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  • What role does artificial intelligence (AI) play in revamping downstream facilities that are scaling back on conventional fuels production while upgrading to capture value from new products?

    Apr-2024

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  • Ujjal Mukherjee, Lummus Technology,

    AI, an integral part of a digital strategy, can be used effectively in retrofitting downstream units. We have a joint venture with TCG Digital, called Lummus Digital, which leverages AI-based platforms such as tcgmcube. We couple this with rigorous first principle-based process technology tools to take available data, quickly create digital twins, and develop unique hybrid solutions. These AI-driven digital solutions can be adjusted within equipment, product specification, and utility constraints to minimise energy and CO₂ emissions while maximising production of the most valuable products. These techniques are applicable to optimising existing operations, designing new plants, or evaluating potential retrofit options. 

    Once the products have been maximised within existing constraints, new solutions are developed with retrofits. This can include the change-out of catalyst systems, the addition of new equipment, and sometimes entire upstream or downstream process technology. All of these impact the overall product slate while remaining within the turndown constraints of the base complex.

    Examples of such strategies include:
    • The introduction of biofeedstocks and waste plastic- derived pyrolysis oils to existing refineries or petrochemical complexes.
    • The elimination of gasoline production while maximising jet and diesel production, high-sulphur fuel oil production, and high-sulphur coke production.
    • Increasing chemicals production from 10-30% and sometimes 50% production of needle coke and anode coke from an existing coker, which is a dramatic shift in crude slates and more. 

    The AI digital twin assesses plant performance under various configurations and integrates with economic and capital cost models to evaluate the full impact of the revamp considered.

     

    Apr-2024


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