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Aaron Smith, Michael Frow, Joe Quddus, Donovan Howell, Thomas Reed, Clark Landrum, Brian Clifton May 2, 2006 The Big Black Box The Crude B Demand Big Crude A Black Crude C Profit


slide-1
SLIDE 1
  • Aaron Smith, Michael Frow,

Joe Quddus, Donovan Howell, Thomas Reed, Clark Landrum, Brian Clifton May 2, 2006

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SLIDE 2

The Big Black Box

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SLIDE 3

The Big Black Box

Demand Crude B Crude C Crude A Costs Profit

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SLIDE 4

The Big Black Box

Demand Crude B Crude C Crude A Costs Profit

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SLIDE 5
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SLIDE 6

Hydrotreating INPUT: Temperature Pressure H2/HC Ratio Sulfur % Nitrogen % OUTPUT: Sulfur % Nitrogen % Aromatic % MODEL: PBR

slide-7
SLIDE 7

http://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_2fig25.gif

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SLIDE 8

A future of energy production…

  • Removal of sulfur, nitrogen, and

aromatics.

  • Government regulations are leading to

increased sulfur removal requirements.

slide-9
SLIDE 9
  • 355

800 2000 0.75-2.0 Heavy Gas Oil 425 700 1500 0.7-1.5 Light Gas Oil 330 400 800 1.0-4.0 Middle Distillate 290 200 300 1.0-5.0 Naptha Temperature (oC) H2 Pressure (psia) H2/HC Space velocity

slide-10
SLIDE 10
  • Cracking is assumed to be insignificant.

– Therefore, properties such as density and molecular weight are assumed to be constant.

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SLIDE 11
  • Cracking is assumed to be insignificant.

– Therefore, properties such as density and molecular weight are assumed to be constant.

slide-12
SLIDE 12
  • 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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SLIDE 13
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SLIDE 14

Delayed Coking INPUT: CCR Pressure OUTPUT: Gas Oil Coke Gas Naptha MODEL: Correlation

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SLIDE 15
  • Used to process

bottoms from the vacuum distillate.

  • Breaks down this

portion into usable napthas, gas, and gas oil.

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SLIDE 16
  • Coke Products

– Shot Coke – Sponge Coke – Needle Coke

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SLIDE 17
  • Most important parameter is the Conradson

Carbon 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
slide-18
SLIDE 18
  • 44.9

51.2 43.1 Gas Oil Yield 15 12.5 17.5 Naptha Yield 9.9 9.1 10.4 Gas Yield 30.2 27.2 29 Coke 35 psig 15 psig Correlation 18.1 CCR (wt%)

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SLIDE 19
  • Modified Equations

– Gas = (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

slide-20
SLIDE 20
  • 44.9

51.2 43.4 49.7 Gas Oil Yield 15 12.5 16.4 13.9 Naptha Yield 9.9 9.1 10.0 9.2 Gas Yield 30.2 27.2 30.2 27.2 Coke 35 psig 15 psig Correlation (35 psig) Correlation (15 psig) 18.1 CCR (wt%)

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SLIDE 21
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SLIDE 22

Catalytic Reforming INPUT: Temperature Pressure % Napthenes % Aromatics % Paraffins OUTPUT: Hydrogen LPG Reformate MODEL: PBR

slide-23
SLIDE 23
slide-24
SLIDE 24
  • Hydrogen Intensive Process Units

Xylenes Isomerization Boilers

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SLIDE 25
  • Simplified reactions and equations from

Case Study 108 by Rase

( ) ( ) ( ) ( )

napthenes

  • f

ing Hydrocrack paraffins

  • f

ing Hydrocrack H napthenes Paraffins H aromatics Napthenes _ _ 4 _ _ 3 2 * 3 1

2 2

+ → ← + → ←

slide-26
SLIDE 26
  • ( )

5 4 3 2 1 2 2

15 15 15 15 15 3 4 C n C n C n C n C n H n H C

n n

+ + + + →  +

( )

5 4 3 2 1 2 2 2

15 15 15 15 15 3 3 3 C n C n C n C n C n H n H C

n n

+ + + + →        − +

+

( )

2 2 2 2

2 H H C H C

n n n n

+ → ←

+

( )

