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Refinery Engineering Integrated Process Modeling and Optimization

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

Refinery Engineering Integrated Process Modeling and Optimization

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

ISBN 13:
9783527333578
ISBN 10:
3527333576
Edition: 1st
Format: Paperback
Copyright: 05/21/2012
Publisher: Wiley-VCH

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Summary

The book provides a very solid introduction to integrated refinery process modeling and optimization, using many of the tools and techniques currently employed in modern refineries. In this very competitive global industry, it is critical to minimize overall operating costs while achieving the maximum possible upgrade for each hydrocarbon molecule. This is commonly referred to as "molecule management". All of these decisions and options require complex computer modeling to aid in the selection of feedstocks and product slates, and in troubleshooting and optimizing the performance of individual refinery processes such as distillation units, fluidized catalytic cracking units, continuous catalyst regeneration reforming units, and hydrocracking and hydrotreating units. And eventually, all of these individual parts have to be pulled together in order to feed a linear program (LP) model capable of optimizing the overall refinery. This complex modeling is the subject of the present book by Ai-Fu Chang, Kiran Pashikanti and Y. A. Liu. This text guides senior-level undergraduates, graduate students, and industrial practitioners how to quantitatively model key refinery reaction and fractionation processes.

Foreword	p. XI
Foreword	p. XIII
Preface	p. XV
Acknowledgements	p. XXI
About the Authors	p. XXIII
Characterization, Physical and Thermodynamic Properties of Oil Fractions	p. 1
Crude Assay	p. 1
Bulk Properties	p. 4
Fractional Properties	p. 6
Interconversion of Distillation Curves	p. 7
Pseudocomponent Generation Based on Boiling-Point Ranges	p. 8
Workshop 1.1 - Interconvert Distillation Curves	p. 13
Workshop 1.2 - Extrapolate an Incomplete Distillation Curve	p. 15
Workshop 1.3 - Calculate MeABP of a Given Assay	p. 18
Workshop 1.4 - Duplicate the Oil Fraction in Aspen HYSYS Petroleum Refining	p. 21
Property Requirements for Refinery Process Models	p. 30
Physical Properties	p. 31
Estimating Minimal Physical Properties for Pseudocomponents	p. 31
Molecular Weight	p. 32
Critical Properties	p. 34
Liquid Density	p. 36
Ideal Gas Heat Capacity	p. 38
Other Derived Physical Properties	p. 39
Process Thermodynamics	p. 42
Thermodynamic Models	p. 43
Mixed or Activity-Coefficient Approach	p. 44
Equation-of-State Approach	p. 46
Miscellaneous Physical Properties for Refinery Modeling	p. 48
Two Approaches for Estimating Fuel Properties	p. 48
Flash Point	p. 49
Freeze Point	p. 50
PNA Composition	p. 50
Conclusions	p. 52
Nomenclature	p. 53
References	p. 55
Atmospheric Distillation Unit	p. 57
Introduction	p. 57
Scope of the Chapter	p. 58
Process Overview	p. 58
Desalting	p. 59
Preheat Train and Heat Recovery	p. 60
Atmospheric Distillation	p. 61
Model Development	p. 63
Feed Characterization	p. 66
Data Requirements and Validation	p. 67
Representative Atmospheric Distillation Unit	p. 73
Building the Model in Aspen HYSYS	p. 75
Entering the Crude Information	p. 75
Selection of a Thermodynamic System	p. 81
Crude Charge and Prefractionation Units	p. 81
Atmospheric Distillation Column - Initial	p. 84
Atmospheric Distillation Column - Side Strippers	p. 86
