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Crude Distillation Unit Simulation using PRO/II with PROVISION for FPCC

Crude Distillation Unit Simulation using PRO/II with PROVISION for FPCC. Prepared by Dr. Jungho Cho. Minimum Information for Crude Distillation Unit Simulation. Whole crude TBP data Whole crude API Lightends analysis about up to C4. Modeling an Atmospheric Crude Tower.

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Crude Distillation Unit Simulation using PRO/II with PROVISION for FPCC

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  1. Crude Distillation Unit Simulationusing PRO/II with PROVISIONfor FPCC Prepared by Dr. Jungho Cho

  2. Minimum Information for Crude Distillation Unit Simulation • Whole crude TBP data • Whole crude API • Lightends analysis about up to C4

  3. Modeling an Atmospheric Crude Tower -25.17x106Kcal/hr -27.80x106Kcal/hr OFF GAS o 161 C 1.41K 123oC 60oC 0.97K LSR : 3,549 T/D (16.9wt%) 0.97K 1 132oC -13.94x106Kcal/hr 376,130 Kg/hr 10 o 180 C , 1.53K 15 STM1 : 1313 Kg/hr 192oC 168oC o HSR : 921 T/D (4.39 wt%) 169 C 28 -9.14x106Kcal/hr 234,857 Kg/hr 31 o 219 C , 1.68K 228oC STM2 : 1243 Kg/hr o 209 C KERO : 1,333 T/D (6.35 wt%) 221oC 38 -12.25x106Kcal/hr 298,087 Kg/hr 43 o 273 C , 1.76K 281oC STM3 : 3418 Kg/hr o 265 C LGO : 3,822 T/D (18.2 wt%) CRUDE : 21,000 T/D 15oC 268oC o 364 C 49 358 o C -16.50x106Kcal/hr 56 STM4 : 11603 Kg/hr o 349 C , 1.85K RESIDUE : 11,375 T/D (54.16 wt%)

  4. Problem Description: • A crude unit is designed to process 21,000 tons per day of 50% • Arabian heavy crude and 50% Arabian light crude. The desired • products are shown in the next slide, with specifications in Table 1. • 250oC steam (assumed to be saturated) is available for stripping. • The condenser is to operate at 123oC and 0.97 Kg/cm2G. • An initial simulation model was constructed as shown in the above • slide. ASTM D86 95% temperatures were used for HSR, Kerosene • and LGO. The overflash (0.03) was set as a specification. A partial • condenser was used to meet the desired temperature of 123oC.

