MOD-4100 Online Crude Oil Analyser for Refinery Optimization

The MOD-4100 Crude Oil Analyser provides online measurement of critical crude oil properties for refinery optimization, crude blending, CDU control and real-time feedstock quality monitoring.
Crude oil quality can change significantly during transportation, storage, blending and crude switching. Continuous online crude oil analysis helps refineries respond faster to changes in feedstock quality, reduce dependence on delayed laboratory results and improve process control.

Crude oil quality can change significantly during transportation, storage, blending and crude switching. Continuous online crude oil analysis helps refineries respond faster to changes in feedstock quality, reduce dependence on delayed laboratory results and improve process control.

Modcon Systems Ltd. provides the MOD 4100 Crude Oil Analyser as part of its industrial analyzer portfolio for real-time process measurement and control.

The newly redesigned MOD-4100 crude analyzer represents a breakthrough in crude oil on-line analysis. It is a single analyzer, that performs on-line a variety of different critical crude oil measurements to provide real-time analytical data, which is highly important for optimized operation processing of crude oils. The new design of the MOD 4100 analyzer system is based on a “Modular Package concept”. It is inspected and tested by the factory, and ready for immediate installation on-site. The following crude oil critical parameters can be measured on-line and correlated to ASTM:

• Salt Concentration (D3230)
• Distillation (D2892, D86)
• SARA (IP-143 and D893-69)
• Emulsion stability (F3045, D4007 and D3707)
• Hydrogen Sulfide content (D5705)
• RVP (D6377 and D323)
• Viscosity (D445 and D2501)
• Water Content (D4928 and D4006)
• Sulfur content (D2622 and D4294)
• Density (D4928 and D1250)

The analyzers are applicable in the oil well, pipes, vessel, tanks, and at any other location in the crude oil supply chain from the oil well during transportation, storage, desalting, and blending until the crude distillation unit. On-line and rapid analysis allows real-time detection of unacceptable levels of quality parameters to take immediate corrective actions.

Contact us to learn more about MOD-4100 crude analyzer

Crude Oil Distillation

• On-line monitoring of the crude oil properties before, between, and after the desalters enables efficient operation of the desalter, at minimum cost of energy and process chemicals.
• On-line monitoring of the physical properties such as the SALT, H2S, and TAN of the crude oils entering the CDU is also of high importance for evaluating the potential of corrosion and fouling that affect the equipment and the pipelines.
• Indicates the transition period between two sequential crude oil feeds.
• Continuous verification of the entire batch complying with its specifications.

System Configuration

• The new MOD 4100 On-line Analytical System is a complete equipment set.
• MOD-4100 allows real-time analysis of critical crude oil properties under field conditions.
• Continuous crude oil sampling from pipelines, tanks, or process vessels, its filtration, and separation from solid particles.
• The analyzer is equipped with an integrated sampling handling and sample condition system, to bring the samples to the physical condition that is required by the analyzer.
• Integrated Analyzer control system.
• Transfer of analysis results to customer’s control room DCS.
• No analyzer shelter is required.
• The analyzer comes installed in an outdoor stainless steel enclosure.
  
  
  
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System Advantages

On-line monitoring of the crude oil qualities also plays a critical role in a variety of different crude oil process optimizations.

Crude Oil Blending:

• Optimization of the ratio between crude oil being blended to provide a blend of required physical properties.
• Reduction of blend cost by maximum incorporation of low-cost crudes in the blend
  

  Online Crude Oil Analysis for Refineries

  The MOD-4100 Crude Oil Analyser provides continuous online measurement of key crude oil properties directly during refinery operation. Real-time crude oil analysis helps operators understand feedstock quality changes faster than laboratory testing alone, supporting better control of crude unit operation, blending decisions and refinery performance.

  Online crude analysis is especially important when processing variable crude blends, opportunity crudes or during crude switching, where changes in feedstock quality can affect distillation behaviour, product yields, energy consumption and downstream unit stability.

  Crude Blending and CDU Optimization

  Crude oil blending has a direct impact on crude distillation unit performance, desalter operation, product quality and refinery margin. By providing continuous crude quality data, the MOD-4100 supports improved crude blending control and helps operators adjust CDU operation according to actual feedstock conditions.

  When integrated with refinery control and optimization systems, online crude oil analysis can support more stable operation, reduced product giveaway, better energy efficiency and improved response to crude quality variation.

  Real-Time Feedstock Quality Monitoring

  Crude oil quality can change during storage, transfer, blending and crude switching. Delayed laboratory results may not provide operators with sufficient time to respond to these changes. The MOD-4100 provides real-time feedstock quality monitoring, allowing refineries to detect crude property changes earlier and make faster operational decisions.

  Continuous monitoring helps improve process visibility, reduce operational uncertainty and support safer, more efficient refinery operation.

  Measured Crude Oil Properties

  The MOD-4100 can be configured to monitor multiple crude oil properties required for refinery operation and optimization. These may include density, API gravity, distillation-related properties, vapour pressure, water content, salt content, sulfur-related parameters and other crude quality indicators, depending on the specific application and configuration.

  By measuring several crude properties online, the analyser provides a more complete view of feedstock behaviour than a single measurement alone.

  Integration with DCS, APC and Modcon.AI

  The MOD-4100 can be integrated with DCS, PLC, SCADA, Advanced Process Control and refinery optimization platforms. Real-time crude oil data can be used by operators, control systems and advanced software tools to support better decision-making and process performance.

  When connected with Modcon.AI, MOD-4100 data can support CDU optimization, crude switch management, process health analysis and AI-enabled recommendations based on live refinery conditions and crude quality changes.