2 6 2 2

3 1 H H C H C

n n n n

+ → ←

slide-27
SLIDE 27
  • [ ](

)( )( )

atm cat lb hr moles T kP . _ , 34750 21 . 23 exp

1

=       − =

  • [ ](

)( )( )

2 2

. _ , 59600 98 . 35 exp atm cat lb hr moles T kP =       − =

  • [ ](

)( )

. _ , 62300 97 . 42 exp

4 3

cat lb hr moles T k k

P P

=       − = =

  • [ ]

3 3 1

, 46045 15 . 46 exp * atm T P P P K

N H A P

=       − = =

[ ]

1 2

, 12 . 7 8000 exp *

=       − = = atm T P P P K

H N P P

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SLIDE 28
  • [ ]

( )( )

. _ _ _ _ _ *

2 2 2

cat lb hr paraffins to converted napthene moles K P P P k r

P P H N P

=         − = −

  • [ ]

( )( )

. _ _ _ _ _

3 3

cat lb hr ing hydrocrack by converted paraffins moles P P k r

P P

=       = −

  • [ ]

( )( )

. _ _ _ _ _ *

1 3 1 1

cat lb hr aromatics to converted napthene moles K P P P k r

P H A N P

=         − = −

  • [ ]

( )( )

. _ _ _ _ _

4 4

cat lb hr ing hydrocrack by converted napthenes moles P P k r

N P

=       = −

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SLIDE 29
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SLIDE 30
slide-31
SLIDE 31
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SLIDE 32

Xylenes Isomerization INPUT: Temperature OUTPUT: Benzene Toluene O-Xylene P-Xylene Ethyl-Benzene MODEL: Correlation

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SLIDE 33
slide-34
SLIDE 34

Paraffins & Napthenes - Blending Mixed Aromatics – Fractionation

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SLIDE 35
slide-36
SLIDE 36

Benzene & Toluene – Solvent Quality Xylenes – Isomerization C9+ Aromatics – Blending

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SLIDE 37
slide-38
SLIDE 38

O-Xylene – Chemical Feedstock Mixed Aromatics – Blending P-Xylene – Chemical Feedstock

slide-39
SLIDE 39
  • Reaction driven by equilibrium
  • Temperature dependence of equilibrium

modeled in Kirk-Othmer Encyclopedia of Chemical Technology

ne EthylBenze Xylene p Xylene

  • Xylene

m → ← − → ← − → ← −

slide-40
SLIDE 40
slide-41
SLIDE 41
slide-42
SLIDE 42

Solvent Extraction INPUT: Temperature S/F Ratio OUTPUT: Lube Oil Aromatics MODEL: Correlation

slide-43
SLIDE 43

!"#

slide-44
SLIDE 44

!"#

Paraffinic Oils - Solvent Dewaxing Mixed Aromatics – Blending

slide-45
SLIDE 45

!"#

  • Furfural Extraction – Averaged K Values

– Benzene from Cyclohexane – Benzene from Iso-octane – 1,6-diphenylhexane from Docosane

  • Temperature (ºR) dependence of K correlated from this

=

− =

N n n

E Extracted 1 1 %

F S K E * =

( )

371 . 7 * 0259 . 5 2

2

− + − = T E T K

slide-46
SLIDE 46

!"#

  • Correlations developed from Institut Français

du Pétrole data

( )

9318 . 0426 . * % + −       = F S ield RaffinateY

( )

9229 . ) 0073 . ( * 0004 . * . .

2

+       −       = F S F S G RaffinateS

slide-47
SLIDE 47

!"#

slide-48
SLIDE 48

!"#

slide-49
SLIDE 49
slide-50
SLIDE 50

Visbreaker INPUT: Temperature OUTPUT: Gas Gasoline Gas Oil Residue MODEL: PFR

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SLIDE 51

$%

slide-52
SLIDE 52

$%

  • Carbon chains cracking into smaller chains of varying

carbon numbers

slide-53
SLIDE 53

A future of energy production…

$%

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
slide-54
SLIDE 54

A future of energy production…

$%

  • Si is formed from all components with carbons greater

than 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
slide-55
SLIDE 55

$%

  • First order kinetics with molar concentrations

∑ ∑

− = + =

− =

2 1 , 2 , i j j i i n i k k i k i

K Cs Cs K rs

+ = −

=

n i j j i j j i

Cs K ro

1 , i i

rs F dz dCs ρ πφ 2 4 1 =

i i

ro F dz dCo ρ πφ 2 4 1 =

slide-56
SLIDE 56

$%

  • Rate Constant dependent on molecular weight

RT B j i j i

j i

e A K

/ , ,

,

=

j i j i

PM b PM b b B ⋅ + ⋅ + =

2 1 ,

[ ]

