Rent 9783527333578 | Refinery Engineering : Integrated Process Modelingand and Optimization | Chang, Ai-fu; Pashikanti, Kiran; Liu, Y.a. @knetbooks.com

Summary Table of Contents Author Biography

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 troublesho... MOREoting 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.

A solid, practical introduction to integrated refinery process modeling and optimization, using many of the tools and techniques currently employed in modern refineries. Additional material, including spreadsheets and simulation files for models and examples, availbable online.

A pioneering and comprehensive guide to predictive modeling of integrated refinery reaction and fractionation systems for process optimization and production planning. See the excellent reviews and strong endorsements by top industrial practitioner and academic expert in petroleum refining and process optimization: "This book by Professor Liu and his colleagues represents a major advance in enabling engineers who are not experts to develop and use state-of-the-art computer models for the simulation and optimization of integrated refinery reaction and fractionation processes. One of the strengths of the book is that it doesn't stop with theory, or even case study examples and hands-on workshops. It covers very practical problems: how to work with real data, how to construct the right level of detail for the problem and the data available, and how to tune the model to actual plant data. Individuals who want to contribute to the development of refinery process modeling or explore new directions will find the extensive review of existing work valuable. This book will also be valuable to industrial practitioners and to academic chemical engineers by exposing them to refinery process modeling and optimization and enabling them to solve realistic problems. The book takes this work from a technology used mostly by experts to a tool that refinery engineers can use in their everyday work." - Lawrence B. Evans, Professor Emeritus of Chemical Engineering, MIT; Founder, Aspen Technology, Inc.; Member, National Academy of Engineering; Past President, American Institute of Chemical Engineers "In this very competitive global industry, it is critical to minimize overall operating costs while achieving the maximum possible "upgrade" for each hydrocarbon molecule (called "molecule management"). This process requires complex computer modeling to help select feedstocks and product slates and troubleshoot and optimize the performance of individual refinery processes (e.g. distillation units, fluidized catalytic cracking units). And eventually, all of these individual parts have to be pulled together to feed a linear program (LP) model capable of optimizing the overall refinery. This complex modeling is the subject of this book by Ai-Fu Chang, Kiran Pashikanti and Y. A. Liu. Based on my review, I believe this book provides a solid introduction to integrated refinery process modeling and optimization, using the tools and techniques currently employed in modern refineries. This book and associated coursework would be a highly desirable investment by any engineering student considering a career in petroleum refining." - Steven R. Cope, ExxonMobil manager of Baytown refinery, the largest refinery in North and South America Additional material available on: www.wiley-vch.de

Petroleum refining is one of the most important yet challenging industries, and continues to be a major contributor in the production of transportation fuels and chemicals. Current economic, regulatory and environmental concerns place significant pressure on refiners to upgrade and optimize the refining process. At the same time, new product demands are urging refiners to explore alternative processing units and feedstocks.

This textbook represents a pioneering and comprehensive introduction to this complex subject, using many of the tools and techniques currently employed in modern refinery process simulation.�

Adopting a systematic and practical approach, the authors include the theory, case studies and hands-on workshops, explaining how to work with real data. As a result, senior-level undergraduate and graduate students, as well as industrial engineers learn how to develop and use the latest computer models for the predictive modeling and optimization of integrated refinery processes.

Additional material is available online providing relevant spreadsheets and simulation files for all the models and examples presented in the book.

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
P... MORE	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.

Ai-Fu Chang received his Ph.D. in the Department of Chemical Engineering at Virginia Polytechnic Institute and State University 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 fractionation 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 reaction and fractionation systems, and of carbon-dioxide capture processes. This textbook grows out of his doctoral dissertation on the predictive modeling of fluid catalytic cracking and catalytic reforming processes. He is currently employed by Chevron Phillips Chemical Company.

Prof. Y.A. Liu is the Frank C. Vilbrandt Endowed Professor of Chemical Engineering at Virginia Polytechnic Institute and State University. He received his B.S. (1967), M.S. (1970), and Ph.D. (1974) degrees from National Taiwan University, Tufts University and Princeton University, respectively. He has published numerous papers and eight books, including four pioneering chemical engineering textbooks on artificial intelligence in chemical engineering (with Thomas E. Quantrille) and on neural networks in bioprocessing and chemical engineering (with D. Richard Baughman). Professor Liu's contributions to chemical engineering teaching and research have been recognized by university, national and international awards and he is a Fellow of the American Institute of Chemical Engineers. For his contributions to teaching, research and industrial outreach, he received the Virginia Outstanding Faculty Award from Governor Jim Gilmore in 2000. He also received the National Friendship Award from China's Premier Zhu Ronjie in 2000.

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