  5. ASTM D86 Temperatures for Side Distillates Products GAP = 2 (-3) GAP = 11 (3) GAP = 12 (3)

  6. Feedstock Characterization for Crude Oils

  7. Feedstock Characterization for Crude Oils

  8. Plot of TBP vs. Liquid Volume % for Arabian Heavy Crude

  9. Lightend Analysis for Arabian Heavy Crude

  10. Feedstock Characterization for Crude Oils

  11. Plot of TBP vs. Liquid Volume % for Arabian Light Crude

  12. Comparison of TBP Curve for Arabian Heavy & Light Crude

  13. Feedstock Characterization for Crude Oils

  14. Lightend Analysis for Arabian Light Crude

  15. Description of PRO/II Input File

  16. Shortcut Simulation 2 #1 3 #2 4 #3 1 5 #4 6

  17. Part 1: Shortcut Simulation TITLE PROB=SHORT,PROJECT=FPCC,USER=DR_JHCHO $$ SHORTCUT MODEL FOR CRUDE UNIT TO CHECK PRODUCT RATES $$ DIME METRIC, LIQV=BBL PRINT STREAM=PART, TBP, INPUT=NONE COMP DATA LIBID 1,H2O/2,C2/3,C3/4,IC4/5,NC4/6,IC5/7,NC5 ASSAY CONV=API63 THERMO DATA METHODS SYSTEM=BK10 STREAM DATA $ PROP STRM=ARAB-H, TEMP=15, PRES=5.033, RATE(WT)=437500, ASSAY=LV SPGR STREAM=ARAB-H, AVG=0.8843,& DATA=4.9035,0.6348/* 4.9657,0.7603/* 6.3165,0.6643/* 7.8273,0.6733/* 8.0584,0.7736/* 9.4522,0.6953/* 11.0033,0.7128/* 11.8134,0.7342/* 13.2141,0.7258/* 14.1386,0.7349/* 15.7578,0.7427/* 17.3845,0.7512/* 18.9837,0.7592/* File Name : Short-BK10.bkp

  18. Part 1: Shortcut Simulationcontinued UNIT OPERATIONS DATA SHORTCUT UID=S01 FEED ARAB-H,ARAB-L,STM1,STM2,STM3,STM4 PROD STREAM=LSR,PHASE=M,PRES=2.443,CUTP(WT)=16.9 PROD STREAM=HSR,PHASE=L,PRES=2.563,CUTP(WT)=21.25 PROD STREAM=KERO,PHASE=L,PRES=2.713,CUTP(WT)=27.6 PROD STREAM=LGO,PHASE=L,PRES=2.793,CUTP(WT)=45.8 PROD STREAM=RESI,PHASE=L,PRES=2.85 COND TYPE=MIXED,TEMP=123 EVALUATE MODEL=REFINE SPEC STREAM=LSR,D86(95),VALUE=153 SPEC STREAM=HSR,D86(5),MINUS,STREAM=LSR,D86(95),VALUE=12 SPEC STREAM=HSR,D86(95),VALUE=196 SPEC STREAM=KERO,D86(5),MINUS,STREAM=HSR,D86(95),VALUE=2 SPEC STREAM=KERO,D86(95),VALUE=234 SPEC STREAM=LGO,D86(5),MINUS,STREAM=KERO,D86(95),VALUE=11 SPEC STREAM=LGO,D86(95),VALUE=337 SPEC STREAM=RESI,RATE(WT),VALUE=473958 FLASH UID=F01 FEED LSR PROD V=VLSR,L=LLSR ISO TEMP=123,PRES=2.003 END

  19. Result Summary for Shortcut (I) ------------- TOTAL STREAM RATES ------------- MOLES WEIGHT LIQUID VOL NORM VAPOR(1) NUM STREAM + PHASE KG-MOL/HR KG/HR BBL/HR M3/HR SECTION TRAYS ------------ - ---------- ---------- ---------- ---------- ------- ----- LSR M 2732.26 162701.65 1423.18 61240.95 1 5.69 HSR L 274.33 39715.51 319.51 6148.78 2 7.29 KERO L 255.80 43070.21 336.65 5733.44 3 4.92 LGO L 761.41 173131.08 1282.52 17066.23 4 3.56 RESI L 958.41 473958.25 3067.05 21481.71 TOTALS 4982.21 892576.70 6428.92 111671.10 21.45 SPECIFICATIONS PARAMETER COMP. SPECIFICATION SPECIFIED CALCULATED TYPE NUM TYPE VALUE VALUE ----------------- ------- ------------- ---------- ---------- STRM LSR D86 95 PCT 1.530E+02 1.530E+02 STRM HSR D86 5 PCT 1.200E+01 1.200E+01 STRM HSR D86 95 PCT 1.960E+02 1.960E+02 STRM KERO D86 5 PCT 2.000E+00 1.961E+00 STRM KERO D86 95 PCT 2.340E+02 2.340E+02 STRM LGO D86 5 PCT 1.100E+01 1.100E+01 STRM LGO D86 95 PCT 3.370E+02 3.370E+02 STRM RESI WT RATE 4.740E+05 4.740E+05

