Providing a solid introduction to integrated refinery process modeling and optimization, this textbook adopts a practical approach, using many of the tools and techniques curr

Taal / Language : English

Inhoudsopgave:
Foreword by Steven R. Cope XI

Foreword by Lawrence B. Evans XIII

Preface XV

Acknowledgements XXI

About the Authors XXIII

1 Characterization, Physical and Thermodynamic Properties of Oil Fractions 1

1.1 Crude Assay 1

1.1.1 Bulk Properties 4

1.1.2 Fractional Properties 6

1.1.3 Interconversion of Distillation Curves 7

1.2 Pseudocomponent Generation Based on Boiling-Point Ranges 8

1.3 Workshop 1.1 – Interconvert Distillation Curves 13

1.4 Workshop 1.2 – Extrapolate an Incomplete Distillation Curve 15

1.5 Workshop 1.3 – Calculate MeABP of a Given Assay 18

1.6 Workshop 1.4 – Duplicate the Oil Fraction in Aspen HYSYS Petroleum Refining 21

1.7 Property Requirements for Refinery Process Models 30

1.8 Physical Properties 31

1.8.1 Estimating Minimal Physical Properties for Pseudocomponents 31

1.8.2 Molecular Weight 32

1.8.3 Critical Properties 34

1.8.4 Liquid Density 36

1.8.5 Ideal Gas Heat Capacity 38

1.8.6 Other Derived Physical Properties 39

1.9 Process Thermodynamics 42

1.9.1 Thermodynamic Models 43

1.9.2 Mixed or Activity-Coefficient Approach 44

1.9.3 Equation-of-State Approach 46

1.10 Miscellaneous Physical Properties for Refinery Modeling 48

1.10.1 Two Approaches for Estimating Fuel Properties 48

1.10.2 Flash Point 49

1.10.3 Freeze Point 50

1.10.4 PNA Composition 50

1.11 Conclusions 52

1.12 Nomenclature 53

1.13 References 55

2 Atmospheric Distillation Unit 57

2.1 Introduction 57

2.2 Scope of the Chapter 58

2.3 Process Overview 58

2.3.1 Desalting 59

2.3.2 Preheat Train and Heat Recovery 60

2.3.3 Atmospheric Distillation 61

2.4 Model Development 63

2.5 Feed Characterization 66

2.6 Data Requirements and Validation 67

2.7 Representative Atmospheric Distillation Unit 73

2.8 Building the Model in Aspen HYSYS 75

2.8.1 Entering the Crude Information 75

2.8.2 Selection of a Thermodynamic System 81

2.8.3 Crude Charge and Prefractionation Units 81

2.8.4 Atmospheric Distillation Column – Initial 84

2.8.5 Atmospheric Distillation Column – Side Strippers 86

2.8.6 Atmospheric Distillation Column – Pumparounds 88

2.8.7 Atmospheric Distillation Column – Final Column Convergence 89

2.8.8 Post-Convergence 91

2.9 Results 91

2.10 Model Applications to Process Optimization 95

2.10.1 Improve the 5% Distillation Point for an Individual Cut 96

2.10.2 Change Yield of a Given Cut 97

2.11 Workshop 2.1 –Rebuild Model Using “Back-blending” Procedure 98

2.11.1 Import Distillation Data into Aspen HYSYS Oil Manager 100

2.11.2 Import Distillation Data into Aspen HYSYS Oil Manager 102

2.11.3 Reorganize Process Flowsheet 104

