Refinery Planning Presentation
Transcript of Refinery Planning Presentation
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Refinery Modeling
Aaron Smith, Michael Frow,Joe Quddus, Donovan Howell,Thomas Reed, Clark Landrum,
Brian CliftonMay 2, 2006
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The
Big
Black
Box
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The
Big
Black
Box
DemandCrude B
Crude C
Crude A
Costs
Profit
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The
Big
Black
Box
DemandCrude B
Crude C
Crude A
Costs
Profit
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Hydrotreating
INPUT:
TemperaturePressure
H2/HC RatioSulfur %Nitrogen %
OUTPUT:
Sulfur %Nitrogen %Aromatic %
MODEL:
PBR
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http://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_2fig25.gif
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A future of energy production
Hydrotreating
Removal of sulfur, nitrogen, andaromatics.
Government regulations are leading toincreased sulfur removal requirements.
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Typical ProcessingConditions
35580020000.75-2.0Heavy Gas
Oil
42570015000.7-1.5Light GasOil
3304008001.0-4.0Middle
Distillate
2902003001.0-5.0Naptha
Temperature(oC)
H2Pressure
(psia)H2/HCSpacevelocity
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Hydrotreating
Cracking is assumed to be insignificant.
Therefore, properties such as density and
molecular weight are assumed to beconstant.
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Hydrotreating
Cracking is assumed to be insignificant.
Therefore, properties such as density and
molecular weight are assumed to beconstant.
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Hydrotreating Model
For MoCo catalyst reaction rates are:
Rates= ksCs2CH2
.75
Raten= knCn1.4CH2.6 Ratear= karCarCH2
http://www.chem.wwu.edu/dept/facstaff/bussell/research/images/thio-HDS.jpg
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Delayed Coking
INPUT:
CCRPressure
OUTPUT:
Gas OilCokeGas
Naptha
MODEL:
Correlation
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Delayed Coking
Used to processbottoms from thevacuum distillate.
Breaks down thisportion into usablenapthas, gas, andgas oil.
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Delayed Coking
Coke Products
Shot Coke
Sponge Coke
Needle Coke
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Delayed Coking Model
Most important parameter is the ConradsonCarbon Residue.
Coke = 1.6 x CCR
Gas = 7.8 + .144 x CCR
Naptha = 11.29 + .343 x CCR
Gas oil = 100 Coke Gas - Naptha
This is an estimate from Gary and Handwerk
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Effect of Pressure onProduct
44.951.243.1Gas Oil Yield
1512.517.5Naptha Yield
9.99.110.4Gas Yield
30.227.229Coke
35 psig15 psigCorrelation
18.1CCR (wt%)
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Delayed Coking Model
Modified EquationsGas = (7.4 + (.1 x CCR)) + (.8 x (P-15)/20)
Naptha = (10.29 + (.2 x CCR)) + (2.5 x (P-15)/20)Coke = (1.5 x CCR) + (3 x (P-15)/20)
Gas oil = 100 Gas Naptha - Coke
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New Correlation
44.951.243.449.7Gas Oil Yield
1512.516.413.9Naptha Yield
9.99.110.09.2Gas Yield
30.227.230.227.2Coke
35 psig15 psigCorrelation(35 psig)
Correlation(15 psig)
18.1CCR (wt%)
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Catalytic
Reforming
INPUT:
TemperaturePressure
% Napthenes% Aromatics% Paraffins
OUTPUT:
HydrogenLPGReformate
MODEL:
PBR
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Catalytic Reforming
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Catalytic ReformingHydrogen Intensive Process Units
Xylenes Isomerization
Boilers
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Catalytic Reforming
Simplified reactions and equations from
Case Study 108 by Rase
( )
( )
( )
( ) napthenesofingHydrocrack
paraffinsofingHydrocrack
HnapthenesParaffins
HaromaticsNapthenes
__4
__3
2
*31
2
2
+
+
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Catalytic Reforming
( ) 543212215151515153
4 Cn
Cn
Cn
Cn
Cn
Hn
HC nn +++++
( ) 5432122215151515153
33 C
nC
nC
nC
nC
nH
nHC nn ++++
+
+
( ) 22222 HHCHC nnnn ++
( ) 2622 31 HHCHC nnnn +
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Catalytic Reforming[ ]
( )( )( )atmcatlbhr
moles
TkP
._,
3475021.23exp1 =
=
)
[ ]( )( )( )2
2._
,5960098.35expatmcatlbhr
molesT
kP =
=
)
[ ]( )( )._
,62300
97.42exp43catlbhr
moles
Tkk PP =
==
))
[ ] 33
1 ,46045
15.46exp*
atmTP
PPK
N
HAP =
==
[ ] 12 ,12.78000
exp*
=
== atm
TPP
PK
HN
PP
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Catalytic Reforming
[ ]
( )( )._
____*
2
22
catlbhr
paraffinstoconvertednapthenemoles
K
PPPkr
