1. Digital InlineDigital Inline
Blending with DeltaVBlending with DeltaV
by
Emerson Process Management
@Copyrights

2. Emerson Process Management Confidential
AgendaAgenda
What is Blending?
How do we do it?
 Blend Ratio Control
 Blend Quality Control & Optimization
Conclusions

3. Emerson Process Management Confidential
What is BlendingWhat is Blending
Definition – Uniform mixing of 3 or more different streams to produce a
product with specific properties
Problems:
 Flow Constraints
 Inventory Constraints
 Accuracy & Precision
 Poor Mixing (Tank stratification)
Approaches
 Sequential Blending
 Continuous Inline Blending

4. Emerson Process Management Confidential
History of BlendingHistory of Blending
Prior to 1990
 Most blending is sequential
1990 – 2000
 Most refinery (gasoline & diesel) blenders upgraded to inline blending
 Some chemical blending converted to inline
2000+
 Gasoline blenders forced to consider optimization
 Most remaining sequential blenders upgrade to inline

5. Emerson Process Management Confidential
Who Uses BlendersWho Uses Blenders
Refineries
 Gasoline
 Diesel
 Distillates, Solvents, Fuel Oils
 Lube Oils
 Asphalt
Chemical Plants
Other
 Baby Formula
The blender is the cash register of the refinery

6. Emerson Process Management Confidential
Blender’s Operating ProblemsBlender’s Operating Problems
Make more grades with more specifications
using many more components
Make the grade on-spec with minimum
giveaway, but don’t use too much of any one
component
Don’t contaminate any finished product tanks
because of bad line-ups, line fill, leaks, etc.
This is a manually intensive operation but
doing it right is key to the refinery’s
profitability
Increase capacity
Blend Operator

7. Emerson Process Management Confidential
Improved Blending BenefitsImproved Blending Benefits
Reduced “Giveaway” - Produce closer to specification, reduced cost of
producing average blend
Reduced Off-spec and co-mingled material
Reduced Reblending - increased capacity on blenders
Reduced Component and Product Inventory - reduced working capital
Reduced Blend period – Blend is on-spec from start to finish
Estimated benefits $0.05 to $0.10 per barrel of
gasoline blended

8. Emerson Process Management Confidential
Sequential Vs. Ratio BlendingSequential Vs. Ratio Blending
One Component at a time
Economical Method (Lower
Installation Cost)
Line Flush required for proper
product quality
Blend Accuracy assured only for
completed batches
Large volume blends will require
long periods of mixing
In-line or all at same time
Requires meter and valve for each
stream
Precise control of blending
Instantaneous alarms on blend
available
Blend quality assured on aborted
blends

9. Emerson Process Management Confidential
An Integrated Application SolutionAn Integrated Application Solution
Consulting
High Performance Field Instrumentation
 Control Valves
 Flowmeters
On-Line Analyzers
 Conventional Analyzers (GC’s, NIR, etc)
 Neural Network based inferential sensors
DeltaV Controller w/ Proven Configuration & Algorithms
Blend Quality Control, Optimization & Scheduling
Turnkey Skid
Installation, Start-up & Training
Financing

10. Emerson Process Management Confidential
FC
Component
Ratio Control
FI AI
Blend Quality
Controller
On-Line Blend
Optimization
Ratio Targets
Component Ratio
& Quality Targets
Component Qualities
& Limits
Desired
Rundown Rate
& Flow Limits
Blend
Planning LP
Prices
Batches
Target Recipes
Target Inventories
Heel Information
Component Quality &
Availability
Blend
Start/Stop
FC
FC
FC
DeltaV Blend
DeltaV Blend Control StrategyDeltaV Blend Control Strategy

11. Emerson Process Management Confidential
Modular DesignModular Design
Continuous or Batch (Tank) In-Line Digital Blending
Recipe Control
 30 recipes with 80 configurable parameters each
 Start/Hold/Resume/Complete logic
 Blend Reports
Component & Additive Ratio Control
 Pacing (Instantaneous ratio control)
 Memory (Total ratio control)
 Ramp up/down
Dual Analyzer Trim Control
 Decoupling