( )

2 3 4

2 1 2 2 1 ,             − −

⋅ + ⋅ + =

a a PM PM i i j i

i j

e PM a PM a a A

11.35 146.95 3 2.06E+06

  • 4.5

1.90E+08 42894 1.51E+12 b a

slide-57
SLIDE 57

$%

  • 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
slide-58
SLIDE 58
slide-59
SLIDE 59

Isomerization INPUT: Temperature H2/HC Ratio OUTPUT: Hydrocarbons C4-C6 MODEL: PFR

slide-60
SLIDE 60
slide-61
SLIDE 61
  • 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.

slide-62
SLIDE 62

A future of energy production…

  • n-Butane
  • n-Pentane
  • n-Hexane

2 4 2 4

2 1 4 H C iso H C n C n

P P K P P K r

− − −

⋅ + ⋅ − =

[ ]

( )

[ ]

5 5 125 . 2 5 2 5

1 0000197 .

C i eq C n eq C n C n

C K C K t H C K r

− − − −

⋅ + − ⋅         ⋅ −         ⋅ − =

∑ ∑

= =

+ ⋅         − =

5 1 , 5 1 , j j j i i j i j i

C K C K r

slide-63
SLIDE 63

A future of energy production…

  • Model inputs

– Temperature, mass flow rate, and H2/HC ratio

  • Model Product form

– Weight percents of the individual isomers

slide-64
SLIDE 64
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SLIDE 65

Hydrocracking INPUT: ºAPI Kw H2 /BBL OUTPUT: Naptha Light Heavy C3 Up i-Butane n-Butane Gas Oil MODEL: Correlation

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SLIDE 66

A future of energy production…

  • Convert higher boiling point petroleum fractions

into lighter fuel products

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SLIDE 67
  • 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

slide-68
SLIDE 68
  • Feedstocks- Heavy distillate stocks, aromatics,

cycle oils, and coker oils

  • Catalysts- zeolites
  • Operating conditions-

500-3000 2000-3000 Pressure (psi) 500-900 750 -800 Temperature (° F) 0.5-10 0.2-1 LHSV (hr-1) 1000-2400 1200-1600 Hydrogen Consumption (SCFB) Distillate Residuum

slide-69
SLIDE 69

"

  • Correlated data from “Oil and Gas

Journal” W.L. Nelson

  • Graphical correlated data was made

continuous for hydrogen feed rate, Kw and API of the feed

  • 3 inputs
  • 5 outputs
slide-70
SLIDE 70
slide-71
SLIDE 71 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

10 20 30 40 50 60 70 80 90 100 500 1000 1500 2000 2500 3000

Hydrogen Rate SCFB

32.5 30 27.5 25 22.5 20 17.5 15 12.5 10 7.5

slide-72
SLIDE 72

y = 1.852E-05x4 - 1.206E-03x3 + 2.920E- 02x2 - 2.531E-01x + 1.546E+00 R2 = 9.992E-01 0.5 1 1.5 2 2.5 3 3.5 4 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 0.0002 0.0004 0.0006 0.0008 0.001 0.0012 0.0014 0.0016 0.0018 10 20 30 40 API of Feed B Constant

slide-73
SLIDE 73

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

slide-74
SLIDE 74

y = -0.7691x + 11.739 R2 = 0.9916 0.5 1 1.5 2 2.5 3 3.5 4 10.5 11 11.5 12 12.5 Kw slope

