Petroleum Refinery Process Modeling: Integrated Optimization Tools and Applications

594 Pages·2018·55.12 MB·English

by  Y. A. Liu, Ai-Fu Chang, Kiran Pashikanti

PetroleumRefineryProcessModeling
Petroleum Refinery Process Modeling
IntegratedOptimizationToolsandApplications
Y.A.Liu,Ai-FuChang,andKiranPashikanti
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v
Contents
AbouttheAuthors xiii
ForewordbyLawrenceB.Evans xv
ForewordbyStevenR.Cope xvii
Preface xix
Acknowledgments xxiii
ScopeofTextbook xxv
SoftwareSelectionandCopyrightNotice xxvii
1 CharacterizationandPhysicalandThermodynamicProperties
ofOilFractions 1
1.1 CrudeAssay 1
1.1.1 BulkProperties 2
1.1.2 FractionalProperties 6
1.1.3 InterconversionofDistillationCurves 7
1.2 BoilingPoint-BasedHypotheticalorPseudocomponent
Generation 8
1.3 Workshop1.1–InterconvertDistillationCurves 13
1.4 Workshop1.2–ExtrapolateanIncompleteDistillationCurve 13
1.5 Workshop1.3–CalculateMeABPofaGivenAssay 13
1.6 Workshop1.4–RepresentanOilFractionbytheOldOilManagerin
AspenHYSYSPetroleumRefining 16
1.7 Workshop1.5–RepresentanOilFractionbytheNewPetroleum
AssayManagerinAspenHYSYSPetroleumRefining 25
1.8 Workshop1.6–ConversionfromtheOilManagertoPetroleumAssay
ManagerandImprovementsofthePetroleumAssayManageroverthe
OilManager 32
1.9 PropertyRequirementsforRefineryProcessModels 33
1.10 PhysicalProperties 36
1.10.1 EstimatingMinimalPhysicalPropertiesforPseudocomponents 36
1.10.2 MolecularWeight 37
1.10.3 CriticalProperties 38
1.10.4 LiquidDensity 40
1.10.5 IdealGasHeatCapacity 42
1.10.6 OtherDerivedPhysicalProperties 43
vi Contents
1.11 ProcessThermodynamics 45
1.11.1 ProcessThermodynamics 47
1.11.2 MixedorActivityCoefficient-BasedApproach 47
1.11.3 Equation-of-StateApproach 49
1.12 MiscellaneousPhysicalPropertiesforRefineryModeling 50
1.12.1 TwoApproachesforEstimatingFuelProperties 51
1.12.2 FlashPoint 52
1.12.3 FreezePoint 52
1.12.4 PNAComposition 53
1.13 Conclusion 54
Nomenclature 55
Bibliography 56
2 AtmosphericorCrudeDistillationUnit(CDU) 59
2.1 Introduction 59
2.2 ScopeoftheChapter 60
2.3 ProcessOverview 60
2.3.1 Desalting 61
2.3.2 PreheatTrainandHeatRecovery 62
2.3.3 AtmosphericDistillation 62
2.4 ModelDevelopment 65
2.4.1 MESHEquations 66
2.4.2 OverallColumnEfficiencyandMurphreeStageEfficiency 66
2.4.3 RecommendationforCorrectlyHandlingtheEfficiency 68
2.4.4 Inside-OutAlgorithmforDistillationColumnCalculation
Convergence 69
2.5 FeedCharacterization 72
2.6 DataRequirementsandValidation 73
2.7 ARepresentativeAtmosphericDistillationUnit 76
2.8 BuildingtheModelinAspenHYSYSPetroleumRefining 77
2.8.1 EnteringtheCrudeInformation 78
2.8.2 SelectionofaThermodynamicModel 84
2.8.3 CrudeChargeandPrefractionationUnits 87
2.8.4 AtmosphericDistillationColumn–Initial 88
2.8.5 AtmosphericDistillationColumn–SideStrippers 95
2.8.6 AtmosphericDistillationColumn–Pumparounds 98
2.8.7 AtmosphericDistillationColumn–AddingCustomStream
Properties 101
2.8.8 Post-Convergence 104
2.9 Results 105
2.10 ModelApplicationstoProcessOptimization 109
2.10.1 Improvethe5%DistillationPointforanIndividualCut 109
2.10.2 ChangeYieldofaGivenCut 109
2.10.3 Workshop2.1–PerformCaseStudiestoQuantifytheEffectsof
StrippingSteamRateandProductDrawRate 111
2.11 Workshop2.2–RebuildModelUsing“Backblending”Procedure 114