P
PHNP =
=
)
)
[ ]( )( )._
____33
catlbhr
inghydrocrackbyconvertedparaffinsmoles
P
Pkr PP =
=
)
)
[ ] ( )( )._____*
1
3
11catlbhr
aromaticstoconvertednapthenemoles
K
PPPkr
P
HANP =
=
)
)
[ ]( )( )._
____44
catlbhr
inghydrocrackbyconvertednapthenesmoles
P
Pkr NP =
=
)
)
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Catalytic Reforming
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Catalytic Reforming
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Xylenes
Isomerization
INPUT:
Temperature
OUTPUT:
BenzeneTolueneO-Xylene
P-XyleneEthyl-Benzene
MODEL:
Correlation
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Xylenes Isomerization
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Xylenes IsomerizationParaffins & Napthenes - Blending
Mixed Aromatics Fractionation
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Xylenes Isomerization
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Xylenes Isomerization
Benzene & Toluene Solvent Quality
Xylenes Isomerization
C9+ Aromatics Blending
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Xylenes Isomerization
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Xylenes IsomerizationO-Xylene Chemical Feedstock
Mixed Aromatics Blending
P-Xylene Chemical Feedstock
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Xylenes Isomerization
Reaction driven by equilibrium
Temperature dependence of equilibriummodeled in Kirk-Othmer Encyclopedia ofChemical Technology
neEthylBenzeXylenepXyleneoXylenem
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Xylenes Isomerization
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Solvent
Extraction
INPUT:
TemperatureS/F Ratio
OUTPUT:
Lube OilAromatics
MODEL:
Correlation
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Solvent Extraction
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Solvent ExtractionParaffinic Oils - Solvent Dewaxing
Mixed Aromatics Blending
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Solvent Extraction Furfural Extraction Averaged K Values
Benzene from Cyclohexane Benzene from Iso-octane
1,6-diphenylhexane from Docosane
Temperature (R) dependence of K correlated from this
=
=N
n
nE
Extracted
0
11%F
SKE *=
( ) 371.7*0259.0522 += TETK
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Solvent Extraction Correlations developed from Institut Franais
du Ptrole data
( ) 9318.00426.0*% +
= F
SieldRaffinateY
( ) 9229.0)0073.0(*0004.0*..2
+
=
F
S
F
SGRaffinateS
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Solvent Extraction
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Solvent Extraction
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Visbreaker
INPUT:
Temperature
OUTPUT:
GasGasolineGas Oil
Residue
MODEL:
PFR
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Visbreaking
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Visbreaking Carbon chains cracking into smaller chains of varying
carbon numbers
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A future of energy production
Visbreaking
Si-2 + O2
Si-3 + O3
Si-j
+ Oj
S2 + Oi-2
S1 + Oi-1
Si
Si forms all components with carbons less than i-1
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A future of energy production
Visbreaking
Si is formed from all components with carbons greaterthan i+1
Si-2 + O2
Si-3 + O3
Si-j + Oj
S2 + Oi-2
S1 + Oi-1
Sn
Sn-1
Sk
Si+3
Si+2
On-i
On-1-i
Ok-i
O3
O2
Si
Si forms all components with carbons less than i-1
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Visbreaking
First order kinetics with molar concentrations
=+=
=
2
1
,
2
,
i
j
jii
n
ik
kiki KCsCsKrs +=
=
n
ij
jijji CsKro1
,
ii rs
FdzdCs 2
41=
i
i roFdz
dCo 2
41=
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Visbreaking
Rate Constant dependent on molecular weight
RTB
jiji
jieAK/
,,,
= jiji PMbPMbbB ++= 210,
[ ]( )
2
3
4
2
1
2
210,
++=
a
a
PMPM
iiji
ij
ePMaPMaaA11.35
146.9532.06E+06
-4.51.90E+08
428941.51E+12
ba
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Visbreaking
Model inputs
Temperature and mass flow rate
Model Product form
Weight percents Components are lumped into 4 categories
Gas: C1-C4
Gasoline: C5-C10 Gas Oil: C11-C21
Residue: C22-C45
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I i ti
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Isomerization
INPUT:
TemperatureH2/HC Ratio
OUTPUT:
HydrocarbonsC4-C6
MODEL:
PFR
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Isomerization
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Isomerization
Main reactants: n-Butane, n-Pentane, n-Hexane
Typically catalyzed-gas phase reaction
Low temperature favors isomer formation
Seven rate laws
Only one of n-Pentanes isomers forms
n-Butane i-Butane
n-Pentane i-Pentane
3-MP 2,2-DMB
2-Mp 2,3-DMB
n-Hex.