12. Emerson Process Management Confidential
OptionsOptions
Basic Customization
 Add/Delete streams
 Custom graphics
 Customer Tags
 Define I/O
 Add/Delete recipes/parameters
Optimization
 Low level optimization in Analyzer control strategies
 High level optimization integration (OPC)
Master Blend Control
 Coordination of multiple blend headers
 Integration of header and pipeline control (OM&S)

13. Emerson Process Management Confidential
OptionsOptions
Simulation
 Training
 Testing
Custom Interfaces (analyzers, optimizers, etc)
Special Calculations & Functions
 Special equipment scheduling and blend line-ups based on production rates,
equipment availability, etc
 Derived Quality Calculations
 Blend grade transition and Tank heel accounting
 Tank Farm Management
 Component, additive & product compatibility checking
 Scheduling and Time-to-completion calculations

14. Emerson Process Management Confidential
Standard DeltaV Blender AlgorithmsStandard DeltaV Blender Algorithms
Blend Ratio Control
 Streams
12 main component flows
4 additive flows
 2 Analyzer trim controllers with decoupling (Optional)
Start/Stop Control
 Sequential blender pump and valve line-ups
1 pump, 1 control valve, 1 flow transmitter per stream
Delay Sequences, ramping up/down
 Analog & Discrete controls and monitoring of auxiliary equipment
Feed and Product tank level Monitoring
Header pressure & temperature control

15. Emerson Process Management Confidential
Blend Start/Stop ControlBlend Start/Stop Control
Startup Sequencing
 Load Blend Order to on-line system
 Log starting conditions to Blend Order DB
 Flush lines
 Zero totalizers
 Select, Line-up, & Start pumps
 Ramp valves open and put FC’s into control
 Start ratio control, ramp to target rate
Shutdown Sequencing
 Ramp down blend rate to minimum
 Place FC’s in manual and close valves
 Shutdown pumps
 Log final blend results to Blend Order DB

16. Emerson Process Management Confidential
Operator InterfaceOperator Interface
Primary Operating Displays
 Blend Setup
 Blend Overview Graphic
 Component & Additive loops
 Analyzer Trim Control
Interlock/Permissive Status
Displays
 Active/Bypassed
Recipe management
Displays
–Load recipes
–Modify recipes
–Save recipes
Support Displays
–Trends
–Alarm management
–Reports

17. Emerson Process Management Confidential
Primary User ViewsPrimary User Views
Blend Control
Recipe Management Blend Setup
Blend Components

18. Emerson Process Management Confidential
FC
Component
Ratio Control
FI AI
Blend Quality
Controller
On-Line Blend
Optimization
Ratio Targets
Component Ratio
& Quality Targets
Component Qualities
& Limits
Desired
Rundown Rate
& Flow Limits
Blend
Planning LP
Prices
Batches
Target Recipes
Target Inventories
Heel Information
Component Quality &
Availability
Blend
Start/Stop
FC
FC
FC
DeltaV Blend
Blend Quality Control & OptimizationBlend Quality Control & Optimization

19. Emerson Process Management Confidential
US Gasoline Regulatory Time LineUS Gasoline Regulatory Time Line
20052004200320022001200019991998199719961995
CARB
CBG
EPA RFG
Phase ll
EPA Low
Sulfur Gasoline
EPA RFG
Complex Model
CARB MTBE
Phase Out
EPA RFG
Simple Model
Each New Regulation Means More Complicated Blending
199419931992
Mandated
Oxygenates

20. Emerson Process Management Confidential
Complicated Gasoline SpecificationsComplicated Gasoline Specifications
Parameter Current California
Specification
Octane Per Grade
RVP 7.0 psi max
Sulfur 80 ppm max
30 ppm av
T50 220 F max
170 F min
200 F av
T90 330 F max
290 F av
Olefins 10 vol % max
4 vol % av
Aromatics 30 vol % max
22 vol % av
Oxygen 2.7 wt % max
1.8 wt % min
To meet these
specifications is a
complicated
multivariable control
problem

21. Emerson Process Management Confidential
Longer term
coordination
Production
Planning
Medium term
definition of activities
Production
Scheduling
Blend
Control
Real-time regulatory
control & optimization
Initial ConditionsPlanned production and/or
material and resource constraints
Current Status and PerformanceTargets and recipes
Interactions between Planning,Interactions between Planning,
Scheduling, and ControlScheduling, and Control

22. Emerson Process Management Confidential
So why isn’t recipe control enough for
blending?
Production PlanningProduction Planning
Linear Program (LP)
Run monthly (weekly?) with average product demand
Selects crudes, intermediates, and product purchases for future period
(one to three months) to meet demand at maximum profit
Sets average blend recipes for period (assumed component quantities and
qualities)

23. Emerson Process Management Confidential
ProblemsProblems
Simplified LP models
Crude assay database
Component properties are different than that assumed by Planning LP
Crudes are run individually or in blends different from average resulting from
the Planning LP
Specific batches of gasoline have to be produced to a specific grade with the
stocks on hand
How can we help solve these
problems?

