Petroleum Refinery Process Modeling

A comprehensive review of the theory and practice of the simulation and optimization of the petroleum refining processes Petroleum Refinery Process Modeling offers a thorough review of how to quantitatively model key refinery reaction and fractionation processes. The text introduces the basics of dealing with the thermodynamics and physical property predictions of hydrocarbon components in the context of process modeling. The authors - three experts on the topic - outline the procedures and include the key data required for building reaction and fractionation models with commercial software. The text shows how to filter through the extensive data available at the refinery and using plant data to begin calibrating available models and extend the models to include key fractionation sub-models. It provides a sound and informed basis to understand and exploit plant phenomena to improve yield, consistency, and performance. In addition, the authors offer information on applying models in an overall refinery context through refinery planning based on linear programming. This important resource: -Offers the basic information of thermodynamics and physical property predictions of hydrocarbon components in the context of process modeling -Uses the key concepts of fractionation lumps and physical properties to develop detailed models and workflows for atmospheric (CDU) and vacuum (VDU) distillation units -Discusses modeling FCC, catalytic reforming and hydroprocessing units Written for chemical engineers, process engineers, and engineers for measurement and control, this resource explores the advanced simulation tools and techniques that are available to support experienced and aid new operators and engineers.

Autorentext
Y.A. Liu, the Alumni Distinguised Professor and the Frank C. Vilbrandt Endowed Professor of Chemical Engineering at Virginia Tech, received his B.S. (1967), M.S. (1970), and Ph.D. (1974) degrees from National Taiwan University, Tufts University and Princeton University, respectively. Professor Liu devoted his school breaks helping petrochemical industries in developing countries and chemical industries in Virginia with technology development and engineering training. He has taught intensive training courses on computer-aided design, advanced process control, energy and water savings, and refinery and polymerization process modeling to over 7,000 practicing engineers in China, Taiwan and United States.

Ai-Fu Chang received his Ph.D. in the Department of Chemical Engineering at Virginia Polytechnic Institute and State University (Virginia Tech) in September, 2011. He received his B.S. in chemical engineering from National Taiwan University in 2001. He completed his doctoral dissertation on integrated process modeling and product design of biodiesel manufacturing, and refinery reaction and fraction systems. The latter was the basis of this textbook. He has worked on several industrial modeling projects, including poly (acrylonitrile-vinyl acetate), hydrocracking, and biodiesel. These projects were collaborative efforts between Virginia Tech, Aspen Technology, and industrial manufacturers. He is currently employed by Chevron Phillips Chemical Company.

Kiran Pashikanti was a PhD student in the Department of Chemical Engineering at Virginia Tech. He received his B.S. in chemical engineering from Virginia Commonwealth University in 2005, and his Ph.D. in chemical engineering from Virginia Tech in September, 2011. He has worked on several industrial modeling projects on integrated modeling of refinery reaction and fraction systems, and of carbon-dioxide capture processes. This textbook grows out of his doctoral dissertation on the predictive modeling of fluid catalytic cracking (FCC) and catalytic reforming processes. He is currently employed by Chevron Phillips Chemical Company.

Inhalt

About the Authors xiii

Foreword by Lawrence B. Evans xv

Foreword by Steven R. Cope xvii

Preface xix

Acknowledgments xxiii

Scope of Textbook xxv

Software Selection and Copyright Notice xxvii

1 Characterization and Physical and Thermodynamic Properties of Oil Fractions 1

1.1 Crude Assay 1

1.1.1 Bulk Properties 2

1.1.2 Fractional Properties 6

1.1.3 Interconversion of Distillation Curves 7

1.2 Boiling Point-Based Hypothetical or Pseudocomponent Generation 8

1.3 Workshop 1.1 Interconvert Distillation Curves 13

1.4 Workshop 1.2 Extrapolate an Incomplete Distillation Curve 13

1.5 Workshop 1.3 Calculate MeABP of a Given Assay 13

1.6 Workshop 1.4 Represent an Oil Fraction by the Old Oil Manager in Aspen HYSYS Petroleum Refining 16

1.7 Workshop 1.5 Represent an Oil Fraction by the New Petroleum Assay Manager in Aspen HYSYS Petroleum Refining 25

1.8 Workshop 1.6 Conversion from the Oil Manager to Petroleum Assay Manager and Improvements of the Petroleum Assay Manager over the Oil Manager 32

1.9 Property Requirements for Refinery Process Models 33

1.10 Physical Properties 36

1.10.1 Estimating Minimal Physical Properties for Pseudocomponents 36

1.10.2 MolecularWeight 37

1.10.3 Critical Properties 38

1.10.4 Liquid Density 40

1.10.5 Ideal Gas Heat Capacity 42

1.10.6 Other Derived Physical Properties 43

1.11 ProcessThermodynamics 45

1.11.1 Process Thermodynamics 47

1.11.2 Mixed or Activity Coefficient-Based Approach 47

1.11.3 Equation-of-State Approach 49

1.12 Miscellaneous Physical Properties for RefineryModeling 50

1.12.1 Two Approaches for Estimating Fuel Properties 51

1.12.2 Flash Point 52

1.12.3 Freeze Point 52

1.12.4 PNA Composition 53

1.13 Conclusion 54

Nomenclature 55

Bibliography 56

2 Atmospheric or Crude Distillation Unit (CDU) 59

2.1 Introduction 59

2.2 Scope of the Chapter 60

2.3 Process Overview 60

2.3.1 Desalting 61

2.3.2 Preheat Train and Heat Recovery 62

2.3.3 Atmospheric Distillation 62

2.4 Model Development 65

2.4.1 MESH Equations 66

2.4.2 Overall Column Efficiency and Murphree Stage Efficiency 66

2.4.3 Recommendation for Correctly Handling the Efficiency 68

2.4.4 Inside-Out Algorithm for Distillation Column Calculation Convergence 69

2.5 Feed Characterization 72

2.6 Data Requirements and Validation 73

2.7 A Representative Atmospheric Distillation Unit 76

2.8 Building the Model in Aspen HYSYS Petroleum Refining 77

2.8.1 Entering the Crude Information 78

2.8.2 Selection of aThermodynamic Model 84

2.8.3 Crude Charge and Prefractionation Units 87

2.8.4 Atmospheric Distillation Column Initial 88

2.8.5 Atmospheric Distillation Column Side Strippers 95

2.8.6 Atmospheric Distillation Column Pumparounds 98

2.8.7 Atmospheric Distillation Column Adding Custom Stream Properties 101

2.8.8 Post-Convergence 104

2.9 Results 105

2.10 Model Applications to Process Optimization 109

2.10.1 Improve the 5% Distillation Point for an Individual Cut 109

2.10.2 Change Yield of a Given Cut 109

2.10.3 Workshop 2.1 Perform Case Studies to Quantify the Effects of Stripping Steam Rate and Product Draw Rate 111

2.11 Workshop 2.2 Rebuild Model Using Backblending Procedure 114

2.11.1 Import Distillation Data into Aspen HYSYS Oil Manager 115

2.11.2 Define a New Blend of the Backblended Crude Feed 116

2.11.3 Build the CDU Model Based on the Backblended Feed 120

2.11.4 Converging Column Model 120

2.11.5 Comparison of Results 123

2.12 Workshop 2.3 Investigate Changes in Product Profiles with New Product Demands 126

2.12.1 Update Column Specifications 126 &lt...