2.11.4 Converging Column Model 106

2.11.5 Comparison of Results 109

2.12 Workshop 2.2 – Investigate Changes in Product Profiles with New Product Demands 111

2.12.1 Update Column Specifications 112

2.12.2 Vary Draw Rate of LGO 113

2.13 Conclusions 115

2.14 Nomenclature 116

2.15 References 116

3 Vacuum Distillation Unit 117

3.1 Process Description 117

3.2 Data Reconciliation 119

3.2.1 Required Data 119

3.2.2 Representation of the Atmospheric Residue 120

3.2.3 Makeup of Gas Streams 123

3.3 Model Implementation 124

3.3.1 Before Building the Process Flowsheet 124

3.3.2 Build a Simplified Model 128

3.3.3 Develop the Rigorous Simulation from a Simplified Model 132

3.4 Model Applications to Process Optimization – VDU Deep-Cut Operation 135

3.5 Workshop – Using Aspen HYSYS Petroleum Refining to Implement the Deep-Cut Operation 139

3.6 References 144

4 Predictive Modeling of the Fluid Catalytic Cracking (FCC) Process 145

4.1 Introduction 146

4.2 Process Description 147

4.2.1 Riser-Regenerator Complex 147

4.2.2 Downstream Fractionation 148

4.3 Process Chemistry 151

4.4 Literature Review 153

4.4.1 Kinetic Models 153

4.4.2 Unit-Level Models 158

4.5 Aspen HYSYS Petroleum Refining FCC Model 159

4.5.1 Slip Factor and Average Voidage 161

4.5.2 21-Lump Kinetic Model 162

4.5.3 Catalyst Deactivation 163

4.6 Calibrating the Aspen HYSYS Petroleum Refining FCC Model 164

4.7 Fractionation 165

4.8 Mapping Feed Information to Kinetic Lumps 168

4.8.1 Fitting Distillation Curves 168

4.8.2 Inferring Molecular Composition 170

4.8.3 Convert Kinetic Lumps to Fractionation Lumps 173

4.9 Overall Modeling Strategy 174

4.10 Results 176

4.11 Model Applications to Process Optimization 184

4.11.1 Improving Gasoline Yield 184

4.11.2 Increasing Unit Throughput 187

4.11.3 Sulfur Content in Gasoline 189

4.12 Model Application to Refinery Production Planning 190

4.13 Workshop 4.1: Guide for Modeling FCC Units in Aspen HYSYS Petroleum Refining 195

4.13.1 Introduction 195

4.13.2 Process Overview 196

4.13.3 Process Data 198

4.13.4 Aspen HYSYS and Initial Component and Thermodynamics Setup 200

4.13.5 Workshop 4.1: Basic FCC Model 204

4.13.6 FCC Feed Configuration 208

4.13.7 FCC Catalyst Configuration 211

4.13.8 FCC Operating Variable Configuration 214

4.13.9 Initial Model Solution 217

4.13.10 Viewing Model Results 219

4.14 Workshop 4.2: Calibrating Basic FCC Model 222

4.15 Workshop 4.3: Build Main Fractionator and Gas Plant System 230

4.16 Workshop 4.4: Model Applications to Process Optimization – Perform Case Study to Identify Different Gasoline Production Scenarios 233

4.17 Workshop 4.5: Model Application to Production Planning – Generate DELTA-BASE Vectors for Linear-Programming (LP)-Based Production Planning 240

