CERT
Beacon 2000-II NIR Process Analyzer
Specialists in Process Efficiency & Energy Conservation
Beacon 2000-II NIR Process Analyzer
The Beacon 2000-II represents a breakthrough in
NIR process analyzer design. The intrinsically
safe probe and low system cost result from a
combination of innovative optics and the
patented application of standard, optical, fiber
technology to NIR analysis.
System Advantages:
Unique Architecture
The Main Analyzer is located in the Control Room,
protected from the process environment. The Main
Analyzer connects, via telecommunications fiber
optics, to the Field Units, which are installed up to 3
km
(2 miles) away, close to the process. Up to 15 Field
Units can be connected to one Main Analyzer.
Intrinsically Safe
The Field Unit uses no electricity, and contains no
moving parts. This 100% optical probe requires no
explosion proof housing or analyzer shelter.
Low Maintenance
Proprietary window material prevents fouling and
eliminates the need to dismantle and clean the probe.
Little or no conditioning is required, further increasing
the system's reliability.
Low Cost
In many applications, the Beacon 2000-II's
performance and price make it an attractive
alternative to traditional analyzers, such as gas
chromatographs or distillation analyzers. No analyzer
shelter is required, and the low maintenance
requirements reduce ownership costs to a minimum.
Field Proven
The Beacon technology has been successfully
implemented in Refinery, Pipeline and Petrochemical
applications.
Beacon 2000-II Specification
Measured properties includes :
Distillation Points
Oxygenates
API Gravity
Cloud Point
Viscosity
Motor Octane
Research Octane
Total Aromatics
Total Ole%
ortho Xylene fins
Field Unit Operating Conditions :
Ambient Temperature
Minimum Sample Temperature
Maximum Sample Temperature
Sample Conditioning Requirement
Maximum Inlet Pressure
Flow Rate Requirement
Sample phase
Weight
Dimensions
Routine Maintenance
Area Classification
:
:
:
:
:
:
:
:
:
:
:
40ºC to +70ºC
Application Specific
Above Cloud Pt. up to 160ºC
Haze-free
550 psi ( 40 bars )
1 l/min to 3 l/min
Liquid
Approximately 7 kg (15 lb.)
H 30 cm - D 38 cm - W 16 cm
None
Probe Intrinsically SafeZ
Applications :
• Gasoline and Diesel on-line blending
• Continuous catalyst regeneration
• Crude distillation unit optimization
• Solvents extraction complex on-line analysis
• Catalytic cracking unit optimization
• Reformer streams on-line analysis
• Pipeline products analysis and identification
Flash Point
Pour Point
Cetane index
Reid Vapor Pressure
% para Xylene
PIONA
Chemical Composition%
Benzene
% meta Xylene
% MTBE and more …
Spectrometer Operation Conditions :
Ambient Temperature
: 0C - 45C (32F - 113F)
Relative Humidity
: 30% - 90% non-condensing
Supply Voltage
: 100/120/220/VAC,
50/60 Hz (3 A max.) Via on-line UPS
Weight
: Approximately 45 kg (100 lb.)
Dimensions
: H 80 cm - D 80 cm - W 60 cm
Routine Maintenance
: Replacement of light source
every 6 months
Area Classification
: General Purpose
Performance Specification :
Cycle time
: 10-30 sec / stream
Main Analyzer Unit to Field Units maximum distance: 3 km
Multiplexing Capability : up to 15 Field Units
Outputs:
• Modbus
• 8 - 16 outputs of 4-20 mA isolated into 600 ohm max.
• 16 outputs of contact closures 0-5 VDC (option)
On-Line NIR Analysis of Blended Gasoline
Static Mixer
Unleaded Gasoline
to Product Tank
Feed Stock Tanks
NIR Field Unit
Fiber Optic Cable
Analyser's Shelter
Beacon
2000-II
PLC
DCS
Optimizer
Figure 1: Measurement loop - Beacon 2000-II
Site Description
The feed stocks to the refinery blending system are produced by the upstream processing units such as FCC and CCR . The composition
of the gasoline changes often due to the variety of the Crude Oil. The NIR System is located in the Analyzer's shelter and is connected via
telecommunication fiber optics to the Field Unit, which is outside the shelter. The Field Unit is connected on-line to the blending header, after
the static mixer. No sample conditioning is needed in order to introduce the sample into the probe. The NIR System is connected via a
RS232 Modbus protocol to the DCS. The measurement of the data is refreshed once every 30 seconds. The blending system is controlled
by an Optimizer (Blending Control Program) which supervises at a higher level than the DCS, with regards to the blending accuracy.