24. Emerson Process Management Confidential
Multi-Period Blend Planning LPMulti-Period Blend Planning LP
Multi-period, multi-blend, executed daily or weekly
Linearized blend models (recursive LP)
Determines optimum blends required to meet specific batches of product demands
Integrated with refinery planning LP
Inputs:
 Product shipments, prices
 Starting inventories
 Projected component rates & qualities
 Target ending inventories
Outputs:
 Finished product batches
 Target recipes for each batch
 Target ending inventories for each period
(products and components)

25. Emerson Process Management Confidential
Traditional Blend Control ArchitectureTraditional Blend Control Architecture
Blend Models
AI
FC FC FC FC FC
AI
MPC Dynamic
Models
Ratio Controls
(Ramping & Pacing)
Flow Targets
Blend Property
Control
Ratio Targets
Blend Scheduling
Target Recipe & Availability
Blend Models
Blend Optimization
Product Quality Targets
Component Flows

26. Emerson Process Management Confidential
Blend Order Management System
Blend Order ManagementBlend Order Management
Blend Order Database
Blend
Start/Stop
Blend Order
Execution
MMI
Blend
Reports
Blend Reporting
Blend
Optimizer

27. Emerson Process Management Confidential
Blend Order ManagementBlend Order Management
User Interface to Blend Order Database
Security functions
 User authority changes with order status
Order Entry
 Load from past orders
Order Management
 Tracks orders through phases
 Confirms required data input before changing phases
 Approvals
 Data validation
Blend Reporting

28. Emerson Process Management Confidential
Blend Order Data ObjectBlend Order Data Object
Blend Order
• Blend Order ID
• Blended Product Name
• Blender ID
• Order Status
• Planned start/end time
• Target Quantity
• Product Quality Targets & Limits (up to 25 qualities)
• Components and target quantities (up to 15 components)
• Additives and target quantities (up to 10 additives)
• Special instructions
• Actual time for each status change
• Final blend results
• Operator comments

29. Emerson Process Management Confidential
Blend Order PhasesBlend Order Phases
Planned
Approved
Selected
Starting
Active
Stopping
Complete
Hold
Blend Planner in Control
Operator in Control

30. Emerson Process Management Confidential
Offline Blend OptimizationOffline Blend Optimization
File based
Load inputs from stored blend orders
Alternative objective functions
Correct for heel
User can modify all inputs
Inputs:
 Target recipe
 Desired finished batch size
 Finished product quality specs
 Component qualities and availability
 Heel quantity and qualities
Outputs:
 Optimal blend qualities
 Optimal recipe
 Final batch size

31. Emerson Process Management Confidential
Blend OptimizationBlend Optimization
• Optimum recipe
• Component usage
• Predicted qualities
Results
RTO+
Real-Time
Optimization Engine
Inputs
• Prices
• Target Recipe
• Product Specs
• Component
Availability
• Current Heel
Quantity & Quality
Objective Function
• Maximize Profit
• Minimize Deviation
from Target Recipe
• Min/Max use of
Specific Component
Blend Models

32. Emerson Process Management Confidential
• Total Blended
Amount
• Predicted Density
• Predicted Qualities
Outputs
Blend ModelsBlend Models
• Component Name
• Amount to be
blended
• Density
• Qualities
• Component Name
• Amount to be
blended
• Density
• Qualities
Components
• Component Name
• Amount to be
blended
• Density
• Qualities
Heel
• Product Name
• Amount
• Density
• Qualities
Blend Models
Blend Quality Library
• Density
• Sulfur
• Octane
• ASTM Distillation
• Aromatics
• Olefins
• Benzene
• RVP...