4.18 Conclusions 247

4.20 Nomenclature 248

4.21 References 249

5 Predictive Modeling of the Continuous Catalyst Regeneration (CCR) Reforming Process 253

5.1 Introduction 254

5.2 Process Overview 255

5.3 Process Chemistry 260

5.4 Literature Review 263

5.4.1 Kinetic Models and Networks 263

5.4.2 Unit-Level models 267

5.5 Aspen HYSYS Petroleum Refining Catalytic Reformer Model 270

5.6 Thermophysical Properties 273

5.7 Fractionation System 274

5.8 Feed Characterization 276

5.9 Model Implementation 280

5.9.1 Data Consistency 280

5.9.2 Feed Characterization 282

5.9.3 Calibration 282

5.10 Overall Modeling Strategy 285

5.11 Results 287

5.12 Model Applications to Process Optimization 293

5.12.1 Effect of Reactor Temperature on Process Yield 293

5.12.2 Effect of Feed Rate on Process Yield 296

5.12.3 Combined Effects on Process Yield 298

5.12.4 Effect of Feedstock Quality on Process Yield 300

5.12.5 Chemical Feedstock Production 301

5.12.6 Energy Utilization and Process Performance 303

5.13 Model Applications to Refinery Production Planning 304

5.14 Workshop 5.1: Guide for Modeling CCR Units in Aspen HYSYS Petroleum Refining 309

5.14.1 Introduction 309

5.14.2 Process Overview and Relevant Data 309

5.14.3 Aspen HYSYS and Initial Component and Thermodynamics Setup 312

5.14.4 Basic Reformer Configuration 316

5.14.5 Input Feedstock and Process Variables 319

5.14.6 Solver Parameters and Running Initial Model 324

5.14.7 Viewing Model Results 326

5.14.8 Updating Results with Molecular Composition Information 329

5.15 Workshop 5.2: Model Calibration 332

5.16 Workshop 5.3: Build a Downstream Fractionation 344

5.17 Workshop 5.4: Case Study to Vary RON and Product Distribution Profile 351

5.18 Conclusions 358

5.19 Nomenclature 358

5.20 References 360

6 Predictive Modeling of the Hydroprocessing Units 363

6.1 Introduction 364

6.2 Aspen HYSYS Petroleum Refining HCR Modeling Tool 369

6.3 Process Description 376

6.3.1 MP HCR Process 376

6.3.2 HP HCR Process 377

6.4 Model Development 378

6.4.1 Workflow of Developing an Integrated HCR Process Model 378

6.4.2 Data Acquisition 379

6.4.3 Mass Balance 381

6.4.4 Reactor Model Development 382

6.4.4.1 MP HCR Reactor Model 383

6.4.4.2 HP HCR Reactor Model 388

6.4.4.2.1 Equivalent Reactor 388

6.4.4.2.2 Reconciliation of HP HCR Reactor Model 390

6.4.5 Delumping of the Reactor Model Effluent and Fractionator Model Development 393

6.4.5.1 Applying the Gauss–Legendre Quadrature to Delump the Reactor Model Effluent 396

6.4.5.2 Key Issue of the Building Fractionator Model: Overall Stage Efficiency Model 398

6.4.5.3 Verification of the Delumping Method: Gaussian–Legendre Quadrature 399

6.4.6 Product Property Correlation 402

6.5 Modeling Results of MP HCR Process 403

6.5.1 Performance of the Reactor and Hydrogen Recycle System 403

6.5.2 Performance of Fractionators 405

6.5.3 Product Yields 407

6.5.4 Distillation Curves of Liquid Products 409

6.5.5 Product Property 412

6.6 Modeling Results of HP HCR Process 415

6.6.1 Performance of the Reactor and Hydrogen Recycle System 415

6.6.2 Performance of Fractionators 417

6.6.3 Product Yields 419

6.6.4 LPG Composition and Distillation Curves of Liquid Products 421

6.6.5 Product Property 422

6.7 Model Applications to Process Optimization 425

6.7.1 H2-to-Oil Ratio vs. Product Distribution, Remained Catalyst Life, and Hydrogen Consumption 425

6.7.2 WART versus Feed Flow Rate versus Product Distribution 427

6.8 Model Application – Delta-Base Vector Generation 429

6.9 Conclusions 432

6.10 Workshop 6.1 – Build Preliminary Reactor Model of HCR Process 433

6.11 Workshop 6.2 – Calibrate Preliminary Reactor Model to Match Plant Data 440

6.12 Workshop 6.3 – Model Applications to Process Optimization 456

6.13 Workshop 6.4 – Connect Reactor Model to Fractionator Simulation 465

6.14 Nomenclature 475

6.15 References 477

Supporting Materials: List of Computer Files 479

Subject Index 483

Extra informatie: Ingenaaid: paperback,kaft slap, 522 pagina's Verschenen: april 2012 Gewicht: 1020 gram Formaat: 238 x 170 x 25 mm Wiley VCH

Chang, Ai-Fu, Refinery Engineering Prijs van Euro 110.95 voor Euro 99.86   In Winkelwagentje

Levertijd: 5 tot 7 werkdagen

vergroot omslag