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

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
HSR 921 T/D (4.39 wt)
169
o
C
28
-9.14x106Kcal/hr 234,857 Kg/hr
31
o
219
C
, 1.68K
228oC
STM2 1243 Kg/hr
o
KERO 1,333 T/D (6.35 wt)
209
C
221oC
38
-12.25x106Kcal/hr 298,087 Kg/hr
43
o
273
C
, 1.76K
281oC
STM3 3418 Kg/hr
o
LGO 3,822 T/D (18.2 wt)
265
C
CRUDE 21,000 T/D
o
268oC
15oC
364
C
49
358
o
C
-16.50x106Kcal/hr
56
STM4 11603 Kg/hr
o
RESIDUE 11,375 T/D (54.16 wt)
349
C
, 1.85K
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 PROBSHORT,PROJECTFPCC,USERDR_JHCHO
SHORTCUT MODEL FOR CRUDE UNIT TO CHECK PRODUCT
RATES DIME METRIC, LIQVBBL PRINT
STREAMPART, TBP, INPUTNONE COMP DATA LIBID
1,H2O/2,C2/3,C3/4,IC4/5,NC4/6,IC5/7,NC5 ASSAY
CONVAPI63 THERMO DATA METHODS SYSTEMBK10
STREAM DATA PROP STRMARAB-H, TEMP15,
PRES5.033, RATE(WT)437500, ASSAYLV SPGR
STREAMARAB-H, AVG0.8843, DATA4.9035,0.6348/
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 Simulation continued
UNIT OPERATIONS DATA SHORTCUT UIDS01 FEED
ARAB-H,ARAB-L,STM1,STM2,STM3,STM4 PROD
STREAMLSR,PHASEM,PRES2.443,CUTP(WT)16.9
PROD STREAMHSR,PHASEL,PRES2.563,CUTP(WT)21.25
PROD STREAMKERO,PHASEL,PRES2.713,CUTP(WT)27
.6 PROD STREAMLGO,PHASEL,PRES2.793,CUTP(WT)
45.8 PROD STREAMRESI,PHASEL,PRES2.85
COND TYPEMIXED,TEMP123 EVALUATE
MODELREFINE SPEC STREAMLSR,D86(95),VALUE153
SPEC STREAMHSR,D86(5),MINUS,STREAMLSR,D86(95)
,VALUE12 SPEC STREAMHSR,D86(95),VALUE196 SPE
C STREAMKERO,D86(5),MINUS,STREAMHSR,D86(95),VALU
E2 SPEC STREAMKERO,D86(95),VALUE234 SPEC
STREAMLGO,D86(5),MINUS,STREAMKERO,D86(95),VALUE
11 SPEC STREAMLGO,D86(95),VALUE337 SPEC
STREAMRESI,RATE(WT),VALUE473958 FLASH
UIDF01 FEED LSR PROD VVLSR,LLLSR ISO
TEMP123,PRES2.003 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 1.530E02
1.530E02 STRM HSR
D86 5 PCT 1.200E01 1.200E01
STRM HSR D86 95 PCT
1.960E02 1.960E02 STRM KERO
D86 5 PCT 2.000E00
1.961E00 STRM KERO
D86 95 PCT 2.340E02 2.340E02
STRM LGO D86 5 PCT
1.100E01 1.100E01 STRM LGO
D86 95 PCT 3.370E02
3.370E02 STRM RESI
WT RATE 4.740E05 4.740E05

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
o
268oC
15oC
364
C
28
358
o
C
30
STM4
o
349
C
, 1.85K
RESIDUE
26
Part 2 Simplest crude column model
UNIT OPERATIONS DATA FLASH UIDF01 FEED
ARAB-H,ARAB-L PROD MCRUDE ISO
TEMP264,PRES3.0 COLUMN UIDT01 PARA
TRAY30,IO100,DAMP0.4 FEED CRUDE,28/STM4,30/ST
M3,25/STM2,17/STM1,7 COND TYPEPART,PRES2.003
PROD OVHD(WT)LSR,147875,WATERWTR,1,976.5,BTMSR
ESI, LDRAW(WT)10L,8,38375/20L,18,55542/30
L,26,159250 DUTY 1,1/2,28 VARY DUTY1,2
PSPE TOP2.443,DPCOL0.44 ESTI MODELREFINERY
SPEC COLUMNT01,TRAY27,PHASEL,RATE(LV),RATIO,
STREAMCRUDE,VALUE0.03 SPEC
STREAMLSR,D86(95),VALUE153 END
File Name Simple-CDU.inp
27
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
HSR 921 T/D (4.39 wt)
169
o
C
17
18
o
219
C
, 1.68K
STM2 1243 Kg/hr
o
KERO 1,333 T/D (6.35 wt)
209
C
25
26
o
273
C
, 1.76K
STM3 3418 Kg/hr
o
LGO 3,822 T/D (18.2 wt)
265
C
CRUDE 21,000 T/D
o
268oC
15oC
364
C
28
358
o
C
30
STM4 11603 Kg/hr
RESIDUE 11,375 T/D (54.16 wt)
, 1.85K
30
Rigorous Simulation (I)
COLUMN UIDT01 PARA TRAY30,IO100,DAMP0.4
FEED CRUDE,28/STM4,30/10V,7/20V,17/30V,25 COND
TYPEPART,PRES2.003 PROD OVHD(WT)LSR,147875,WA
TERWTR,1,976.5,BTMSRESI,