2.11.1 ImportDistillationDataintoAspenHYSYSOilManager 115
Contents vii
2.11.2 DefineaNewBlendoftheBackblendedCrudeFeed 116
2.11.3 BuildtheCDUModelBasedontheBackblendedFeed 120
2.11.4 ConvergingColumnModel 120
2.11.5 ComparisonofResults 123
2.12 Workshop2.3–InvestigateChangesinProductProfileswithNew
ProductDemands 126
2.12.1 UpdateColumnSpecifications 126
2.12.2 VaryDrawRateofLGO 127
2.13 Workshop2.4–InvestigatetheEffectsofProcessVariablesonProduct
Qualities 129
2.14 Workshop2.5–ApplicationofColumnInternalTools(Column
HydraulicAnalysis) 131
2.15 Workshop2.6–ApplicationofthePetroleumDistillation
Column 140
2.16 Conclusions 144
Nomenclature 145
Bibliography 145
3 VacuumDistillationUnit 147
3.1 ProcessDescription 147
3.2 PlantDataReconciliation 149
3.2.1 RequiredData 149
3.2.2 RepresentationoftheAtmosphericResidue 149
3.2.3 MakeupofGasStreams 152
3.3 ModelImplementation 154
3.3.1 PlantDataandModelingApproaches 155
3.3.2 Workshop3.1–BuildtheSimplifiedVDUModel 157
3.3.3 Workshop3.2–BuildtheRigorousModelfromaSimplified
Model 165
3.4 ModelApplication–VDUDeep-CutOperation 172
3.5 Workshop3.3–SimulationoftheVDUDeep-CutOperation 176
Bibliography 180
4 PredictiveModelingoftheFluidCatalyticCracking(FCC)
Process 183
4.1 Introduction 184
4.2 ProcessDescription 185
4.2.1 Riser–RegeneratorComplex 185
4.2.2 DownstreamFractionation 187
4.3 ProcessChemistry 188
4.4 LiteratureReview 190
4.4.1 KineticModels 190
4.4.2 Unit-LevelModels 193
4.5 AspenHYSYSPetroleumRefiningFCCModel 195
4.5.1 SlipFactorandAverageVoidage 196
4.5.2 21-LumpKineticModel 197
4.5.3 CatalystDeactivation 198
viii Contents
4.6 CalibratingtheAspenHYSYSPetroleumRefiningFCCModel 199
4.7 Fractionation 200
4.8 MappingFeedInformationtoKineticLumps 203
4.8.1 FittingDistillationCurves 203
4.8.2 InferringMolecularComposition 205
4.8.3 ConvertKineticLumpstoFractionationLumps 208
4.9 OverallModelingStrategy 209
4.10 Results 211
4.11 Applications 220
4.11.1 ImprovingGasolineYield 220
4.11.2 IncreasingUnitThroughput 223
4.11.3 SulfurContentinGasoline 224
4.12 RefineryPlanning 225
4.13 Workshop4.1–GuideforModelingFCCUnitsinAspenHYSYS
PetroleumRefining 231
4.13.1 Introduction 231
4.13.2 ProcessOverview 231
4.13.3 ProcessData 231
4.13.4 AspenHYSYSandInitialComponentandThermodynamics
Setup 231
4.13.5 BasicFCCModel 238
4.13.6 FCCFeedConfiguration 241
4.13.7 FCCCatalystConfiguration 246
4.13.8 FCCOperatingVariableConfiguration 250
4.13.9 InitialModelSolution 252
4.13.10 ViewingModelResults 253
4.14 Workshop4.2–CalibratingBasicFCCModel 258
4.15 Workshop4.3–BuildtheModelforMainFractionatorandGasPlant
System 267
4.15.1 T201_MainFractionator 267
4.15.2 OverheadWetGasSystem,PrimaryStripperColumnT302_Stripper,
andDebutanizerorGasolineStabilizationColumn
T304_Stabilizer 275
4.15.3 T301_Absorber,PrimaryAbsorberandT303_ReAbsorber,SpongeOil
Absorber,orReabsorptionColumn 281
4.16 Workshop4.4–PerformCaseStudiestoQuantifyEffectsofKeyFCC
OperatingVariables 285
4.17 Workshop4.5–GenerateDelta-BaseVectorsforLinearProgramming
(LP)-BasedPlanning 291
4.18 Conclusions 297
Nomenclature 298
Bibliography 299
5 PredictiveModelingofContinuousCatalystRegeneration
(CCR)ReformingProcess 303
5.1 Introduction 304
5.2 ProcessOverview 304
Contents ix
5.3 ProcessChemistry 311