  20. Result Summary for Shortcut (II) LSR 3,644 T/D (3,549) #5.69 HSR #7.29 953 T/D (921) KERO #4.92 1,034 T/D (1,333) CRUDE LGO #3.56 4,155 T/D (3,822) 21,000 T/D RESID 11,214 T/D (11,375) Min No of Tray = 21.45 File Name = SHORT-BK10.out

  21. Shortcut Result for GS Method (III) BK10 GS DESIGN LSR 3,644 T/D (3,549) 3,904 #5.69 #6.02 HSR #7.29 953 T/D (921) 955 #7.98 KERO #4.92 1,034 T/D (1,333) 1,031 #5.19 CRUDE LGO #3.56 4,155 T/D (3,822) 4,146 #3.55 21,000 T/D RESID 11,214 T/D (11,375) 10,954 Min No of Tray = 21.45 (22.53) File Name = SHORT-BK10.out SHORT-GS.out

  22. ASTM D86 Curvefor LSR & HSR

  23. ASTM D86 Curvefor KERO & LGO

  24. ASTM D86 Curve for RESIDUE

  25. Simplest Crude Column Model LSR • No Pumparounds • No Sidestrippers • Specify • - Naphtha D86 95% • - Overflash • Vary • - Condenser Duty • - Flash Zone Duty 1 2 STM1 7 8 HSR STM2 17 18 KERO STM3 25 26 LGO 15oC 268oC o 364 C 28 358 o C STM4 30 o 349 C , 1.85K RESIDUE

  26. Part 2 : Simplest crude column model UNIT OPERATIONS DATA $ FLASH UID=F01 FEED ARAB-H,ARAB-L PROD M=CRUDE ISO TEMP=264,PRES=3.0 $ COLUMN UID=T01 PARA TRAY=30,IO=100,DAMP=0.4 FEED CRUDE,28/STM4,30/STM3,25/STM2,17/STM1,7 COND TYPE=PART,PRES=2.003 PROD OVHD(WT)=LSR,147875,WATER=WTR,1,976.5,BTMS=RESI,& LDRAW(WT)=10L,8,38375/20L,18,55542/30L,26,159250 DUTY 1,1/2,28 VARY DUTY=1,2 PSPE TOP=2.443,DPCOL=0.44 ESTI MODEL=REFINERY SPEC COLUMN=T01,TRAY=27,PHASE=L,RATE(LV),RATIO,& STREAM=CRUDE,VALUE=0.03 SPEC STREAM=LSR,D86(95),VALUE=153 END File Name = Simple-CDU.inp

  27. GAP : 12, 12, 0 GAP : 11, 11, -12.4 Comparison btn Design, Shortcut & Rigorous(1) GAP : 2, 2, -13

  28. Comparison btn Design, Shortcut & Rigorous(1)

  29. Part 3 : Add Sidestrippers OFF GAS o 161 C • No Pumparounds • Specify • - Naphtha D86 95% • - Overflash • - Stripped product 95% points • Vary • - Condenser Duty • - Flash Zone Duty • - Draw Rates 1.41K 123oC 60oC 0.97K 0.97K 2 LSR : 3,549 T/D (16.9wt%) 7 o 180 C , 1.53K 8 STM1 : 1313 Kg/hr o HSR : 921 T/D (4.39 wt%) 169 C 17 18 o 219 C , 1.68K STM2 : 1243 Kg/hr o 209 C KERO : 1,333 T/D (6.35 wt%) 25 26 o 273 C , 1.76K STM3 : 3418 Kg/hr o 265 C LGO : 3,822 T/D (18.2 wt%) CRUDE : 21,000 T/D 15oC 268oC o 364 C 28 358 o C 30 STM4 : 11603 Kg/hr , 1.85K RESIDUE : 11,375 T/D (54.16 wt%)

