Refining Technology in the Petroleum, Metals and ...

Refining Technology in the Petroleum,

Metals and Bioprocesses Industries

São Paulo, Mar 01st, 20181

Brenno C. Menezes

Postdoc, email: [email protected]

University of São Paulo

São Paulo, SP, BR

Galo Carrillo Le Roux

Professor of Chemical Engineering

University of São Paulo

São Paulo, SP, BR

Lecture 2

Lecture 2

USP, Mar 01st, 2018

TYPE OF ASSESSMENT:

M = 70% Test + 30% Project

Tests = (2.5*Test1 + 4.5*Test2)/7

Project = 1.0 Writing (in English: extra point)

1.0 Scope + Complexity

1.0 Tools handled in the group

Project deadline: 31-May

Refining Technology in the Petroleum, Metals and Bioprocesses Industries

Introduction16%

Petroleum50%

Metals17%

Bioprocesses17%

Ref Tech22-Feb Introduction 1 22-Feb Energy and Material balances: World and Brazil

1-Mar Introduction/Project Reserves, Production and Consumption

2 1-Mar Flowsheet Structures, Ref Tech Comparison and Fundaments

OpenIMPL, Types of Projects, Main Papers

8-Mar Petroleum 3 8-Mar Caracterization of Petroleum and derivatives

15-Mar Petroleum Distillation and other separation processes

22-Mar Petroleum 4 15-Mar OpenIMPL Tutorial

29-Mar No Class Blending and distillation problems

5-Apr Petroleum 5 22-Mar Catalytic, Thermal Cracking, Solvent Deasphalting

12-Apr Petroleum PETRO-SIM Tutorial: CDU and VDU

19-Apr Petroleum 29-Mar No Class

6 5-Apr Hydrotreating and Hydrocracking

Reforming, Isomerization and Alkylation

7 12-Apr Supporting Processes and Natural Gas Processing

Petrochemicals

8 19-Apr OpenIMPL Tutorial: Alkylation process (scalar-based)

OpenIMPL Tutorial: Refinery-wide problems (structural-based)

26-Apr Exam 1 9 26-Apr Exam: Introduction and Petroleum

3-May Metals 10 3-May Minerals and metallic derivatives. Physical Metallurgy

10-May Metals Metal processing: smelting, conversion, others

11 10-May Electrochemical processes: deposit of metals and alloys

Other metallurgic processes

17-May Bioprocesses 12 17-May

24-May Bioprocesses

13 24-May

31-May Exam 2 14 31-May Exam: Introduction, Petroleum, Metals and

Bioprocesses

Main routes, biomasses and biological platforms. Biorefineries:

conventional and advanced.

Biorefinery concepts in comparison with the petroleum and

minerals refining. Bioportfolio in industry

Outline

1) Flowsheet Superstructures and Elements

Rodrigues et al. (2016)

2) Refining Technology Comparison and Fundaments

4) Types of Projects


3) Open IMPL

USP, Mar 01st, 2018

5) Conclusions

6) Homework

Outline

1) Flowsheet Superstructures





3) Open IMPL

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5) Conclusions

6) Homework

How do we represent the flowsheet?

Perimeters – Supply/Demand Points or Sources/Sinks

Pools – Inventory or Holdup

Batch-Processes – Variable-Size & Fixed-Time (VSFT) or Fixed-Size & Variable-Time (FSVT)

Continuous-Processes – Blenders, Splitters, Separators, Reactors , Fractionators & Black-Boxes

Parcels – Moveable/Transportable Inventory or Holdup with Round-Trip Travel-Time

Pipelines – Moveable/Transportable Inventory as FIFO (First-In-First-Out)

Port-In – Flows into a Unit (similar to a nozzle).

Port-Out – Flows out of a Unit

Dimensional-Processes – Geometry Transforms (Reels, Rolls, Sheets, Ingots, Logs, etc.)