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A future of energy production
Isomerization
n-Butane
n-Pentane
n-Hexane
2
4
2
4
214
H
Ciso
H
CnCn
PPK
PPKr
+=
[ ] ( )[ ]55
125.0
2
525 10000197.0 CieqCneq
CnCn CKCKt
H
CKr
+
=
==
+
=
5
1
,
5
1
,
j
jjii
j
iji CKCKr
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A future of energy production
Isomerization
Model inputs Temperature, mass flow rate, and H2/HC ratio
Model Product form
Weight percents of the individual isomers
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Hydrocracking
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Hydrocracking
INPUT:
APIKwH2/BBL
OUTPUT:
NapthaLightHeavy
C3Upi-Butane
n-Butane
Gas Oil
MODEL:
Correlation
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A future of energy production
Hydrocracking
Convert higher boiling point petroleum fractions
into lighter fuel products
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Hydrocracking Complementary Reactions
Cracking reactions Provides olefins for hydrogenation
R-C-C-C-R + heat R-C=C + C-R
Hydrogenation reactions
Provides heat for cracking
R-C=C + H2 R-C-C + heat
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Hydrocracking Feedstocks- Heavy distillate stocks, aromatics,
cycle oils, and coker oils
Catalysts- zeolites
Operating conditions-
500-30002000-3000Pressure (psi)
500-900750 -800Temperature (F)
0.5-100.2-1LHSV (hr-1)
1000-24001200-1600HydrogenConsumption (SCFB)
DistillateResiduum
Hydrocracking Model
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Hydrocracking Model
Development
Correlated data from Oil and GasJournal W.L. Nelson
Graphical correlated data was made
continuous for hydrogen feed rate, Kwand API of the feed
3 inputs
5 outputs
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Hydrocracking Model
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Hydrocracking Model
y = 0.84165e0.00096x
R2= 0.99872
y = 0.91507e0.00099x
R2= 0.99903
y = 1.03077e0.00102x
R2= 0.99873
y = 1.17542e0.00105x
R2= 0.99820
y = 1.35330e0.00110x
R2= 0.99840
y = 1.48461e0.00120x
R2= 0.99938
y = 1.64851e0.00129x
R2= 0.99707
y = 1.80073e0.00143x
R2= 0.98730
y = 2.20169e0.00147x
R2= 0.98763
y = 2.67927e0.00153x
R2= 0.98715
y = 3.40926e0.00157x
R2= 0.98555
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000 2500 3000
Hydrogen Rate SCFB
32.5
30
27.5
25
22.5
20
17.5
15
12.510
7.5
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Hydrocracking Model
y = 1.852E-05x4- 1.206E-03x3+ 2.920E-02x2-
2.531E-01x + 1.546E+00
R2= 9.992E-01
0
0.5
1
1.5
2
2.5
3
3.5
4
0 10 20 30 40
API of Feed
A
Constant
y = 6.024E-11x6- 6.539E-09x5+ 2.738E-
07x4- 5.600E-06x3+ 5.935E-05x2- 2.996E
04x + 1.509E-03
R2= 9.982E-01
0
0.0002
0.00040.0006
0.0008
0.001
0.0012
0.0014
0.0016
0.0018
0 10 20 30 40
API of Feed
BC
onstant
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Hydrocracking Model
Vol% of light naptha
Hydrogen Rate(SCFB) 7.5 10 12.5 15 17.5 20 22.5 25
2500 Kw=12.1 9.25 11 13 16 21 30 45 80
diff. from Kw=10.9 0.75 1 1 1.25 1.75 2.5 5 7.5
8.11% 9.09% 7.69% 7.81% 8.33% 8.33% 11.11% 9.38%
1500 Kw=12.1 3.4 4 4.8 5.8 7.3 9.1 11.25 14.25
diff. from Kw=10.9 0.35 0.45 0.5 0.55 0.7 1 1.5 1.75
10.29% 11.25% 10.42% 9.48% 9.59% 10.99% 13.33% 12.28%
500 Kw=12.1 1.4 1.55 1.7 2 2.3 2.8 3.4 4.2
diff. from Kw=10.9 0.1 0.17 0.2 0.2 0.25 0.3 0.35 0.4
7.14% 10.97% 11.76% 10.00% 10.87% 10.71% 10.29% 9.52%
API
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Hydrocracking Model