  30. Rigorous Simulation (I) COLUMN UID=T01 PARA TRAY=30,IO=100,DAMP=0.4 FEED CRUDE,28/STM4,30/10V,7/20V,17/30V,25 COND TYPE=PART,PRES=2.003 PROD OVHD(WT)=LSR,147875,WATER=WTR,1,976.5,BTMS=RESI,& LDRAW(WT)=10L,8,38375/20L,18,55542/30L,26,159250 DUTY 1,1/2,28 VARY DUTY=1,2 PSPE TOP=2.443,DPCOL=0.44 ESTI MODEL=REFINERY $ SPEC TRAY=2,TEMP,VALUE=161 SPEC COLUMN=T01,TRAY=27,PHASE=L,RATE(LV),RATIO,& STREAM=CRUDE,VALUE=0.03 $ OVERFLASH SPEC STREAM=LSR,D86(95),VALUE=153 $ LSR D86 95% File Name = NO-PA-CDU-BK10.inp

  31. Rigorous Simulation (II) SIDESTRIPPER UID=S01 PARA TRAY=2 FEED 10L,1/STM1,2 PROD OVHD=10V,BTMS(WT)=HSR,38375 PSPE TOP=2.563 SPEC STREAM=HSR,D86(95),VALUE=196 $ HSR D86 95% VARY FEED=10L SIDESTRIPPER UID=S02 PARA TRAY=2 FEED 20L,1/STM2,2 PROD OVHD=20V,BTMS(WT)=KERO,55542 PSPE TOP=2.713 SPEC STREAM=KERO,D86(95),VALUE=235 $ KERO D86 95% VARY FEED=20L SIDESTRIPPER UID=S03 PARA TRAY=2 FEED 30L,1/STM3,2 PROD OVHD=30V,BTMS(WT)=LGO,159250 PSPE TOP=2.793 SPEC STREAM=LGO,D86(95),VALUE=337 $ LGO D86 95% VARY FEED=30L END

  32. GAP : 12, 5.4, 5.3 GAP : 11, 1.7, -1.2 Examining Simulation Results: U-type GAP : 2, -5.5, -8

  33. Comparison btn Design, Shortcut, U-type-BK10 & U-type-GS

  34. Part 4 : Add Pumparound Coolers -25.17x106Kcal/hr -27.80x106Kcal/hr OFF GAS o 161 C 1.41K 123oC 60oC 0.97K LSR : 3,549 T/D (16.9wt%) 0.97K 2 132oC -13.94x106Kcal/hr 376,130 Kg/hr 7 o 180 C , 1.53K 8 STM1 : 1313 Kg/hr 192oC 168oC o HSR : 921 T/D (4.39 wt%) 169 C 17 -9.14x106Kcal/hr 234,857 Kg/hr 18 o 219 C , 1.68K 228oC STM2 : 1243 Kg/hr o 209 C KERO : 1,333 T/D (6.35 wt%) 221oC 25 -12.25x106Kcal/hr 298,087 Kg/hr 26 o 273 C , 1.76K 281oC STM3 : 3418 Kg/hr o 265 C LGO : 3,822 T/D (18.2 wt%) CRUDE : 21,000 T/D 15oC 268oC o 364 C 28 358 o C -16.50x106Kcal/hr 30 STM4 : 11603 Kg/hr o 349 C , 1.85K RESIDUE : 11,375 T/D (54.16 wt%)