Pilelines – Stackable Inventory as LIFO (Last-In-First-Out)

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UOPSS = STN x RTN

Models •Quantity (quantity) • Logistics (quantity & logic) •Quality (quantity & quality)

• Quantity details:• Flows, holdups, yields, etc.

• Logic details:• Setups, startups, switchovers, shutdowns and sequence-dependent

switchovers, etc.

• Quality details:• Densities, components, properties, conditions and coefficients i.e., catalyst

activity, enthalpy, etc.

How do we formulate the variables and constraints?

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USP, Mar 01st, 2018

Continuous versus batch operations

Batch-processes -> accumulated over time

Example: a batch distillation operation consists of an initial quantity of feed material being batched into a piece of equipment and during its operation, one or more product materials can be continuously or semi-continuously drawn out (Henley and Seader 1981; Phismister and Seider 2001).

Continuous-processes -> there is a negligible rate of accumulation

In a continuous process none of the feeds or products remains inside the unitsuch that the mass of material charged equals the mass of material dischargedfor any time interval, window or period during its operation

Batch process is usually characterized by its quantity-size or batch-size whereasa continuous process is described by its quantity-size per time or charge-rate.Batch processes have inventory or holdup whereas continuous processes havezero inventory or holdup.

Batch-Processes – Variable-Size & Fixed-Time (VSFT) or Fixed-Size & Variable-Time (FSVT)

Continuous-Processes – Blenders, Splitters, Separators, Reactors , Fractionators & Black-Boxes

USP, Mar 01st, 2018

Oil & Gas Upstream to Midstream (Well Scheduling)

• Schedule the startup of wells in oil & gas field reservoirs over a multi-decade time-horizon with year or month time-periods subject to resource constraints such as rig and water availability, plant capacity, etc.

• Novelty is to represent each well as a “batch-process” with relative time-varying yields (i.e., declining curve profile).

Upstream Reservoirs

Rig to Position Well Head

Kelly, J.D., Menezes, B.C., Grossmann, “Decision Automation for Oil and Gas Well Startup Scheduling Using MILP”, ESCAPE 27, October, 2017.

Midstream Plant

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From Distillates to Diesel (Diesel Scheduling)

• Distillates rundown to hydrotreaters, etc. and then are blended into various grades of diesel to meet the sales demands.

• Capture spot market opportunities when possible.

Spot v. Contract Orders

Kelly, J.D., Menezes, B.C., Grossmann, “Logistics Optimization for Dispositions and Depooling of distillates in Oil-Refineries ”, ESCAPE 28, June, 2018.

Outline






3) Open IMPL

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5) Conclusions

6) Homework

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The overall or total flow and flow-property balances in open-equation or implicit-form can be seen in the following equations: (NT corresponds to the number of time-periods)

Blending operations with recipes

The blend recipes ri denote the fraction, intensity or transfer coefficient of a feed stream i flow with respect to or divided by the product stream flow as below:

xift: in-flow variables at each time-period with i = {1,2,3}

yipt: individual stream property variables where p may also be a set or list of properties for multi-property blenders.

out-flow and out-property are labeled xft

and ypt respectively.

(Kelly and Zyngier, 2017)

USP, Mar 01st, 2018

The total flow balance is identical to the blender operation where all of the out-properties are simply set equal to the in-property as :

Splitting operations with ratios

The split ratios rj denote the fraction of a product stream j flow with respect to or divided by the feed stream flow as below:

xjft: out-flow variables at each time-period with j = {1,2,3}


USP, Mar 01st, 2018

Usually a separator is primarily designed to be simplifications of more rigorous vapor–liquid separation processes such as equilibrium flash, distillation, fractionation and evaporation although they can also be used to model solid–solidseparations of fines and lumps in mining and minerals processing (i.e., crushing beneficiation).

