refinery planning with an integrated model for fluid catalytic cracking (fcc)

8/12/2019 Refinery Planning with an Integrated Model for Fluid Catalytic Cracking (FCC)

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2010 Aspen Technology, Inc. All rights reserved

November 2010

Refinery Planning with an Integrated Modelfor Fluid Catalytic Cracking (FCC)

Presented by: Prof. Y. A. Liu, Kiran PashikantiVirginia Tech-Sinopec


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Refinery planning with integrated

FCC modelKiran Pashikanti*

Y.A. Liu**

Yun Shen and Peng Zhang +

Yanhua Qi and Jianzhang Qiu + +

Yushi Chen, Xumei Di and Jianping Wang +++

AspenTech/ SINOPEC Center of Excellence in Process System EngineeringDepartment of Chemical Engineering

Virginia Polytechnic Institute and State University, Blacksburg, VA 24061*Email: [email protected]

; phone: (540) 231-3980**Email: [email protected]; phone : (540) 231-7800

+ SINOPEC Yangzi Petrochemical Corporation, Nanjing+ + SINOPEC Research Institute for Petroleum Processing, Beijing

+++ SINOPEC Petro-Cyber Works Information Technology Co., Ltd. Shanghai
mailto:[email protected]:[email protected]


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Overview

IntroductionSINOPEC Yangzi (YZ) FCC process

Model development and resultsCase studies: Gasoline yield, feed rate, feed blends

Aspen PIMS LP application

Key business benefitsConclusions


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Yangzi Petrochemical Corporation(SINOPEC)

YangziPetrochemical

Yangzi Refinery Capacity(Current) 9.0 million tons/year 180,722 Barrels/day (BPD)


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YZPC FCC process

UOP one-riser, one-regenerator configuration

115 tons/day (19,000 BPD)

Feeds: VR, VGO, CGOMaximum Gasoline-Diesel(MGD) Process multiplefeed points in FCC riser

Product

T-102REGEN

T-101REACTOR

Lift Gas

Mixed Feed

Dispersion Steam

Lift Gas Steam

Stripping Steam

Steam

Steam

Flue Gas

Air/O 2 Mix

Off-Spec and HN Recycle

VR Vacuum Resid

VGO Vacuum Gas Oil

CGO Coker Gas Oil


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Available process data

Mixed Feed

Partial D-1160 (up to 70%)

Density (kg/m3)

Concarbon (wt%)

Metals (Na, Ni, V, etc.)

SARA (Saturates, Aromatics, Resins, Asphaltenes) (wt%)

Sulfur and Nitrogen


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Available process dataProducts

Yields (flowrate) of key products: Dry gas, LPG, gasoline, diesel,slurry and coke (calculated by difference)

Key properties of liquid products: Density, sulfur content, flashpoint, ASTM D-86 distillation (gasoline and diesel)

Complete lab analysis of gas products with full C3 and C4 molarcompositions


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Contributions

Extend partial distillation curves with log-normal and beta statistical functions

Improves prediction of aromatic kineticlumps (2% - 4% deviation from plantmeasurement)


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Contributions


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Contributions

Standard petroleumcomponent list does not

include thesecomponents

Consistent with plantmeasurements

cis-2-butene

2M-13-C4==

tr2-Pentene

cis2-Pentene

2M-2-butene

3M-1-butene

Cyclopentene

Cyclopentane

Benzene


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Model development

Obtain five months of plant data(Jan-09 to May-09)

Remove extraneous datasetsExtend distillation curves

Model based on Jan-09 dataCalibrate

Validate model continuouslywith updated data sets

Optimization case studiesLP application study


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HYSYS/Refining model

Rigorous Tray-by-Tray simulation ofmain fractionationcolumn

Short-cut separation

with componentsplitter for quickviews of plant cuts

FCC with complete gas plantincluding overheadcompressors, absorbers andstabilizers


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HYSYS/Refining model

Originally developed in 2006.5Updated to 7.0Verified to work well with 7.1

No changes are required from either2006.5 or 7.0

Model must be solved from scratchwhen versions change (5-10 minutes)


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Results:Fractionated product yields

Calibration-case:

LPG shows the largestdeviation (1.5%), so we expectlargest deviations in LPG

Validation-case:

Good agreement with keyplant products (gasoline,diesel)

Dry gas and slurry are notsignificant to the user


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Results (Validation):LPG composition

Model shows good agreementwith measured plant values

NOTE: These values are nottotal yields but thefractionated yields from therigorous de-propanizercolumn


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Results (Validation):Dry gas

Model shows good agreementwith measured plant valuesfor key components C1, C2,C2=

NOTE: These values are nottotal yields but thefractionated yields from therigorous de-C2 column

H2 yields deviate because H2is calculated by difference incalibration


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Results (Validation):ASTM D-86

Prediction of the distillation curvesfor gasoline and diesel are importantto the refinery.

