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Implementation of a Digital Twin strategy in your refinery requires unique application based on your key business initiatives. Oftentimes these projects will start small and then broaden out.  In order to implement this process in your refinery it is important to outline clear business objectives and identify issues that need addressing. Additionally, refiners must determine if these issues are compatible with a data driven approach. Finally identifying how the digital twin will provide value in addressing business needs is key. In order for a project to qualify for a digital twin solution the project needs to be compatible with virtual copies of the asset, being driven by data and models, which could monitor and provide predictive information, to make better operating decisions (Beck, 2020). At this stage the industry has many successful digital twin case studies in refineries which provide evidence the value that these products can add. Many of our partners have developed off-the-shelf digital technologies suites that can be easily integrated.

The first step is to hydrotreat the heavy naphtha feed to remove impurities such as sulfur and nitrogen to prevent damage to the reformer’s platinum catalysts. A naphtha hydrotreater is utilized to secure this result.

Next, the feed is sent through a series of 3-4 reactor vessels. A platinum and alumina catalyst to drive the reaction within each vessel. Also, for each reactor there is a furnace to inject additional heat as the reaction is endothermic. The product from the reformer (reformate) is a highly aromatic naphtha-range stream, as well as some by-product lighter material and hydrogen. (Energy Insights by Mckinsey, 2021).

Inputs

The input to the reformer is a hydrotreated, high N+A naphtha

Outputs

The major outputs of the reformer process are reformate (later blended into gasoline), hydrogen (used as feed for hydrotreaters/crackers) and reformer gas (Energy Insights by Mckinsey, 2021).