y = -0.7691x + 11.739
R2= 0.9916
0
0.5
1
1.5
2
2.5
3
3.5
4
10.5 11 11.5 12 12.5
Kw
slope
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Hydrocracking Equations
HBw AeKpvol = )00833.000833.1(% 1
)%(11.739)+K0.7691-(% 1w2 pvolpvol =
)%(0.337% 13 pvolpvol =)%(0.186% 14 pvolpvol =
)%(0.091% 15 pvolpvol +=
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Hydrocracking Model
Hydrogen
(SCFB)
15 2500 12.1 16.4 39.9
actual 15.0 40.5
20 750 10.9 3.3 11.0actual 3.5 10.0
30 1250 10.9 16.3 54.7
actual 13.0 43.0
API Kw vol% p1 vol% p2
9%
25%
7%
1%
27%
9%
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Solvent
Dewaxing
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Dewaxing
INPUT:
CompositionTemperature
OUTPUT:
WaxLube Oil
MODEL:
Correlation
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A future of energy production
Solvent Dewaxing
Separate high pour point waxes from
lubricating oils
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Solvent Dewaxing
Feedstocks Distillate and residual stocks heavy gas oils
Solvents Ketones (MEK) and Propane
Operating conditions
Solvent to oil ratio 1:1 to 4:1
Desired pour point of product
Dewaxing Model
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Development Correlation from Energy and Fuels
Krishna et. al. 3 experimentally determined parameters
3 inputs
2 outputs
2/1)/100log(0 ACLAPCAPPT ++=
( )( ))(100
)(100%)(productPC
feedPCwtOilYield
=
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Dewaxing Model ErrorBC2 NC6 NC7 NC8 NC9 NC10
C 375-500 375-400 400-425 425-450 450-475 475-500
wax wt% 46.8 44.88 47.28 48.41 48.72 47.05
CL 26.89 24.13 25.13 27.14 29.05 31PPT act. 48 39 45 48 51 57
PPT pred. 48.0 41.0 44.0 48.9 52.8 55.9
error % 0.1% 5.0% 2.3% 1.8% 3.5% 1.9%
dewaxing model Desired PPT= 10PPT low 9.99 9.50 9.77 9.82 9.65 9.81
PPT high 10.01 10.50 10.23 10.18 10.35 10.19
wax wt% low 0.368 0.819 0.608 0.336 0.202 0.133
wax wt% high 0.369 0.931 0.643 0.352 0.220 0.139
yield low 0.5340 0.5558 0.5304 0.5176 0.5138 0.5302yield high 0.5340 0.5564 0.5306 0.5177 0.5139 0.5302
error % 0.001% 0.112% 0.036% 0.016% 0.019% 0.006%
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Alkylation
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INPUT:
Iso-butaneButylene /Propylene
Reaction time
OUTPUT:PropaneButaneAlkylate
MODEL:
Correlation
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Alkylation PFD
http://www.prod.exxonmobil.com/refiningtechnologies/pdf/AlkyforWR02.pdf
Exxon-Mobil Autorefrigeration H2SO4 alkylation
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Alkylation
*Lots of side reactions
Alk l i
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Alkylation
O
FE
SV
OIIF
)(100
)/(=
FOI )/(
=EI
=OSV)(
= volumetric isobutane/olefin ratio in feed
isobutane in reactor effluent, liquid volume %
F= Factor defined by A.V. Mrstikolefin space velocity, v/hr/v
Progress in Petroleum Technology AV Mrstik et al. ACS Publications
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Polymerization
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INPUT:
Iso-butaneButylene /Propylene
OUTPUT:GasolineDiesel
MODEL:
Correlation
PolymerizationPolymerizationPolymerizationPolymerization
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Converts Propylenes and butylenes into saturatedcarbon chains
1st used Catalytic Solid Phosphoric Acid (SPA) on
silica fell out of popularity in 1960s. Now experimenting with Zeolites.
