- Aaron Smith, Michael Frow,
Joe Quddus, Donovan Howell, Thomas Reed, Clark Landrum, Brian Clifton May 2, 2006
Aaron Smith, Michael Frow, Joe Quddus, - - PowerPoint PPT Presentation
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
Joe Quddus, Donovan Howell, Thomas Reed, Clark Landrum, Brian Clifton May 2, 2006
Demand Crude B Crude C Crude A Costs Profit
Demand Crude B Crude C Crude A Costs Profit
Hydrotreating INPUT: Temperature Pressure H2/HC Ratio Sulfur % Nitrogen % OUTPUT: Sulfur % Nitrogen % Aromatic % MODEL: PBR
http://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_2fig25.gif
A future of energy production…
aromatics.
increased sulfur removal requirements.
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
– Therefore, properties such as density and molecular weight are assumed to be constant.
– Therefore, properties such as density and molecular weight are assumed to be constant.
– Rates= ksCs2CH2.75 – Raten= knCn1.4CH2.6 – Ratear= karCarCH2
http://www.chem.wwu.edu/dept/facstaff/bussell/research/images/thio-HDS.jpg
Delayed Coking INPUT: CCR Pressure OUTPUT: Gas Oil Coke Gas Naptha MODEL: Correlation
bottoms from the vacuum distillate.
portion into usable napthas, gas, and gas oil.
– Shot Coke – Sponge Coke – Needle Coke
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
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%)
– 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
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%)
Catalytic Reforming INPUT: Temperature Pressure % Napthenes % Aromatics % Paraffins OUTPUT: Hydrogen LPG Reformate MODEL: PBR
Xylenes Isomerization Boilers
Case Study 108 by Rase
2 2
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
+ → ←
−
)( )( )
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
( )( )
. _ _ _ _ _ *
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
= = −
Xylenes Isomerization INPUT: Temperature OUTPUT: Benzene Toluene O-Xylene P-Xylene Ethyl-Benzene MODEL: Correlation
Paraffins & Napthenes - Blending Mixed Aromatics – Fractionation
Benzene & Toluene – Solvent Quality Xylenes – Isomerization C9+ Aromatics – Blending
O-Xylene – Chemical Feedstock Mixed Aromatics – Blending P-Xylene – Chemical Feedstock
modeled in Kirk-Othmer Encyclopedia of Chemical Technology
ne EthylBenze Xylene p Xylene
m → ← − → ← − → ← −
Solvent Extraction INPUT: Temperature S/F Ratio OUTPUT: Lube Oil Aromatics MODEL: Correlation
Paraffinic Oils - Solvent Dewaxing Mixed Aromatics – Blending
– Benzene from Cyclohexane – Benzene from Iso-octane – 1,6-diphenylhexane from Docosane
=
− =
N n n
E Extracted 1 1 %
F S K E * =
( )
371 . 7 * 0259 . 5 2
2
− + − = T E T K
du Pétrole data
( )
9318 . 0426 . * % + − = F S ield RaffinateY
( )
9229 . ) 0073 . ( * 0004 . * . .
2
+ − = F S F S G RaffinateS
Visbreaker INPUT: Temperature OUTPUT: Gas Gasoline Gas Oil Residue MODEL: PFR
carbon numbers
A future of energy production…
Si-2 + O2 Si-3 + O3 Si-j + Oj S2 + Oi-2 S1 + Oi-1
Si
A future of energy production…
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
− = + =
− =
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 =
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
1.90E+08 42894 1.51E+12 b a
– Temperature and mass flow rate
– Weight percents – Components are lumped into 4 categories
Isomerization INPUT: Temperature H2/HC Ratio OUTPUT: Hydrocarbons C4-C6 MODEL: PFR
– 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.
A future of energy production…
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
A future of energy production…
– Temperature, mass flow rate, and H2/HC ratio
– Weight percents of the individual isomers
Hydrocracking INPUT: ºAPI Kw H2 /BBL OUTPUT: Naptha Light Heavy C3 Up i-Butane n-Butane Gas Oil MODEL: Correlation
A future of energy production…
into lighter fuel products
– Cracking reactions
R-C-C-C-R + heat → R-C=C + C-R
– Hydrogenation reactions
R-C=C + H2→ R-C-C + heat
cycle oils, and coker oils
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
Journal” W.L. Nelson
continuous for hydrogen feed rate, Kw and API of the feed
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
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
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
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
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
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
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
H B w
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 + =
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%
Solvent Dewaxing INPUT: Composition Temperature OUTPUT: Wax Lube Oil MODEL: Correlation
A future of energy production…
lubricating oils
– Distillate and residual stocks – heavy gas oils – Solvents – Ketones (MEK) and Propane
– Solvent to oil ratio 1:1 to 4:1 – Desired pour point of product
Krishna et. al.
