2. Joe Fillion, Value Consultant, Invensys
Total Performance HF Optimization through Advanced Measurement Solutions for HF Alkylation
Joe Fillion, Value Consultant, Invensys
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3. HF Alkalation
Converts low value Iso-Butane to high value Octane using HF as the catalyst (1942 technology)
Up until 2000, manual samples / lab tests were the only way to monitor HF concentration – hi risk
FT-NIR hit the market in 2000 – a good solution that is VERY expensive and hard to keep running
ACA.HF from Invensys: Trial complete in 2009 with success.

4. Performance through HF Measurement
Total Performance.HF
Optimization
Measurement
ACA.HF
Acid Catalyst Analyzer
HCA.HF
Hydrocarbon Analyzer
Optimum.HF
Predictive Control and First-Principles Based Online Modeling
The ACA.HF is not merely an analyzer, but an essential element in a comprehensive optimization strategy
Slide 4
2009 IPS North America Client Conference

5. Overview
The ACA.HF provides performance equivalent or better to FTNIR, with an expected installed cost less than half of FTNIR’s $1.5 million. Ease of installation and reliability are much, much greater than FTNIR.
Maintenance and cost of ownership for the base sensors is extremely low
MTBF estimated to be > 29 years for sensors
This does not take into consideration corrosion issues.
Typical commissioning time is 1-2 days
Breakthrough Product of the year by Process Magazine
Selected as one of the 4 finalist in the Kirkpatrick Award 5
Invensys proprietary & confidential
© Invensys 11/12/2018

6. Value Proposition Safety:
On-line measurements vs. manual samples taken to the Lab.
Increased value and decreased costs
Increase Octane by running at optimum (running at 87% HF)
Closed loop control on temperature control (steam)
Reduce amount of HF from 45 – 50 bbls to 25 bbls
At $700 per bbls and less regeneration costs by keeping the HF in the unit and not have it go out with the ASO
Avoid Acid Run away

7. The ACA.HF Measurement Solution
For online analysis of %HF, %Water and %ASO in HF alkylation catalyst
Design objective: Affordable with reliable accuracy
A multivariable analyzer¹ based on the application of proven Foxboro measurement technologies that are long-established in HF service
Exceeds the precision of HF analysis with FTNIR²
The ACA.HF is the new standard in safety, simplicity, reliability, and accuracy for HF catalyst analysis
¹ Patent Granted ; international rights apply
² ABB FTPA2000-HP20 FTNIR-based HF Acid Analyzer 7
Invensys proprietary & confidential
© Invensys 11/12/2018

8. ACA.HF – Features
Non-spectroscopic analyzer system designed to measure all components in HF alkylation catalyst:  HF, water, and acid-soluble oil (ASO)
Direct chemical measurement
An integrated panel-mounted analyzer system for installation in the alkylation unit
All wetted parts associated with the analyzer system and sample handling are made with Hastelloy-C, Monel (optional) Teflon®, and Kalrez® (Chemraz®).
Measurement is performed on sample flowing continuously through tubing and components half-inch or larger, minimizing pressure drops that cause flashing of light hydrocarbons 8
Invensys proprietary & confidential
© Invensys 11/12/2018

9. ACA.HF – Features Cont’d
Unaffected by sample temperature variation Manual valves to isolate the analyzer system and purge with isobutane, alkylate, nitrogen, etc. Modular design for easy swap-out of measurement sensors and components Utilizes proven measurement technologies with an established history of service in HF applications Internal data logging and historizing of KPI’s to enable quick and easy diagnostics No wear elements requiring preventative maintenance Easy algorithm adjustment if necessary 9
Invensys proprietary & confidential
© Invensys 11/12/2018

10. ACA.HF: The IOM Approach to HF Catalyst Analysis
Goal: Apply a simple solution to a simple problem:
Take a ternary (3-component) sample and characterize using 2 appropriately chosen sensors.
Use industrialized field proven sensors, a rugged automation controller and industry standard software, combined with application knowhow.
Package solution to work “out of the box” and have a significantly low cost of ownership compared with competitive techniques.
Slide 10

11. Ternary Sample (HF Catalyst) Characterization with Two Measurements*
Conductivity of HF Catalyst
HF and H2O are each almost non- conductive when pure.
When H2O dissolves in HF, it reacts to form ions, which are conductive:
2HF + H2O → HF2- + H3O+
When hydrocarbon (ASO) dissolves in HF, no conductive ions are formed.
In HF catalyst, conductivity is directly proportional to H2O content.*
Density of HF Catalyst
HF and H2O have almost identical densities—about 1.0 g/cc; therefore H2O has negligible effect on the density of HF.
The acid-soluble organics (ASO) in HF catalyst have densities of about 0.6 g/cc.
ASO in HF reduces the density below that of an HF/H2O mixture.
In HF catalyst, density is directly proportional to ASO content.*
* Temperature must also be taken into account.
Slide 11

12. Ternary Sample (HF Catalyst) Characterization with Two Measurements
Two measurements alone give us only “2 equations with 3 unknowns”. However, in addition to the H2O concentration being proportional to conductivity, and the ASO concentration to density, the chemical system is also bounded mathematically:
%HF + %ASO + %H2O = 100 (94)
Giving us our 3rd equation.
For simplicity, we’ve been glossing over the fact that temperature enters into both the conductivity and density measurements. That’s because temperature compensation of these measurements is a long-established technique which is readily implemented.
Also, the dependence of conductivity solely on %H2O and density solely on %ASO is not perfect. Therefore we used conductivity and density terms in our final equations for both %H2O and %ASO. 12
Invensys proprietary & confidential
© Invensys 11/12/2018

13. All valves are manual shutoff valves:
Measurement of continuously-flowing sample
No automated valves for stop-flow analysis
No wear elements requiring preventative maintenance

14. Slide 14

15. Performance and Validation16
Invensys proprietary & confidential
© Invensys 11/12/2018

16. ACA.HF Validation
Results cover 4 months (84 run days): July 9 – November 1, 2009
Refinery process unit was Shutdown August 12 to September 23
Based on Direct Comparison with FTNIR Results at the ConocoPhillips refinery in Sweeny, TX
4-minute interval data
FTNIR analysis on stopped-flow sample
ACA.HF analyzes continuously-flowing sample conditioned to remove phase-separated isobutane
Only instantaneous readings were used in the current comparison
4-second measurement interval (signal averaging possibilities)
Sample temperature not controlled 17
Invensys proprietary & confidential
© Invensys 11/12/2018

17. %HF by Invensys ACA.HF and ABB FTNIR18
Invensys proprietary & confidential
© Invensys 11/12/2018

18. %Water by Invensys ACA.HF and ABB FTNIR19
Invensys proprietary & confidential
© Invensys 11/12/2018

19. %ASO by Invensys ACA.HF and ABB FTNIR20
Invensys proprietary & confidential
© Invensys 11/12/2018