77 US$/m 3 63,84 US$/m 3 1,00 US$/m 3 difference ,00 US$/batch x m 3 x 40 batches/month ,00 US$/month Measurement problem hydrotreated diesel flow Error = 230 m 3 /day x 12 month/year ,00 US$/year 19

21 Using reconciled data: benefits and profits Data quality improvement: profits Gasoil feed flow to FCC unit Unidade (Tudo) Produto (Tudo) Data reconciliation procedure detected that the feed flow 7000 meter was misreading flow by 300 m 3 /day. Without SIGMAFINE The system, lack of 300 m 3 it /day would take of processed quite a long time feed to discover the mistake because of running tank operations (maybe only in a test run). operation 5000 Normal unit operation Unit back to Medidor represents 4000 a liquid loss of US$ 477,000/month or Dados Vazão (t/dia) Feed flow meter working properly US$ 5,700,000/year Data Unit shut down

22 Using reconciled data: benefits and profits Data quality improvement: profits Solvent Loss, entrainment, US$ m Financial Volum etric losses entrainm of the aromatic ent losses removal from unit, the aromatic total amount removal by month unit, total amounts by from month Jun 2006 from to Jun 2006 may to m ay Data reconciliation group detected rubber Potential solvent profit (more depends expensive) on the being difference degraded between to gasoline rubber (less solvent expensive) Total and gasoline solvent by entrainment: entrainment, prices 14 in a % of feed aromatic Total annual extraction losses: unit. US$ 0.7 million Date 21

23 Using reconciled data: benefits and profits Project profit of US$ 36,1 million in 2006 in two refineries 22

24 Perspectives and future applications Oil loss models Kinds of losses Hydraulic Models 23

25 Perspectives and future applications Ten Rules for the Good Life 1) Never put off till tomorrow what you can do today. 2) Never trouble another for what you can do yourself. 3) Never spend your money before you have it. 4) Never buy what you do not want because it is cheap; it will never be dear to you. 5) Pride costs us more than hunger, thirst, and cold. 6) Never repent of having eaten too little. 7) Nothing is troublesome that we do willingly. 8) Don't let the evils which have never happened cost you pain. 9) Always take things by their smooth handle. 10) When angry, count to ten before you speak; if very angry, count to one hundred. Author: Thomas Jefferson 24

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