Separating operations with recoveries

In addition, for each outlet stream we also require that the sum of the components in each stream must equal unity as follows which provides the necessary stream component normalization. The recover of j=2 and c=2:

The overall or total flow is the same as both blender and splitter. And, similar to the blender for properties, there are individual bilinear flow-component balances for each component as:

yckt: individual stream component variables at each time-period with k = {1,2}


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The component balances for each reactant and product species which states that each component or species must conserve at the molecular or atomic level as follows: (g is the chemical reaction index, k is the component index, xg,t is the extent-of-reaction and rg,c is the component’s stoichiometric coefficient involved in each reaction.)

Reacting operations with reactions

The second set of equations to complete the reactor operation is to ensure that the component fractions or compositions within the outlet stream are normalized identical to the separator operation:


USP, Mar 01st, 2018

The set of bilinear equations to formulate how the flow on each outlet stream is a function of the inlet flow, inletcomposition and the renderings of each cut per component per outlet stream, where rj,k,h is the rendering for each outlet stream, each inlet composition and each cut respectively.

Fractionating operations with renderings

The set of equations to model the composition of each new outlet component c3 and c4 on the three outlet streams is given by the bilinear component flow balance equation below: (wck,h,kk is the new component kkcomposition amount for each inlet component and cut respectively.)


components c1 and c2 in are distributed or cut into five cuts denoted as the overall cut set {h1,h2,h3,h4,h5}

USP, Mar 01st, 2018

Conditions (z1t, z2t and z3t) can either be independent variables or they can be dependent on other variables in the system if needed by specifying other relationships.

Black-box operations with relationships

Each yield may be an arbitrary nonlinear function or formula of the conditions (or any other variable) and a stream property may also be any general relationship of the conditions such as: (ryn() and rynp() are the relationships relating the operating conditions to the stream yields and properties respectively for stream n)

Yields (y1t, y2t, y3t, y4t and y5t) are identical to recipes, ratios, recoveries, reaction stoich. and renderings, except that when modeling a unit-operation (both convergent and divergent), it requires a characteristic charge-size if it is a continuous-unit or a batch-size if it is a batch-unit we declare as xt. The set of equations relating a stream flow to its yield and its unit-operation’s size is as follows:


Outline






3) Open IMPL

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5) Conclusions

6) Homework

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Petroleum Refinery

(Khor and Varvarezos, 2017)

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Petroleum Refinery

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Bio Refinery

Thermochemical = yellow squaresMechanical processes = white squaresChemical/Biochemical = blue squares

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Bio Refinery(Jong and Jungmeier, 2015)

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(Jong and Jungmeier, 2015)

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Metals Refinery

(Spitz and Trudinger, 2009)

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Metals Refinery

www.ptable.com

http://www.ptable.com/

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Copper Refinery

http://www.aurubis.com/

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Copper Refinery

http://www.umicore.com/

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Iron Refinery

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Outline






3) Open IMPL

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5) Conclusions

6) Homework

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Outline






3) Open IMPL

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5) Conclusions

6) Homework

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(Khor and Varvarezos, 2017)

Simulation Optimization

Outline






3) Open IMPL

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5) Conclusions

6) Homework

Conclusions

37

Impact in Industry to replace energy and material by bio-of-things (BoT) :

• Biorefinery prices is still expensive in comparison with petroleum.

• Needs of technological frontier with the research, development anddeployment (RD&D) of more advanced biorefineries to produce morecomplex bioproducts for energy andmaterial.

• Demands of:

• advances in biomass processing;

• biotechnology involvement inside the supply chain and market of theother refining technologies

• coproduction of bioproducts together with materials, chemicals, food,feed, etc., adding the necessary value to the bioportfolio.

AICHE-17, Nov 2nd, 2017AICHE-17, Nov 2nd, 2017

Outline





5) Conclusions


3) Open IMPL

6) Homework

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USP, Mar 01st, 2018

Obligatory

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Advised

Refining Technology in the Petroleum, Metals and ...

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