2 / 1 ) / 100 log( A CL A PC A PPT + + =
( ) ( )
) ( 100 ) ( 100 %) ( product PC feed PC wt OilYield − − =
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%
Alkylation INPUT: Iso-butane Butylene / Propylene Reaction time OUTPUT: Propane Butane Alkylate MODEL: Correlation
http://www.prod.exxonmobil.com/refiningtechnologies/pdf/AlkyforWR02.pdf
Exxon-Mobil Autorefrigeration H2SO4 alkylation
*Lots of side reactions
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
“Progress in Petroleum Technology” AV Mrstik et al. ACS Publications
Polymerization INPUT: Iso-butane Butylene / Propylene OUTPUT: Gasoline Diesel MODEL: Correlation
carbon chains
silica fell out of popularity in 1960s.
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
controlled either by injecting cold propane quench or by generating steam.
CO School of Mines http://jechura.com/ChEN409/11%20Alkylation.pdf http://www.personal.psu.edu/users/w/y/wyg100/fsc432/Lecture%2015.htm
saturated carbon chains by means of zeolite catalysis (ZSM-5)
saturated carbon chains by means of zeolite catalysis (ZSM-5)
saturated carbon chains by means of zeolite catalysis (ZSM-5)
79 MON 92 RON Octane 0.73 Specific Gravity
[Tabak, 1986]
Charge
Temperature = 550K Total Pressure = 5430 kPa
Propylene partial pressure = 7~3470kPa.
*Depending on desired chain length
Charge
Temperature = 550K Total Pressure = 5430 kPa
Propylene partial pressure = 7~3470kPa.
*Depending on desired chain length
Polymerization
+ PBR-gas phase
+ Produce either diesel or gasoline range chains
number = 92 (RON)
Alkylation
+ Liquid catalysis
agitation
consumed per gallon product ++Typical octane number = 96(RON)
VS
Deasphalting INPUT: %Heavies Temperature Pressure OUTPUT: %Heavies Lube oil MODEL: Correlation
http://www.scielo.br/scielo.php?script=sci_arttext&pid=S0104-66322000000300012&lng=pt&nrm=iso
Typical Propane Deasphalting
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
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]
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
Catalytic Cracking INPUT: Kw Temperature OUTPUT: Gas Oil Gasoline LPG Dry Gas Coke MODEL: PFR
the bottom of the riser tube where it meets very hot regenerated catalyst.
cracked as it passes up the riser.
1
http://www.uyseg.org/catalysis/petrol/petrol2.htm
Temperature Inlet Feed Properties
separates from the mixture and is steam stripped
2
http://www.uyseg.org/catalysis/petrol/petrol2.htm
cracking is “coke” or carbon that forms on the surface of the catalyst.
be regenerated.
3
http://www.uyseg.org/catalysis/petrol/petrol2.htm
entering a combustion chamber and mixed with superheated air
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
A B C D E
Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231
A B C D E
Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231
A B C D E
Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231
A B C D E
Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231
A B C D E
Ancheyta-Juarez, Jorge, “Estimation of Kinetic Constants….”, Energy & Fuels, 2000, 14, 1226-1231
– One-dimensional tubular reactor
– Cracking only takes place in the riser – Dispersion/Adsorption inside catalyst is negligible – Coke deposited does not affect the fluid flow
– 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 – 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
6 – 48 h-1
6 – 48 h-1
6 – 48 h-1
Blending INPUT: 35 streams OUTPUT: Gasoline Regular Premium LPG Coke Lube Oil Wax Asphalt
A future of energy production…
streams from refinery units
– Propane gas, lube oil, asphalt, wax, and coke
linearize the blending behavior
=
i i i mix
BI x BI
i component
fraction volume the is Index Blending the is Where
i
x BI
=
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
– Octane (normal 87, premium 91) – Reid Vapor Pressure (EPA mandated) – Maximum additive amounts
– Market conditions (Price, Demand) – Incoming streams from refinery units
improved by using thermodynamically based methods
* i iP
– Fuel oils – Lube oils – Diesel fuel
pour point, cloud point, flash point, and diesel index
purchasing and processing
– Specification (Octane, n-Butane, etc.) – Demand with HIGHEST profit
– Crude oil purchase – Processing variables
A future of energy production…
A future of energy production…
A future of energy production…
A future of energy production…
∈ ∈ ∈ ∈ ∈ ∈
∗ − ∗ − ∗ =
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
cl AL co AC cp MANU
, , , , , ,
Pongsakdi, Arkadej, et. al, “Financial risk….”, Int. J. Production Economics, accepted 20 April 2005
∈ ∈ ∈ ∈ ∈ ∈
∗ − ∗ − ∗ =
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
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
∈ ∈ ∈ ∈ ∈ ∈
∗ − ∗ − ∗ =
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
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
∈ ∈ ∈ ∈ ∈ ∈
∗ − ∗ − ∗ =
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
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
to help Solver find the optimal crude selection
to help Solver find the optimal crude selection
– Crude A: $71.88 / barrel (Australia) – Crude B: $72.00 / barrel (Kazakhstan) – Crude C: $71.20 / barrel (Saudi Arabia) – Regular Gasoline:
– Premium Gasoline:
Energy Information Administration, U.S. Department of Energy http://www.eia.doe.gov/oil_gas/petroleum/info_glance/petroleum.html
– Maximum Profit: $21 per barrel – Crude Selection:
– Demand exactly met
solvents, fuel oils, lube oils, etc.