Correlations based on the distillationand density yield flash point andassociated properties.

The model shows good predictionsfor distillation curves (from rigorousfractionation).

Calculated flash point meets refineryspecification target (


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Results (Validation):Density and flash point

HYSYS petroleum componentsaccurately represent the densities ofthe diesel and gasoline product

Refiner is satisfied with the flashpoint prediction. It is consistent withthe refiners own internalcorrelations.


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Results (Validation):Operating temperature profiles

The model is also a guide to help pin-point problems with processequipment.

The prediction of the temperatureprofile is critical for optimizing thecuts from the main fractionator

NOTE: We use rigorous models for allcolumns


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Case Study 1:Gasoline optimization

TypicalOperatingrange (+-5 C)

Maximum Gasoline


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Case Study 2:Feed rate changes

The curve for 540C isbelow that of 510C

because of gasolineovercracking

We expect the curve forthe 540 C ROT here


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Case Study 3:Blending VR with VGO feed

VR = Vacuum Resid VGO = Vacuum Gas Oil

VR is a cheaper feedstock to use and improves profitability

How much VR can we blend with VGO while meeting sulfur limit of stabilizedgasoline?


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Existing Aspen PIMS tableThe base vector comesfrom averaged yieldsbased on historicaldata (last quarter,2008)

The delta-vectors forSPG (specific gravity),CON (concarbon) andSUL (sulfur) areestimated from plantexperience with thefeed type


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LP-vector generation for PIMS

Historical

Current Plant Data

Create model with HYSYS

Calibrate and validate

Repeat until model isvalidated Apply model for different

simulation cases

ASW

New scenarios:

Increase gasoline production

Change feed rate

Updated PIMS vectors

Reflects refinery operation more accurately


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Linearizing FCC model


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Linearizing FCC model

Use the delta-base utility tool from HYSYS Utilities menu

(Now called Aspen PIMS Support Utility)


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* Gasoline Plan

TEXT BA1 SPG CON SUL

FREE 1 1 1

WBALC1F FCC FEED

WBALHS3 FCC Sour Gas -0.0065 -0.0003 -0.0004 -0.0082

WBALGAS Dry Gas -0.0394 -0.0011 -0.0014 0.0000

WBALFCL LPG after de-Sulfur -0.1740 0.0025 0.0041 0.0000

WBALFCN FCC Gasoline -0.3929 0.0098 0.0081 0.0000

WBALFCD FCC Diesel -0.2899 -0.0057 -0.0033 0.0000

WBALFCR FCC Slurry -0.0381 -0.0032 -0.0038 0.0082

WBALCKE FCC Coke -0.0544 -0.0020 -0.0034 0.0000WBALLOS Loss -0.0048 0.0000 0.0000 0.0000

BA1 SPG CON SUL

-0.00439 0.00068 0.00007 -0.00567

-0.02527 0.00069 0.00033 0.00025

-0.19386 0.02213 0.00271 0.00164

-0.4421 0.09480 0.00621 0.00330

-0.16058 -0.07677 -0.00175 0.00040

-0.11163 -0.10067 -0.00305 -0.00030

-0.06218 0.05913 -0.00453 0.00038

Partial results for a new delta-base-table computed from therigorous model. This tablecorrectly reflects current unitoperation.