C C
C
C + C C
C
C
C C
C
CC C
C
C
C C C + C C C C C
C
CC C
- Polymerization reaction is highly exothermic and temperature iscontrolled either by injecting cold propane quench or by
generating steam.
- Propane is also recycled to help control temperature
CO School of Mines http://jechura.com/ChEN409/11%20Alkylation.pdfhttp://www.personal.psu.edu/users/w/y/wyg100/fsc432/Lecture%2015.htm
Z litZ litZ litZ lit P l i tiP l i tiP l i tiP l i ti
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ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerization Converts propylenes and butylenes into
saturated carbon chains by means ofzeolite catalysis (ZSM-5)
Z litZ litZ litZ lit P l i tiP l i tiP l i tiP l i ti
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ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerization Converts propylenes and butylenes into
saturated carbon chains by means ofzeolite catalysis (ZSM-5)
ZeoliteZeoliteZeoliteZeolite Pol e izatioPol e izatioPol e izatioPol e izatio
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ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerization Converts propylenes and butylenes into
saturated carbon chains by means ofzeolite catalysis (ZSM-5)
79MON
92RON
Octane
0.73SpecificGravity
[Tabak, 1986]
ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerization
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ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerizationCharge
17wt.% Propylene
10.7 wt.% Propane
36.1 wt.% 1-butene
27.2 wt.% isobutane
Temperature = 550K
Total Pressure =5430 kPa
Propylene partial pressure =7~3470kPa.
*Depending on desiredchain length
ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerization
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ZeoliteZeoliteZeoliteZeolite PolymerizationPolymerizationPolymerizationPolymerizationCharge
17wt.% Propylene
10.7 wt.% Propane
36.1 wt.% 1-butene
27.2 wt.% isobutane
Temperature = 550K
Total Pressure =5430 kPa
Propylene partial pressure =7~3470kPa.
*Depending on desiredchain length
Polymerization
+ PBR-gas phase
Alkylation
- CSTR- liquid phaseVS
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+ PBR-gas phase
- Solid catalysis
+ Produce eitherdiesel or gasolinerange chains
- Typical octanenumber = 92(RON)
- CSTR liquid phase
+ Liquid catalysis
- Requires very vigorousagitation
- Typically .1lbmacidconsumed per gallonproduct
++Typical octane number =96(RON)
VS
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Deasphalting
INPUT MODEL:
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INPUT:
%HeaviesTemperaturePressure
OUTPUT:%HeaviesLube oil
MODEL:
Correlation
Propane Deasphalting - PFD
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Propane Deasphalting - PFD
http://www.scielo.br/scielo.php?script=sci_arttext&pid=S0104-66322000000300012&lng=pt&nrm=iso
Typical Propane Deasphalting
Propane Deasphalting
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Propane Deasphalting
Types
1. Sub Critical. (below 369K) Modeled first byRobert E. Wilson in 1936. Hildebrandsolubility parameters now used.
2. Super Critical. (above 369K) Now popular.High selectivity. No good model.
Both remove greater than 99% asphalt
Sub Critical Propane
Deasphalting
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Deasphalting
21
=
VTRH g
=
=H
=gR
Hildebrand solubility
Solubility Parameter [J/mol]
Heat of vaporization [J/mol]
Universal gas Constant [8.314J/mol/K]T = Temperature [K]V = molar volume [L/mol]
Super Critical Propane
Deasphalting
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Deasphalting
Models typically break down near the critical point. Including
Redlick-Kwong, Soave-Redlick-Kwong and Perturbed-Hard-Chain(PHC). Therefore correlations have to be used.