  35. A-type Simulation (I) COLUMN UID=T01 PARA TRAY=30,IO=100,DAMP=0.4 FEED CRUDE,28/STM4,30/10V,7/20V,17/30V,25 COND TYPE=PART,PRES=2.003 PROD OVHD(WT)=LSR,147875,WATER=WTR,1,976.5,BTMS=RESI,& LDRAW(WT)=10L,8,38375/20L,18,55542/30L,26,159250 DUTY 1,1/2,28/3,7,-13.94/4,17,-9.14/5,25,-12.25 PA FROM=8,TO=7,RATE(WT)=376130 PA FROM=18,TO=17,RATE(WT)=234857 PA FROM=26,TO=25,RATE(WT)=298087 VARY DUTY=1,2 PSPE TOP=2.443,DPCOL=0.44 ESTI MODEL=REFINERY SPEC COLUMN=T01,TRAY=27,PHASE=L,RATE(LV),RATIO,& STREAM=CRUDE,VALUE=0.03 $ OVERFLASH SPEC STREAM=LSR,D86(95),VALUE=153 $ LSR D86 95% SIDESTRIPPER UID=S01 PARA TRAY=2 FEED 10L,1/STM1,2 PROD OVHD=10V,BTMS(WT)=HSR,38375 PSPE TOP=2.563 SPEC STREAM=HSR,D86(95),VALUE=196 $ HSR D86 95% VARY FEED=10L File Name = With-PA-CUD-BK10.inp

  36. A-type Simulation (II) SIDESTRIPPER UID=S02 PARA TRAY=2 FEED 20L,1/STM2,2 PROD OVHD=20V,BTMS(WT)=KERO,55542 PSPE TOP=2.713 SPEC STREAM=KERO,D86(95),VALUE=235 $ KERO D86 95% VARY FEED=20L SIDESTRIPPER UID=S03 PARA TRAY=2 FEED 30L,1/STM3,2 PROD OVHD=30V,BTMS(WT)=LGO,159250 PSPE TOP=2.793 SPEC STREAM=LGO,D86(95),VALUE=337 $ LGO D86 95% VARY FEED=30L FLASH UID=F02 FEED LSR PROD V=OFF-GAS,L=LNAPHTHA ISO TEMP=60,PRES=2.003 END

  37. GAP : 12, -14.6, -20.2 GAP : 11, -4.7, -9.5 Examining Simulation Results: A-type GAP : 2, -17.4, -21.7

  38. Increasing the sidestripper stage number : 3 from 2 SIDESTRIPPER UID=S01 PARA TRAY=3 FEED 10L,1/STM1,3 PROD OVHD=10V,BTMS(WT)=HSR,38375 PSPE TOP=2.563 SPEC STREAM=HSR,D86(95),VALUE=196 $ HSR D86 95% VARY FEED=10L SIDESTRIPPER UID=S02 PARA TRAY=3 FEED 20L,1/STM2,3 PROD OVHD=20V,BTMS(WT)=KERO,55542 PSPE TOP=2.713 SPEC STREAM=KERO,D86(95),VALUE=235 $ KERO D86 95% VARY FEED=20L SIDESTRIPPER UID=S03 PARA TRAY=3 FEED 30L,1/STM3,3 PROD OVHD=30V,BTMS(WT)=LGO,159250 PSPE TOP=2.793 SPEC STREAM=LGO,D86(95),VALUE=337 $ LGO D86 95% VARY FEED=30L END