The old table consistentlyunderestimates gasoline and LPGyields, thus underestimating theactual product profits . Updated PIMS vectors from Common Model Utility


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Examples of beneficial changes inprocess operations

Improving equilibrium catalyst activity (MAT)from 66% to 68.5% results in more profitable

product distribution (10.2 million RMB/yr),while coke yield remains under 6.5%

Increasing riser outlet/reactor pressure from300 kPa to 310 kPa promotes higher LPG andgasoline yield (3.0 million RMB/yr)


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Economic paybackMillion RMB/yr Million USD/yr

FCC 13.23 1.94

MP HCR 24.36 3.57

HP HCR 7.29 1.07

Reformer 3.46 0.51

Total 48.34 7.08

Through changes in process operations without new investment as identifiedby Apsen HYSYS Petroleum Refining modeling and optimization

Evaluated by SINOPEC ,Yangzi Petrochemical Corporation (March 2010)


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Related work

Our group has also modeled:Catalytic Reformer

High-Pressure HydrocrackerMedium-Pressure Hydrocracker

Complete plant-scale models for YangziPetrochemical Corporation withdownstream fractionations


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Thank you!AspenTech

Steven Dziuk

Darin CampbellGlenn DissingerZhiming Huang

Chau-Chyun ChenVikas DholeJohn Adams

Maurice Jett

SINOPEC

Dai Houliang

Cao XianghongLi DefangPan Xinrong

Guan Xinhu


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2010 Aspen Technology, Inc. All rights reserved | 35

AspenTech TrainingGetting the most from your people and your software

I was able to use what I learned in this class and within an hour close themultiple recycle loops that had been bothering us for months

Accelerateknowledge transfer

Establishbest practices

Learn fromindustryexperts

Raiseskill levels

Unlock greaterbusiness value


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Want to see similar results?

http://support.aspentech.com/training

Consider a training class from AspenTech
http://support.aspentech.com/traininghttp://support.aspentech.com/traininghttp://support.aspentech.com/training


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Aspen HYSYS Training

Process Modeling (Refining Industry Focus) (EHY102)December 13, 2010 Houston, Texas

January 4, 2011 Virtual - Americas

January 31, 2011 Houston, Texas

February 22, 2011 Houston, Texas

http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102

Optimize engineering work processes using the full power and flexibility of Aspen HYSYS to build, evaluate and optimize flowsheets.

Learn the shortcuts for efficient use of the software to build steady statesimulations for refining processes.
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102


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Aspen HYSYS Petroleum Refining:Refinery Modeling (Aspen RefSYS) (EHY341)

December 15, 2010 Houston, Texas


March 21, 2011 Houston, Texas


Gain experience on the use of the most advanced technology for rigorousrefinery simulation

Utilize flowsheet and FCC reactor model to understand refinerys trueoperating window

Explore the data generation tools which enable improved planning andscheduling decisions


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Aspen HYSYS: Using Aspen Simulation Workbook (EHY121)

December 3, 2010 Houston, Texas


May 7, 2011 Houston, Texas

May 9, 2011 Virtual - Americas


Embed and link an Aspen HYSYS Simulation case and variables withinMS Excel without using any programming languages.

Link models with process data and create plant data tables.

Learn how to publish and deploy models using ASW.

Prepare a standard basis project.


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Aspen PIMS Training

Aspen PIMS: Introduction to Refinery Planning (RPA101)

December 6 , 2010 Houston, Texas


January 10, 2011 Reading, UK


http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=RPA101

Build refinery LP planning models in PIMS to generate optimum plansincluding evaluating alternative crudes, intermediate feedstocks, outsideblendstocks, process unites, products, and markets.

Develop LP structure in order to solve optimization problem includinginterpreting and analyzing the LP solutions.
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=RPA101http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=RPA101


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AspenTech Training: Making it easy

Simply by participating today you have earned a 10% trainingdiscount to help you get started

1. You will receive a Discount Coupon. Fill in your details. This coupon isonly valid for use by the webinar attendee and is not transferable.

2. Go to AspenTech training website http://support.aspentech.com/trainingand select the course you want to attend and register for the course

3. Email the completed Discount Coupon to the respective AspenTechtraining coordinators in your region

4. The training coordinator will process your registration with the discounted

rate.5. The discount expires December 31, 2010. Registration must take place

before expiration for the discount to apply. No restriction on the coursedate.

Save the Date!
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Questions


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Contact Information

Prof Y.A LiuVirginia TechEmail: [email protected]

Kiran PashikantiVirginia TechEmail: [email protected]

Steve Dziuk AspenTech (Aspen HYSYS family Product Manager)Email: [email protected]

Ken Dooley AspenTech (Industry Marketing)Email: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Thank you.

refinery planning with an integrated model for fluid catalytic cracking (fcc)

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