Typically operate atT=400KPressure=55 barRatio= 4:1 propane to oil
mixture
Pressure (bar)
Phase Equilibria in Supercritical Propane Systems for Separation of Continuous Oil Mixtures Radosz, Maciej et al. Ind. Eng. Chem. Res. 1987, 26, 731-737
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Catalytic
Cracking
INPUT: MODEL:
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INPUT:
KwTemperature
OUTPUT:Gas OilGasolineLPGDry Gas
Coke
PFR
Fluidized Catalytic Cracking
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Fluidized Catalytic Cracking
Pretreated feedstock is fed intothe bottom of the riser tubewhere it meets very hotregenerated catalyst.
The feed vaporizes and iscracked as it passes up theriser. 1
http://www.uyseg.org/catalysis/petrol/petrol2.htm
Fluidized Catalytic Cracking
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Fluidized Catalytic Cracking
Different yields of products willoccur depending on:
Temperature
Inlet Feed Properties
Top of the riser, the catalystseparates from the mixture andis steam stripped
The final product exits the topof the reactor
2
http://www.uyseg.org/catalysis/petrol/petrol2.htm
Fluidized Catalytic Cracking
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Fluidized Catalytic Cracking
One product from catalyticcracking is coke or carbon thatforms on the surface of thecatalyst.
To reactivate catalyst, it mustbe regenerated.
3
http://www.uyseg.org/catalysis/petrol/petrol2.htm
Fluidized Catalytic Cracking
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z y g
Catalysis is regenerated byentering a combustion chamberand mixed with superheated air
Energy released fromregenerating the catalysis isthen coupled with the inlet feedat the bottom of the riser
Cracking4
http://www.uyseg.org/catalysis/petrol/petrol2.htm
Fluidized Catalytic Cracking
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A B C
DE
Ancheyta-Juarez, Jorge, Estimation of Kinetic Constants., Energy & Fuels,2000, 14, 1226-1231
y g
Fluidized Catalytic Cracking
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A B C
DE
Ancheyta-Juarez, Jorge, Estimation of Kinetic Constants., Energy & Fuels,2000, 14, 1226-1231
y g
Fluidized Catalytic Cracking
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A B C
DE
Ancheyta-Juarez, Jorge, Estimation of Kinetic Constants., Energy & Fuels,2000, 14, 1226-1231
y g
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Fluidized Catalytic Cracking
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A B C
DE
8 kinetic constants
One catalyst deactivation
Gas Oil considered as a second order reaction
Ancheyta-Juarez, Jorge, Estimation of Kinetic Constants., Energy & Fuels,2000, 14, 1226-1231
g
Fluidized Catalytic Cracking
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Assumptions
One-dimensional tubular reactor
No radial and axial dispersion
Cracking only takes place in the riser
Dispersion/Adsorption inside catalyst isnegligible
Coke deposited does not affect the fluid flow
Fluidized Catalytic Cracking
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Change Temperature
Inlet Feed
Mass Balance:
dtdt
dCCC ii *0 +=
i
C
Li rWHSVdz
dy = )(1
Fluidized Catalytic Cracking
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Change Temperature
Inlet Feed
Mass Balance:
dtdt
dCCC ii *0 +=
i
C
Li rWHSVdz
dy = )(1
TEMPERATURE:480, 500, 520 C
Fluidized Catalytic Cracking
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Constant C/O Ratio of 5 Varying space velocity (WHSV)
6 48 h-1
Gas Oil Conversion ~ 70 %
Gasoline ~ 50%
LPG ~ 12 %
Fluidized Catalytic Cracking
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Constant C/O Ratio of 5 Varying space velocity (WHSV)
6 48 h-1
Gas Oil Conversion ~ 70 %
Gasoline ~ 50%
LPG ~ 12 %
Fluidized Catalytic Cracking
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Constant C/O Ratio of 5 Varying space velocity (WHSV)
6 48 h-1
Gas Oil Conversion ~ 70 %
Gasoline ~ 50%
LPG ~ 12 %
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Blending
INPUT:
35 streams
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OUTPUT:Gasoline
RegularPremium
LPG
CokeLube Oil
WaxAsphalt
Blending
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A future of energy production
Final products are created by blendingstreams from refinery units
35 streams from 13 units are blended
30 streams are used in gasoline
5 streams are other products
Propane gas, lube oil, asphalt, wax, andcoke
Blending Indexes
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Most properties do not blend linearly Empirical blending indexes are used to
linearize the blending behavior