slide-75
SLIDE 75

&

H B w

Ae K p vol

= ) 00833 . 00833 . 1 ( %

1

) % ( 11.739) + K 0.7691

  • (

%

1 w 2

p vol p vol ⋅ = ) % ( 0.337 %

1 3

p vol p vol =

) % ( 0.186 %

1 4

p vol p vol = ) % ( 0.09 1 %

1 5

p vol p vol + =

slide-76
SLIDE 76

Hydrogen (SCFB) 15 2500 12.1 16.4 39.9 actual 15.0 40.5 20 750 10.9 3.3 11.0 actual 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%

slide-77
SLIDE 77
slide-78
SLIDE 78

Solvent Dewaxing INPUT: Composition Temperature OUTPUT: Wax Lube Oil MODEL: Correlation

slide-79
SLIDE 79

A future of energy production…

!"#

  • Separate high pour point waxes from

lubricating oils

slide-80
SLIDE 80

!"#

  • 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

slide-81
SLIDE 81

# "

  • Correlation from “Energy and Fuels”

Krishna et. al.

  • 3 experimentally determined parameters
  • 3 inputs
  • 2 outputs

2 / 1 ) / 100 log( A CL A PC A PPT + + =

( ) ( )

) ( 100 ) ( 100 %) ( product PC feed PC wt OilYield − − =

slide-82
SLIDE 82

#

BC2 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 31 PPT 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= 10 PPT 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 0.5302 yield 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%

slide-83
SLIDE 83
slide-84
SLIDE 84

Alkylation INPUT: Iso-butane Butylene / Propylene Reaction time OUTPUT: Propane Butane Alkylate MODEL: Correlation

slide-85
SLIDE 85

' (

http://www.prod.exxonmobil.com/refiningtechnologies/pdf/AlkyforWR02.pdf

Exxon-Mobil Autorefrigeration H2SO4 alkylation

slide-86
SLIDE 86

'

*Lots of side reactions

slide-87
SLIDE 87

'

O F E

SV O I I F ) ( 100 ) / ( =

F

O I ) / (

=

E

I

=

O

SV ) (

= volumetric isobutane/olefin ratio in feed isobutane in reactor effluent, liquid volume %

F= Factor defined by A.V. Mrstik

  • lefin space velocity, v/hr/v

“Progress in Petroleum Technology” AV Mrstik et al. ACS Publications

slide-88
SLIDE 88
slide-89
SLIDE 89

Polymerization INPUT: Iso-butane Butylene / Propylene OUTPUT: Gasoline Diesel MODEL: Correlation

slide-90
SLIDE 90
  • Converts Propylenes and butylenes into saturated

carbon 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 C C C C C C C C + C C C → C C C C C C

  • Polymerization reaction is highly exothermic and temperature is

controlled 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.pdf http://www.personal.psu.edu/users/w/y/wyg100/fsc432/Lecture%2015.htm

slide-91
SLIDE 91

) ) ) )

  • Converts propylenes and butylenes into

saturated carbon chains by means of zeolite catalysis (ZSM-5)

slide-92
SLIDE 92

) ) ) )

  • Converts propylenes and butylenes into

saturated carbon chains by means of zeolite catalysis (ZSM-5)

slide-93
SLIDE 93

) ) ) )

  • Converts propylenes and butylenes into

saturated carbon chains by means of zeolite catalysis (ZSM-5)

79 MON 92 RON Octane 0.73 Specific Gravity

[Tabak, 1986]

slide-94
SLIDE 94

) ) ) )

Charge

  • 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 desired chain length

slide-95
SLIDE 95

) ) ) )

Charge

  • 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 desired chain length

slide-96
SLIDE 96

Polymerization

+ PBR-gas phase

  • Solid catalysis

+ Produce either diesel or gasoline range chains

  • Typical octane

number = 92 (RON)

Alkylation

  • CSTR- liquid phase

+ Liquid catalysis

  • Requires very vigorous

agitation

  • Typically .1lbm acid

consumed per gallon product ++Typical octane number = 96(RON)

VS

slide-97
SLIDE 97
slide-98
SLIDE 98

Deasphalting INPUT: %Heavies Temperature Pressure OUTPUT: %Heavies Lube oil MODEL: Correlation

slide-99
SLIDE 99

* + (

http://www.scielo.br/scielo.php?script=sci_arttext&pid=S0104-66322000000300012&lng=pt&nrm=iso