5.4 LiteratureReview 313
5.4.1 KineticModelsandNetworks 314
5.4.2 Unit-LevelModels 317
5.5 AspenHYSYSPetroleumRefiningCatalyticReformerModel 319
5.6 ThermophysicalProperties 323
5.7 FractionationSystem 323
5.8 FeedCharacterization 324
5.9 ModelImplementation 328
5.9.1 DataConsistency 329
5.9.2 FeedCharacterization 330
5.9.3 Calibration 330
5.10 OverallModelingStrategy 333
5.11 Results 335
5.12 Applications 340
5.12.1 EffectofReactorTemperatureonProcessYields 341
5.12.2 EffectofFeedRateonProcessYields 344
5.12.3 CombinedEffectsonProcessYields 345
5.12.4 EffectofFeedstockQualityonProcessYields 346
5.12.5 ChemicalFeedstockProduction 347
5.12.6 EnergyUtilizationandProcessPerformance 349
5.13 RefineryProductionPlanning 350
5.14 Workshop5.1–GuideforModelingCCRUnitsinAspenHYSYS
PetroleumRefining 354
5.14.1 Introduction 354
5.14.2 ProcessOverviewandRelevantData 354
5.14.3 AspenHYSYSandInitialComponentandThermodynamic
Setup 356
5.14.4 BasicReformerConfiguration 358
5.14.5 InputFeedstockandProcessVariables 362
5.14.6 SolverParametersandRunningtheInitialModel 368
5.14.7 ViewingModelResults 370
5.14.8 UpdatingResultswithMolecularCompositionInformation 372
5.15 Workshop5.2.–ModelCalibration 376
5.16 Workshop5.3–BuildaDownstreamFractionationSystem 387
5.17 Workshop5.4.–CaseStudytoVaryRONandProductDistribution
Profile 395
5.18 Conclusion 400
Nomenclature 400
Bibliography 402
6 PredictiveModelingoftheHydroprocessingUnits 405
6.1 Introduction 406
6.2 AspenHYSYSPetroleumRefiningHCRModelingTool 411
6.3 ProcessDescription 416
6.3.1 MPHCRProcess 416
6.3.2 HPHCRProcess 419
x Contents
6.4 ModelDevelopment 419
6.4.1 WorkflowofDevelopinganIntegratedHCRProcessModel 419
6.4.2 DataAcquisition 421
6.4.3 MassBalance 421
6.4.4 ReactorModelDevelopment 424
6.4.4.1 MPHCRReactorModel 424
6.4.4.2 HPHCRReactorModel 430
6.4.5 DelumpingoftheReactorModelEffluentandFractionatorModel
Development 435
6.4.5.1 ApplyingtheGauss–LegendreQuadraturetoDelumptheReactor
ModelEffluent 438
6.4.5.2 KeyIssueoftheBuildingFractionatorModel–OverallStage
EfficiencyModel 440
6.4.5.3 VerificationoftheDelumpingMethod–Gaussian–Legendre
Quadrature 440
6.4.6 ProductPropertyCorrelation 442
6.5 ModelingResultsofMPHCRProcess 444
6.5.1 PerformanceoftheReactorandHydrogenRecycleSystem 444
6.5.2 PerformanceofFractionators 445
6.5.3 ProductYields 447
6.5.4 DistillationCurvesofLiquidProducts 449
6.5.5 ProductProperty 451
6.6 ModelingResultsofHPHCRProcess 454
6.6.1 PerformanceoftheReactorandHydrogenRecycleSystem 454
6.6.2 PerformanceofFractionators 455
6.6.3 ProductYields 455
6.6.4 LPGCompositionandDistillationCurvesofLiquidProducts 459
6.6.5 ProductProperty 462
6.7 ModelApplications 464
6.7.1 H -to-OilRatioversusProductDistribution,RemainedCatalystLife,
2
andHydrogenConsumption 464
6.7.2 WARTVersusFeedFlowRateVersusProductDistribution 466
6.8 ModelApplication–Delta-BaseVectorGeneration 468
6.9 Workshop6.1–BuildaPreliminaryReactorModelofHCR
Process 471
6.10 Workshop6.2–CalibratePreliminaryReactorModeltoMatchPlant
Data 481
6.11 Workshop6.3–CaseStudies 497
6.12 Workshop6.4–FractionationSystemforHCRReactor 505
6.13 Conclusion 512
Nomenclature 513
Bibliography 514
7 Alkylation,DelayedCoking,andRefinery-Wide
Simulation 517
7.1 Alkylation 517
7.1.1 ProcessDescription 517