Atmospheric Distillation Column - Pumparounds	p. 88
Atmospheric Distillation Column - Final Column Convergence	p. 89
Post-Convergence	p. 91
Results	p. 91
Model Applications to Process Optimization	p. 95
Improve the 5% Distillation Point for an Individual Cut	p. 96
Change Yield of a Given Cut	p. 97
Workshop 2.1 - Rebuild Model Using "Back-blending" Procedure	p. 98
Import Distillation Data into Aspen HYSYS Oil Manager	p. 100
Import Distillation Data into Aspen HYSYS Oil Manager	p. 102
Reorganize Process Flowsheet	p. 104
Converging Column Model	p. 106
Comparison of Results	p. 109
Workshop 2.2 - Investigate Changes in Product Profiles with New Product Demands	p. 111
Update Column Specifications	p. 112
Vary Draw Rate of LGO	p. 113
Conclusions	p. 115
Nomenclature	p. 116
References	p. 116
Vacuum Distillation Unit	p. 117
Process Description	p. 117
Data Reconciliation	p. 119
Required Data	p. 119
Representation of the Atmospheric Residue	p. 120
Makeup of Gas Streams	p. 123
Model Implementation	p. 124
Before Building the Process Flowsheet	p. 124
Build a Simplified Model	p. 128
Develop the Rigorous Simulation from a Simplified Model	p. 132
Model Applications to Process Optimization - VDU Deep-Cut Operation	p. 135
Workshop - Using Aspen HYSYS Petroleum Refining to Implement the Deep-Cut Operation	p. 139
References	p. 144
Predictive Modeling of the Fluid Catalytic Cracking (FCC) Process	p. 145
Introduction	p. 146
Process Description	p. 147
Riser-Regenerator Complex	p. 147
Downstream Fractionation	p. 148
Process Chemistry	p. 151
Literature Review	p. 153
Kinetic Models	p. 153
Unit-Level Models	p. 158
Aspen HYSYS Petroleum Refining FCC Model	p. 159
Slip Factor and Average Voidage	p. 161
21-Lump Kinetic Model	p. 162
Catalyst Deactivation	p. 163
Calibrating the Aspen HYSYS Petroleum Refining FCC Model	p. 164
Fractionation	p. 165
Mapping Feed Information to Kinetic Lumps	p. 168
Fitting Distillation Curves	p. 168
Inferring Molecular Composition	p. 170
Convert Kinetic Lumps to Fractionation Lumps	p. 173
Overall Modeling Strategy	p. 174
Results	p. 176
Model Applications to Process Optimization	p. 184
Improving Gasoline Yield	p. 184
Increasing Unit Throughput	p. 187
Sulfur Content in Gasoline	p. 189
Model Application to Refinery Production Planning	p. 190
Workshop 4.1: Guide for Modeling FCC Units in Aspen HYSYS Petroleum Refining	p. 195
Introduction	p. 195
Process Overview	p. 196
Process Data	p. 198
Aspen HYSYS and Initial Component and Thermodynamics Setup	p. 200
Workshop 4.1: Basic FCC Model	p. 204
FCC Feed Configuration	p. 208
FCC Catalyst Configuration	p. 211
FCC Operating Variable Configuration	p. 214
Initial Model Solution	p. 217
Viewing Model Results	p. 219
Workshop 4.2: Calibrating Basic FCC Model	p. 222
Workshop 4.3: Build Main Fractionator and Gas Plant System	p. 230
Workshop 4.4: Model Applications to Process Optimization - Perform Case Study to Identify Different Gasoline Production Scenarios	p. 233
Workshop 4.5: Model Application to Production Planning - Generate Delta-Base Vectors for Linear-Programming (LP)-Based Production Planning	p. 240
Conclusions	p. 247
Nomenclature	p. 248
References	p. 249
Predictive Modeling of the Continuous Catalyst Regeneration (CCR) Reforming Process	p. 253
Introduction	p. 254
Process Overview	p. 255
Process Chemistry	p. 260
Literature Review	p. 263
Kinetic Models and Networks	p. 263
Unit-Level Models	p. 267
Aspen HYSYS Petroleum Refining Catalytic Reformer Model	p. 270
Thermophysical Properties	p. 273
Fractionation System	p. 274
Feed Characterization	p. 276
Model Implementation	p. 280
Data Consistency	p. 280