Typical Propane Deasphalting

slide-100
SLIDE 100

*

Types 1. Sub Critical. (below 369K) Modeled first by Robert E. Wilson in 1936. Hildebrand solubility parameters now used. 2. Super Critical. (above 369K) Now popular. High selectivity. No good model. Both remove greater than 99% asphalt

slide-101
SLIDE 101

!% *

2 1

        − ∆ = V T R H

g

δ

= δ

= ∆H

=

g

R

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]

slide-102
SLIDE 102

! *

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 at

T=400K Pressure=55 bar Ratio= 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

slide-103
SLIDE 103
slide-104
SLIDE 104

Catalytic Cracking INPUT: Kw Temperature OUTPUT: Gas Oil Gasoline LPG Dry Gas Coke MODEL: PFR

slide-105
SLIDE 105

(

  • Pretreated feedstock is fed into

the bottom of the riser tube where it meets very hot regenerated catalyst.

  • The feed vaporizes and is

cracked as it passes up the riser.

1

http://www.uyseg.org/catalysis/petrol/petrol2.htm

slide-106
SLIDE 106

(

  • Different yields of products will
  • ccur depending on:

Temperature Inlet Feed Properties

  • Top of the riser, the catalyst

separates from the mixture and is steam stripped

  • The final product exits the top
  • f the reactor

2

http://www.uyseg.org/catalysis/petrol/petrol2.htm

slide-107
SLIDE 107

(

  • One product from catalytic

cracking is “coke” or carbon that forms on the surface of the catalyst.

  • To reactivate catalyst, it must

be regenerated.

3

http://www.uyseg.org/catalysis/petrol/petrol2.htm

slide-108
SLIDE 108

(

  • Catalysis is regenerated by

entering a combustion chamber and mixed with superheated air

  • Energy released from

regenerating the catalysis is then coupled with the inlet feed at the bottom of the riser Cracking

4

http://www.uyseg.org/catalysis/petrol/petrol2.htm

slide-109
SLIDE 109

A B C D E

Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231

(

slide-110
SLIDE 110

A B C D E

Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231

(

slide-111
SLIDE 111

A B C D E

Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231

(

slide-112
SLIDE 112

A B C D E

Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231

(

slide-113
SLIDE 113

A B C D E

  • 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

(

slide-114
SLIDE 114
  • Assumptions

– One-dimensional tubular reactor

  • No radial and axial dispersion

– Cracking only takes place in the riser – Dispersion/Adsorption inside catalyst is negligible – Coke deposited does not affect the fluid flow

(

slide-115
SLIDE 115
  • Change

– Temperature – Inlet Feed Mass Balance:

dt dt dC C C

i i

*

0 +

=

(

i C L i

r WHSV dz dy ∗ = ) ( 1 ρ ρ

slide-116
SLIDE 116
  • Change

– Temperature – Inlet Feed Mass Balance:

dt dt dC C C

i i

*

0 +

=

(

i C L i

r WHSV dz dy ∗ = ) ( 1 ρ ρ

TEMPERATURE: 480, 500, 520 ºC

slide-117
SLIDE 117
  • Constant C/O Ratio of 5
  • Varying space velocity (WHSV)

6 – 48 h-1

  • Gas Oil Conversion ~ 70 %
  • Gasoline ~ 50%
  • LPG ~ 12 %

(

slide-118
SLIDE 118
  • Constant C/O Ratio of 5
  • Varying space velocity (WHSV)

6 – 48 h-1

  • Gas Oil Conversion ~ 70 %
  • Gasoline ~ 50%
  • LPG ~ 12 %

(

slide-119
SLIDE 119
  • Constant C/O Ratio of 5
  • Varying space velocity (WHSV)

6 – 48 h-1

  • Gas Oil Conversion ~ 70 %
  • Gasoline ~ 50%
  • LPG ~ 12 %

(

slide-120
SLIDE 120
slide-121
SLIDE 121

Blending INPUT: 35 streams OUTPUT: Gasoline Regular Premium LPG Coke Lube Oil Wax Asphalt

slide-122
SLIDE 122

A future of energy production…

,

  • Final products are created by blending

streams 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, and coke

slide-123
SLIDE 123

,#

  • Most properties do not blend linearly
  • Empirical blending indexes are used to

linearize the blending behavior

=

i i i mix

BI x BI

i component

  • f

fraction volume the is Index Blending the is Where

i

x BI

slide-124
SLIDE 124

,#

     