  39. GAP : 12, -12.8, -11.8 GAP : 11, -1.3, -0 Examining Simulation Results: A-type GAP : 2, -15.7, -14.6

  40. Increasing the flowrate of stripping steam (1)

  41. Examining Simulation Results: Sidestripper = 2 tray

  42. Increasing the flowrate of stripping steam (2)

  43. Examining Simulation Results: Sidestripper = 3 tray

  44. Increasing the flowrate of stripping steam (3)

  45. Examining Simulation Results: Sidestripper = 4 tray

  46. Part 5 : Blend Products to make the Feed • NAPHTHA • HSR • FEED CRUDE • KEROSENE • LGO • RESIDUE

  47. Sidecut Properties

  48. Part 5: Shortcut Simulation TITLE PROB=SHORT,PROJECT=FPCC,USER=DR_JHCHO $$ SHORTCUT MODEL FOR CRUDE UNIT TO CHECK PRODUCT RATES $$ DIME METRIC, LIQV=BBL PRINT STREAM=PART, TBP, INPUT=NONE COMP DATA LIBID 1,H2O/2,C2/3,C3/4,IC4/5,NC4 ASSAY CONV=API63 THERMO DATA METHODS SYSTEM=BK10 STREAM DATA $ PROP STRM=NAPH,TEMP=15,PRES=5.033,RATE(WT)=147875, ASSAY=LV SPGR STREAM=NAPH, AVG=0.7037 D86 STREAM=NAPH, DATA=10,74/30,88/50,104/70,122/& 90,146/95,153/100,162 LIGHTEND STREAM=NAPH, PERCENT(WT)=7.1,& COMP(LV)=2,0.05/3,1.5/4,0.95/5,4.6,NORM $ PROP STRM=HSR,TEMP=15,PRES=5.033,RATE(WT)=38413, ASSAY=LV SPGR STREAM=HSR, AVG=0.7836 D86 STREAM=HSR, DATA=0,138/5,165/10,172/30,179/50,183/70,187/& 90,193/95,196/100,204 File Name : Short-BK10.bkp

  49. PROP STRM=KERO,TEMP=15,PRES=5.033,RATE(WT)=55563, ASSAY=LV SPGR STREAM=KERO, AVG=0.8034 D86 STREAM=KERO, DATA=0,168/5,198/10,203/30,210/50,215/70,221/& 90,229/95,235/100,251 PROP STRM=LGO,TEMP=15,PRES=5.033,RATE(WT)=159250, ASSAY=LV SPGR STREAM=LGO, AVG=0.8456 D86 STREAM=LGO, DATA=0,218/5,246/10,254/30,268/50,283/70,301/& 90,328/95,337/100,378 PROP STRM=RESID,TEMP=15,PRES=5.033,RATE(WT)=473899, ASSAY=LV SPGR STREAM=RESID, AVG=0.9713 D1160 STREAM=RESID, DATA=0,319/5,368/10,381/30,454/50,533/70,684/& 90,874 PROP STRE=STM1, PRES=4.533, PHASE=V, COMP(WT)=1,1313 PROP STRE=STM2, PRES=4.533, PHASE=V, COMP(WT)=1,1243 PROP STRE=STM3, PRES=4.533, PHASE=V, COMP(WT)=1,3418 PROP STRE=STM4, PRES=45.33, PHASE=V, COMP(WT)=1,11603 OUTPUT FORMAT=REFINE

  50. UNIT OPERATIONS DATA SHORTCUT UID=S01 FEED NAPH,HSR,KERO,LGO,RESID,STM1,STM2,STM3,STM4 PROD STREAM=LSRP,PHASE=M,PRES=2.443,CUTP(WT)=16.9 PROD STREAM=HSRP,PHASE=L,PRES=2.563,CUTP(WT)=21.29 PROD STREAM=KERP,PHASE=L,PRES=2.713,CUTP(WT)=27.64 PROD STREAM=LGOP,PHASE=L,PRES=2.793,CUTP(WT)=45.84 PROD STREAM=RESP,PHASE=L,PRES=2.85 COND TYPE=MIXED,TEMP=123 EVALUATE MODEL=REFINE SPEC STREAM=LSRP,D86(95),VALUE=153 SPEC STREAM=HSRP,D86(5),MINUS,STREAM=LSRP,D86(95),VALUE=12 SPEC STREAM=HSRP,D86(95),VALUE=196 SPEC STREAM=KERP,D86(5),MINUS,STREAM=HSRP,D86(95),VALUE=2 SPEC STREAM=KERP,D86(95),VALUE=235 SPEC STREAM=LGOP,D86(5),MINUS,STREAM=KERP,D86(95),VALUE=11 SPEC STREAM=LGOP,D86(95),VALUE=337 SPEC STREAM=RESP,RATE(WT),VALUE=473958 FLASH UID=F01 FEED LSRP PROD V=VLSR,L=LLSR ISO TEMP=123,PRES=2.003 END

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