Properties Description
The properties measured below are typical for a blending control, for both Premium and Regular Unleaded Gasoline:
Property Name
Model Range
Units
MON
RVP
FBP
84.2 - 86.8
9.0 - 10.5
Octane Number
PSI
180 - 200
deg. C
Customer Benefits
Octane giveaway is reduced by 0.3 octanes thereby saving 6 cents US/bbl.
Catalyst Regeneration On-Line NIR Analysis
LPG
Stabilizr
Separation
H2
Naphtha feed
Reactor 1
NIR
Reactor 2
Reactor 3
Field unit 1
Piona
Initial Boiling Pt.
10% Distl
50% Distl
90% Distl
Final Boiling Pt.
Density
NIR
Reactor 4
NIR
Plarformate
Field unit 2
Benzene
Toluene
Xylene
Ethyl Benzene
RON
Total Aromatics
= Field Unit
Site Description
The Continuous Catalyst Regeneration (CCR) unit, converts naphtha feedstock to high octane gasoline for gasoline blending. The rundown
stream is also used as an aromatics feedstock for the petrochemical industries. The optimal process severity is highly dependent on the naphtha
feed composition.
A sketch of the plant is shown in Figure 1. PetroMetriX Beacon field units are located at the input and output of the CCR unit. They are
connected to the main analyzer, located in the general purpose equipment room approximately 200 meters away, via telecommunications fiber
optics. The Beacon main analyzer is connected through a Modbus interface to a Honeywell TDC 3000 in the main control room.
Distillation Model
A calibration model for naphtha feed distillation properties was prepared in co-operation with the refinery laboratory. Distillation properties of a set
of about 35 samples were measured by the refinery lab, while the NIR spectra were measured by PetroMetriX. The calibration models were
installed by modem connection to the main analyzer, located in the equipment room at the CCR plant.
Properties measured with the NIR analyz
Naphtha Feed
Platformate
PIONA
Initial Boiling Point
Benzene
Toluene
T10%
Ethyl Benzene
T50%
Xylene
T90%
Final Boiling Point
RON
Total Aromatics
Density
Customer Benefits
A recent feasibility study carried out at this plant showed benefits of $0.45million per year for replacing only the conventional RON analyzer, and
some additional $0.5million when applied together with advance process control software.
On-Line NIR Analysis in Crude Distillation Unit
LPG
Process Area
Light Naphtha
Full Range Naphtha Stabilizer
Splitter
Kerosene
Atm.
distil.
Column Light Atm. Gas Oil
Heavy Naphtha
'Crude oil
Heavy Atm. Gas Oil
Atm. bottom
Vacuum
distil.
Column
Light Vac. Gas Oil
Heavy Vac. Gas Oil
Fiber Optic
Cable
Nir Analyzer Probe
Vac. bottom
Equipment Room
DCS
DCS
PLC
Beacon
2000-II
Analyzer
Site Description
A Crude Distillation Unit fractionates streams as Light Naphtha, Kerosene, Light Atmospheric Gas Oil, Heavy Atmospheric Gas Oil and Light
Vacuum Gas Oil. These streams are monitored for advanced control purposes. A fast sample loop of about 15m is connected between the sample
tap and the intrinsically safe sample probe. Fiber Optic cables connect the sample probes to the Main Analyzer, which is located in the crude unit
equipment room. The Analyzer installed has a capability of multiplexing up to 7 channels. It communicates with the plant DCS via a bidirectional
Modbus Protocol.
Properties measured per Stream using the NIR analyser
Light Naphtha
Kerosene
Light Atmospheric
Gas Oil
Heavy Atmospheric.
Gas Oil
Light Vacuum
Gas Oil
D(15)
D(15)
D(15)
D(15)
D(15)
T90%
T90%
T90%
T90%
T90%
Flash Pt.
Cloud Pt.
Cloud Pt.
Cloud Pt.
Cloud Pt.
Freeze Pt.
Pour Pt.
Pour Pt.
Pour Pt.
Pour Pt.
Customer Benefits
The traditional Analyzers for the above mentioned properties are located in a special shelter, which is maintained as EEx by a purging technique
and air-conditioning. In addition, the high annual maintenance costs of these Analyzers are huge. By installing the Beacon 2000-II NIR Analyzer, it
replaces the traditional analyzer, and the customer saves on maintenance $180,000 per annum. The Crude Unit works under Advanced Control
S/W. This means that the data provided by the OnLine System is always up-to-date and reliable. All the properties can be measured within 3
minutes whilst with a traditional Analyzer it could take up to 20 minutes.
On-Line NIR Analysis of Diesel
Analyzer
Field Units
A
Atm.
Crude
Distillation Diesel Fuel
Tower
A
Diesel Fuel
Atm.