33. Emerson Process Management Confidential
Inputs
• Prices
• Target Recipe
• Product Specs
• Component
Availability
• Current Heel
Quantity & Quality
RTO+
Real-Time Optimization Engine
Objective Function
• Maximize Profit
• Minimize Deviation
from Target Recipe
• Min/Max use of
Specific Component
Blend Models
• Optimum recipe
• Component usage
• Predicted qualities
Results
Off-Line
Optimizer
Multiple Optimizer ApplicationsMultiple Optimizer Applications
Real-Time Database
Inputs
• Prices
• Target Recipe
• Product Specs
• Component
Availability
• Current Heel
Quantity & Quality
RTO+
Real-Time Optimization Engine
Objective Function
• Maximize Profit
• Minimize Deviation
from Target Recipe
• Min/Max use of
Specific Component
Blend Models
• Optimum recipe
• Component usage
• Predicted qualities
Results
On-Line
Optimizer
Blend Order Database
Inputs
• Prices
• Target Recipe
• Product Specs
• Component
Availability
• Current Heel
Quantity & Quality
RTO+
Real-Time Optimization Engine
Objective Function
• Maximize Profit
• Minimize Deviation
from Target Recipe
• Min/Max use of
Specific Component
Blend Models
• Optimum recipe
• Component usage
• Predicted qualities
Results
Blend Quality
Control

34. Emerson Process Management Confidential
Online Blend OptimizationOnline Blend Optimization
Executes every 5-15 minutes
Runs for blend orders that are “Active”
Operator selects objective function
Outputs recommended results even in open-loop
Handles reduced degrees of freedom (e.g. 1 or more controllers in Auto)
Accommodates actual component qualities and blend model update from
analyzers or lab
Inputs:
 Automatically loaded from RT database and blend order system
Outputs:
 Optimal instantaneous quality targets
 Optimal recipe
 Target batch size

35. Emerson Process Management Confidential
Components
Product
Tankage
Total
Blend
On-Spec
Heel
Components
Product
In-Line
Each
Part of
Blend
On-Spec
Online Analyzers
Blend Property Control
Online Blend Optimization
Product Certification
Two Basic Types of BlendingTwo Basic Types of Blending

36. Emerson Process Management Confidential
Accelerated Heel CorrectionAccelerated Heel Correction
Final
Target
Percent of Blend
Octane
0% 100%
Heel
Current
Tank Quality
Blend header
target adjusted
to meet
final target
Current Blend
Header Target

37. Emerson Process Management Confidential
Blend ExecutionBlend Execution
FC
Component
Ratio Control
FI AI
Blend Quality
Controller
Ratio Targets
Component Qualities
& Limits
Desired Rundown Rate,
Header Pressure, Flow and
Valve Limits
FC
FC
FC
PI
Product Quality
Targets

38. Emerson Process Management Confidential
Blend Quality ControlBlend Quality Control
RTO+
Real-Time
Optimization Engine
Blend Models
• Executes 1-2 minutes
• Specifications can be:
- Target
- Range
- Max or min
Real-TimeDatabase
• Current Blend Quality Targets & Specs
• Current Component Ratios
• Blend Quality Analyzers
• Component Limits & Qualities
• Component ratio targets
• Predicted qualities
Objective Function
• Primary: Meet Quality Specs
• Secondary: Minimize Deviation from
Current Recipe

39. Emerson Process Management Confidential
SummarySummary
Pre-engineered proven application
 Reduced risk
Leading Technology hardware platform
 Non-proprietary
 Longest Life Expectancy
Easily customized and extended
 Integrate virtually any feature or function as required
Complete Engineering support from start to finish
 Consultation
 Main Automation Contractor
The Global Industry Leader

40. Emerson Process Management Confidential
Technical AdvantagesTechnical Advantages
Integrated suite of applications on DeltaV
Scaleable, Modular
Automated Startup/Shutdown
No need for multivariable control layer
 Dynamics are trivial
 No step tests required
 Incorporates non-linearity
 Simplifies architecture
Integrated set of blend models used by all applications
 Non-linear
 Biased by lab or analyzer data
 Incorporate RFG simple and complex models
Integrated blend order management & reports

41. Emerson Process Management Confidential
Moving ForwardMoving Forward
Complete Blend Optimization Modules
Parallel Effort to Develop Movements & Inventory Solution
 Leverage Terminal Automation Solution