Fluor Achieves Significant Time Savings in SRU Simulation

技术

分析与建模 - 过程分析
应用基础设施与中间件 - 数据交换与集成

适用行业

化学品
石油和天然气

适用功能

流程制造
质量保证

用例

过程控制与优化
预测性维护

服务

软件设计与工程服务
系统集成

挑战

Fluor, a leading engineering and construction company, faced a challenge in modeling sulfur recovery units (SRUs) with both liquid elemental sulfur and vapor allotropes. The process typically required several simulation files which were iterated manually to balance material and energy recycle loops required in the COPE II process. Multiple files were generally required because of an inability to use multiple property packages in a single simulation. This manual adjustment of the recycle streams was time-consuming and introduced room for error. Fluor needed a solution that could integrate multiple property packages into a single simulation and offer several other benefits for their SRU COPE II modeling.

关于客户

Fluor is one of the world’s largest publicly traded engineering, procurement, fabrication, construction and maintenance companies. It is experienced in and licenses a whole portfolio of sulfur technologies to help their clients’ meet environmental requirements with a cost-effective solution. Fluor/GAA has developed their own patented COPE II process, which uses high levels of oxygen enrichment to increase processing capacity of a sulfur recovery unit (SRU) or tail gas treating unit (TGTU) and utilizes a recycle stream to moderate the temperature in the furnace. The company is always on the lookout for ways to increase efficiency and reduce costs for their clients.

解决方案

Fluor implemented Aspen HYSYS V10, a solution that allowed them to simulate the entire sulfur recovery unit, including recycle streams, in a single file. This solution integrated multiple property packages into a single simulation, offering several benefits for Fluor/GAA’s SRU COPE II modeling. It provided several empirical models for prediction of the reaction furnace temperature, based on feedstock composition, configuration and level of oxygen enrichment. It also offered unit operation blocks for critical specialized equipment such as sulfur condensers and updated estimations for dissolved H2S and H2Sx, for better prediction of the sulfur degassing system, especially for O2-enriched SRU. The solution also allowed easy incorporation of multiple recycle streams and integration of the SRU with upstream and downstream processing steps or units in one simulation.

运营影响

Fluor was able to save a week’s worth of simulation effort, which they could pass on to their client.
The savings come from being able to converge more rapidly than if they were manually converging multiple recycle streams across simulations, while also reducing errors from the manual operation.
Fluor was able to evaluate different configurations of oxygen enrichment in the reactor model, with empirical correlations built in for more accurate modeling.

数量效益