Crude
Distillation
Tower
Unit 2
Unit 1
to Storage
From Reformer
Modbus to
DCS
Main
Analyzer
Crude Unit
Instrument Room
Site Description
An oil refinery in Kansas uses on line NIR (Near InfraRed) analysis to monitor its crude distillation. The NIR instrument is a PetroMetriX Beacon
2000-II analyzer. A fast sample loop connects the intrinsically safe sample probe to the fuel streams. Two distillation towers are monitored using
the Beacon's multiplexing capability. The same instrument measures an additional Reformate stream. Standard telecommunications fiber optics
connect the sample probes to the main analyzer, which is located in the crude unit instrument room.
The analyzer was installed with a x7 multiplexer, to allow simple expansion of the system in the future. The analyzer communicates with a
Honeywell TDC3000 through a Modbus interface. Communication with the TDC300 is bi-directional, so the analyzer can receive commands sent
to it by the operators in the control room.
Customer Benefits
The on line data provided by the system is used by the TDC 3000 for process optimization.
The Beacon NIR system can be easily expanded to measure other process streams in the refinery.
Table 1: Fuel properties measured with the NIR instrument
Diesel Fuel
90% Distillation
Cloud Point
Pour Point
On-Line NIR Analysis in Extraction Complex
Site Description
A petrochemical plant in Haifa uses on line NIR (Near Infra Red) analysis to monitor its processes and provide data for process control. A sketch
of the plant is shown in Figure 1. The NIR instrument is a PetroMetrix Beacon Analyzer. The Analyzer, which is located in the control room,
connects to sample probes throughout the plant, using a multiplexer and telecommunication fiber optics. It interfaces to a Honeywell TDC3000
through a Modbus interface.
Customer Benefits
The NIR analyzer replaces gas chromatographs that were previously used in these applications. The NIR analysis has much faster response
time and lower maintenance requirements than the GCs typically used in these applications. The faster response time and reliable continuous
data provided by the analyzer (see Table 1) resulted in improved control of the process units :
• Analysis of naphtha feed to the catalytic reformer allows advanced control of the reformer.
• Analysis of the reformate, used as feed for the petrochemical plant, can be used for advanced control of the etrochemical processes.The
reformate is also analyzed for Octane, as it is used in the refinery for gasoline blending.
• In the ortho-Xylene process, the instrument monitors the ortho-Xylene to total Xylenes ratio. This allows higher recovery, better purity and
increased production of ortho-Xylene. Less contaminant enters thepara-Xylene process, due to the improved ortho-Xylene recovery.
• In the para-Xylene process, the NIR analyzer monitors the percent of para-Xylene and other aromatics in the process, allowing greater
throughput and recovery while maintaining product purity.
Although one might not expect NIR to be able to distinguish between Xylene isomers, the high resolution of the instrument allows this on-line
analysis. Multiplexing several probes results in cost efficient analysis at several points in the plant. Installation was very straightforward:
telecommunications fiber optic was laid in existing trays to the probe locations. The only other utility required was standard electric power.
The field units (sample cells) are maintenance free. No sample conditioning was required, beyond cooling some of the streams to be within the
sample cells range. Due to the nature of the measurements, there is no need to periodically update the calibration models. The Beacon NIR
process analyzer has proven to be both reliable and cost effective in this application. The information provided by the analyzer has increased
plant efficiency.
Table 1: Properties measured with the NIR instrument
Field Unit 1: Naphtha
Field Unit 2: Reformate
Field Unit 3: p-Xylene
Field Unit 4: o-Xylene
PIONA
Initial Boiling Point
Benzene
para-Xylene
ortho-Xylene
ortho-Xylene
total Xylenes
10% Distillation
Toluene
Xylene
50% Distillation
Ethyl Benzene
Ethyl Benzene
90% Distillation
Final Boiling Point
RON
meta-Xylene
Total Aromatics
Density
Subject to change without notice
FMCIG/ModconNIR/Ver1/1007
3000/02/2004/3499
A-34/35, MIDC, Industrial Estate, 'H' Block, Pimpri, Pune - 411 018. India.
Tel.: 91(0)20 - 27442020 Fax: 91(0)20 - 27442040
E-mail: [email protected]
Branches : Ahmedabad, Alibag, Bangalore, Bhopal, Chandigarh, Chennai, Coimbatore, Delhi,
Hyderabad, Indore, Jamshedpur, Kolkata, Lucknow, Madurai, Mumbai, Nagpur, Navi Mumbai,
Pune, Surat, Vadodara, Visakhapatnam
Website : www.forbesmarshall.com
Solutions
Forbes Marshall Pvt. Ltd.