=i
iimix BIxBI
icomponentoffractionvolumetheisIndexBlendingtheisWhere
ixBI
Blending Indexes( ) 25.1RVPVPBI =Reid Vapor Pressure
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=08.0
1
pp TBIPour Point
10
10
log3
log
+=vBIViscosity Index
=05.0
1
CLCL TBICloud Point
6.42
24141188.6log10
+=
F
F
TBI
Flash Point
( )[ ]APBIAP 00657.0exp124.1=Aniline Point
( )RVPVPBI =e d apo essu e
Gasoline Blending
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Specifications: Octane (normal 87, premium 91)
Reid Vapor Pressure (EPA mandated)
Maximum additive amounts Inputs:
Market conditions (Price, Demand)
Incoming streams from refinery units Objective: Maximize Profit
Gasoline Blending
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Vapor pressure blending can beimproved by using thermodynamicallybased methods
Raoult's Law
=
*
ii
PxP
Blending
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Other possible products Fuel oils
Lube oils
Diesel fuel
Blending requires data for aniline point,pour point, cloud point, flash point, anddiesel index
Refinery Planning
Addresses the planning of short-term crude oil
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Addresses the planning of short-term crude oilpurchasing and processing
Does not address risk or uncertainty
Determine purchasing schedule to meet: Specification (Octane, n-Butane, etc.)
Demand with HIGHEST profit
Decision Variables: Crude oil purchase
Processing variables Temperatures, Pressures, Blending mixtures
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A future of energy production
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A future of energy production
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A future of energy production
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A future of energy production
Refinery Planning
Max Profit
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=
Tt Cc Tt Cctctctctctc
Tt Cctc
o ppclALcoACcpMANU ,,,,,,
Pongsakdi, Arkadej, et. al, Financial risk., Int. J. Production Economics, accepted 20 April 2005
Refinery Planning
Max Profit
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=
Tt Cc Tt Cctctctctctc
Tt Cctc
o pp
clALcoACcpMANU,,,,,,
Product Sales
Amount of product producedin that time period multipliedby
unit sale price of product c
Pongsakdi, Arkadej, et. al, Financial risk., Int. J. Production Economics, accepted 20 April 2005
Refinery Planning
Max Profit
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=
Tt Cc Tt Cctctctctctc
Tt Cctc
o pp
clALcoACcpMANU,,,,,,
Product Sales
Amount of product producedin that time period multipliedby
unit sale price of product c
Crude Oil Costs
Amount of crude oil refined inthat time period multipliedby
unit purchase price of crude oil
Pongsakdi, Arkadej, et. al, Financial risk., Int. J. Production Economics, accepted 20 April 2005
Refinery Planning
Max Profit
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=
Tt Cc Tt Cctctctctctc
Tt Cctc
o pp
clALcoACcpMANU,,,,,,
Product Sales
Amount of product producedin that time period multipliedby
unit sale price of product c
Crude Oil Costs
Amount of crude oil refined inthat time period multipliedby
unit purchase price of crude oil
Discounted Expense
Amount of product volumethat cannot satisfy demand
multipliedby discounted price
Pongsakdi, Arkadej, et. al, Financial risk., Int. J. Production Economics, accepted 20 April 2005
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Modeling
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A Visual Basic macro in Excel was usedto help Solver find the optimal crudeselection
Model Inputs
Inputs:
Crude A: $71 88 / barrel (Australia)
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Crude A: $71.88 / barrel (Australia)
Crude B: $72.00 / barrel (Kazakhstan) Crude C: $71.20 / barrel (Saudi Arabia)
Regular Gasoline:
$2.75 / gal ($2.12) Demand: 310,000 bbl/month
Premium Gasoline:
$3.00 / gal ($2.31)
Demand: 124,000 bbl/month
Energy Information Administration, U.S. Department of Energyhttp://www.eia.doe.gov/oil_gas/petroleum/info_glance/petroleum.html
Model Results
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Outputs: Maximum Profit: $21 per barrel
Crude Selection:
Crude A: 150,000 bbl/month Crude B: 150,000 bbl/month
Crude C: 300,000 bbl/month
Demand exactly met
Future Work
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Include storage of crude and products Include risk and uncertainty
Demand changing over time
Wider variety of products: diesel,solvents, fuel oils, lube oils, etc.
Questions?
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