=

08 . 1 p p

T BI Pour Point

ν ν

10 10

log 3 log + =

v

BI Viscosity Index

     

=

05 . 1 CL CL

T BI Cloud Point

6 . 42 2414 1188 . 6 log10 − + − =

F F

T BI

Flash Point

( )

[ ]

AP BI AP 00657 . exp 124 . 1 =

Aniline Point

( )

25 . 1

RVP VPBI =

Reid Vapor Pressure

slide-125
SLIDE 125
  • ,
  • 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
slide-126
SLIDE 126
  • ,
  • Vapor pressure blending can be

improved by using thermodynamically based methods

  • Raoult's Law

=

* i iP

x P

slide-127
SLIDE 127

,

  • Other possible products

– Fuel oils – Lube oils – Diesel fuel

  • Blending requires data for aniline point,

pour point, cloud point, flash point, and diesel index

slide-128
SLIDE 128
  • Addresses the planning of short-term crude oil

purchasing 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
slide-129
SLIDE 129

A future of energy production…

slide-130
SLIDE 130

A future of energy production…

slide-131
SLIDE 131

A future of energy production…

slide-132
SLIDE 132

A future of energy production…

slide-133
SLIDE 133
  • . #

∑∑ ∑∑ ∑∑

∈ ∈ ∈ ∈ ∈ ∈

∗ − ∗ − ∗ =

T t C c T t C c t c t c t c t c t c T t C c t c

  • p

p

cl AL co AC cp MANU

, , , , , ,

Pongsakdi, Arkadej, et. al, “Financial risk….”, Int. J. Production Economics, accepted 20 April 2005

slide-134
SLIDE 134
  • . #

∑∑ ∑∑ ∑∑

∈ ∈ ∈ ∈ ∈ ∈

∗ − ∗ − ∗ =

T t C c T t C c t c t c t c t c t c T t C c t c

  • p

p

cl AL co AC cp MANU

, , , , , ,

!

Amount of product produced in that time period multiplied by unit sale price of product c Pongsakdi, Arkadej, et. al, “Financial risk….”, Int. J. Production Economics, accepted 20 April 2005

slide-135
SLIDE 135
  • . #

∑∑ ∑∑ ∑∑

∈ ∈ ∈ ∈ ∈ ∈

∗ − ∗ − ∗ =

T t C c T t C c t c t c t c t c t c T t C c t c

  • p

p

cl AL co AC cp MANU

, , , , , ,

!

Amount of product produced in that time period multiplied by unit sale price of product c

/

Amount of crude oil refined in that time period multiplied by unit purchase price of crude oil Pongsakdi, Arkadej, et. al, “Financial risk….”, Int. J. Production Economics, accepted 20 April 2005

slide-136
SLIDE 136
  • . #

∑∑ ∑∑ ∑∑

∈ ∈ ∈ ∈ ∈ ∈

∗ − ∗ − ∗ =

T t C c T t C c t c t c t c t c t c T t C c t c

  • p

p

cl AL co AC cp MANU

, , , , , ,

!

Amount of product produced in that time period multiplied by unit sale price of product c

/

Amount of crude oil refined in that time period multiplied by unit purchase price of crude oil

#

Amount of product volume that cannot satisfy demand multiplied by discounted price Pongsakdi, Arkadej, et. al, “Financial risk….”, Int. J. Production Economics, accepted 20 April 2005

slide-137
SLIDE 137
  • A Visual Basic macro in Excel was used

to help Solver find the optimal crude selection

slide-138
SLIDE 138
  • A Visual Basic macro in Excel was used

to help Solver find the optimal crude selection

slide-139
SLIDE 139
  • Inputs:

– 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 Energy http://www.eia.doe.gov/oil_gas/petroleum/info_glance/petroleum.html

slide-140
SLIDE 140
  • 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

slide-141
SLIDE 141

(0

  • 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.

slide-142
SLIDE 142

12