Feed Characterization	p. 282
Calibration	p. 282
Overall Modeling Strategy	p. 285
Results	p. 287
Model Applications to Process Optimization	p. 293
Effect of Reactor Temperature on Process Yield	p. 293
Effect of Feed Rate on Process Yield	p. 296
Combined Effects on Process Yield	p. 298
Effect of Feedstock Quality on Process Yield	p. 300
Chemical Feedstock Production	p. 301
Energy Utilization and Process Performance	p. 303
Model Applications to Refinery Production Planning	p. 304
Workshop 5.1: Guide for Modeling CCR Units in Aspen HYSYS Petroleum Refining	p. 309
Introduction	p. 309
Process Overview and Relevant Data	p. 309
Aspen HYSYS and Initial Component and Thermodynamics Setup	p. 312
Basic Reformer Configuration	p. 316
Input Feedstock and Process Variables	p. 319
Solver Parameters and Running Initial Model	p. 324
Viewing Model Results	p. 326
Updating Results with Molecular Composition Information	p. 329
Workshop 5.2: Model Calibration	p. 332
Workshop 5.3: Build a Downstream Fractionation	p. 344
Workshop 5.4: Case Study to Vary RON and Product Distribution Profile	p. 351
Conclusions	p. 358
Nomenclature	p. 358
References	p. 360
Predictive Modeling of the Hydroprocessing Units	p. 363
Introduction	p. 364
Aspen HYSYS Petroleum Refining HCR Modeling Tool	p. 369
Process Description	p. 376
MP HCR Process	p. 376
HP HCR Process	p. 377
Model Development	p. 378
Workflow of Developing an Integrated HCR Process Model	p. 378
Data Acquisition	p. 379
Mass Balance	p. 381
Reactor Model Development	p. 382
MP HCR Reactor Model	p. 383
HP HCR Reactor Model	p. 388
Equivalent Reactor	p. 388
Reconciliation of HP HCR Reactor Model	p. 390
Delumping of the Reactor Model Effluent and Fractionator Model Development	p. 393
Applying the Gauss-Legendre Quadrature to Delump the Reactor Model Effluent	p. 396
Key Issue of the Building Fractionator Model: Overall Stage Efficiency Model	p. 398
Verification of the Delumping Method: Gaussian-Legendre Quadrature	p. 399
Product Property Correlation	p. 402
Modeling Results of MP HCR Process	p. 403
Performance of the Reactor and Hydrogen Recycle System	p. 403
Performance of Fractionators	p. 405
Product Yields	p. 407
Distillation Curves of Liquid Products	p. 409
Product Property	p. 412
Modeling Results of HP HCR Process	p. 415
Performance of the Reactor and Hydrogen Recycle System	p. 415
Performance of Fractionators	p. 417
Product Yields	p. 419
LPG Composition and Distillation Curves of Liquid Products	p. 421
Product Property	p. 422
Model Applications to Process Optimization	p. 425
H₂-to-Oil Ratio vs. Product Distribution, Remained Catalyst Life, and Hydrogen Consumption	p. 425
WART versus Feed Flow Rate versus Product Distribution	p. 427
Model Application - Delta-Base Vector Generation	p. 429
Conclusions	p. 432
Workshop 6.1 - Build Preliminary Reactor Model of HCR Process	p. 433
Workshop 6.2 - Calibrate Preliminary Reactor Model to Match Plant Data	p. 440
Workshop 6.3 - Model Applications to Process Optimization	p. 456
Workshop 6.4 - Connect Reactor Model to Fractionator Simulation	p. 465
Nomenclature	p. 475
References	p. 477
Supporting Materials: List of Computer Files	p. 479
Subject Index	p. 483
Table of Contents provided by Ingram. All Rights Reserved.

Amazon no longer offers textbook rentals. We do!

Refinery Engineering Integrated Process Modeling and Optimization

Refinery Engineering Integrated Process Modeling and Optimization

9783527333578

3527333576

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Table of Contents

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