LDRAW(WT)10L,8,38375/20L,18,55542/30L,26,159250
DUTY 1,1/2,28 VARY DUTY1,2 PSPE
TOP2.443,DPCOL0.44 ESTI MODELREFINERY
SPEC TRAY2,TEMP,VALUE161 SPEC
COLUMNT01,TRAY27,PHASEL,RATE(LV),RATIO,
STREAMCRUDE,VALUE0.03 OVERFLASH SPEC
STREAMLSR,D86(95),VALUE153 LSR D86 95
File Name NO-PA-CDU-BK10.inp
31
Rigorous Simulation (II)
SIDESTRIPPER UIDS01 PARA TRAY2 FEED
10L,1/STM1,2 PROD OVHD10V,BTMS(WT)HSR,38375
PSPE TOP2.563 SPEC STREAMHSR,D86(95),VALUE196
HSR D86 95 VARY FEED10L SIDESTRIPPER
UIDS02 PARA TRAY2 FEED 20L,1/STM2,2 PROD
OVHD20V,BTMS(WT)KERO,55542 PSPE TOP2.713
SPEC STREAMKERO,D86(95),VALUE235 KERO D86
95 VARY FEED20L SIDESTRIPPER UIDS03 PARA
TRAY2 FEED 30L,1/STM3,2 PROD
OVHD30V,BTMS(WT)LGO,159250 PSPE TOP2.793
SPEC STREAMLGO,D86(95),VALUE337 LGO D86 95
VARY FEED30L END
32
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
HSR 921 T/D (4.39 wt)
169
o
C
17
-9.14x106Kcal/hr 234,857 Kg/hr
18
o
219
C
, 1.68K
228oC
STM2 1243 Kg/hr
o
KERO 1,333 T/D (6.35 wt)
209
C
221oC
25
-12.25x106Kcal/hr 298,087 Kg/hr
26
o
273
C
, 1.76K
281oC
STM3 3418 Kg/hr
o
LGO 3,822 T/D (18.2 wt)
265
C
CRUDE 21,000 T/D
o
268oC
15oC
364
C
28
358
o
C
-16.50x106Kcal/hr
30
STM4 11603 Kg/hr
o
RESIDUE 11,375 T/D (54.16 wt)
349
C
, 1.85K
35
A-type Simulation (I)
COLUMN UIDT01 PARA TRAY30,IO100,DAMP0.4
FEED CRUDE,28/STM4,30/10V,7/20V,17/30V,25 COND
TYPEPART,PRES2.003 PROD OVHD(WT)LSR,147875,WA
TERWTR,1,976.5,BTMSRESI,
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 FROM8,TO7,RATE(WT)376130 PA
FROM18,TO17,RATE(WT)234857 PA
FROM26,TO25,RATE(WT)298087 VARY DUTY1,2
PSPE TOP2.443,DPCOL0.44 ESTI MODELREFINERY
SPEC COLUMNT01,TRAY27,PHASEL,RATE(LV),RATIO,
STREAMCRUDE,VALUE0.03 OVERFLASH SPEC
STREAMLSR,D86(95),VALUE153 LSR D86
95 SIDESTRIPPER UIDS01 PARA TRAY2 FEED
10L,1/STM1,2 PROD OVHD10V,BTMS(WT)HSR,38375
PSPE TOP2.563 SPEC STREAMHSR,D86(95),VALUE196
HSR D86 95 VARY FEED10L
File Name With-PA-CUD-BK10.inp
36
A-type Simulation (II)
SIDESTRIPPER UIDS02 PARA TRAY2 FEED
20L,1/STM2,2 PROD OVHD20V,BTMS(WT)KERO,55542
PSPE TOP2.713 SPEC STREAMKERO,D86(95),VALUE2
35 KERO D86 95 VARY FEED20L SIDESTRIPPER
UIDS03 PARA TRAY2 FEED 30L,1/STM3,2 PROD
OVHD30V,BTMS(WT)LGO,159250 PSPE TOP2.793
SPEC STREAMLGO,D86(95),VALUE337 LGO D86 95
VARY FEED30L FLASH UIDF02 FEED LSR PROD
VOFF-GAS,LLNAPHTHA ISO TEMP60,PRES2.003 END
37
Examining Simulation Results A-type
GAP 2, -17.4, -21.7
38
Increasing the sidestripper stage number 3 from
2
SIDESTRIPPER UIDS01 PARA TRAY3 FEED
10L,1/STM1,3 PROD OVHD10V,BTMS(WT)HSR,38375
PSPE TOP2.563 SPEC STREAMHSR,D86(95),VALUE196
HSR D86 95 VARY FEED10L SIDESTRIPPER
UIDS02 PARA TRAY3 FEED 20L,1/STM2,3 PROD
OVHD20V,BTMS(WT)KERO,55542 PSPE TOP2.713
SPEC STREAMKERO,D86(95),VALUE235 KERO D86
95 VARY FEED20L SIDESTRIPPER UIDS03 PARA
TRAY3 FEED 30L,1/STM3,3 PROD
OVHD30V,BTMS(WT)LGO,159250 PSPE TOP2.793
SPEC STREAMLGO,D86(95),VALUE337 LGO D86 95
VARY FEED30L END
39
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 PROBSHORT,PROJECTFPCC,USERDR_JHCHO
SHORTCUT MODEL FOR CRUDE UNIT TO CHECK PRODUCT
RATES DIME METRIC, LIQVBBL PRINT
STREAMPART, TBP, INPUTNONE COMP DATA LIBID
1,H2O/2,C2/3,C3/4,IC4/5,NC4 ASSAY
CONVAPI63 THERMO DATA METHODS
SYSTEMBK10 STREAM DATA PROP
STRMNAPH,TEMP15,PRES5.033,RATE(WT)147875,
ASSAYLV SPGR STREAMNAPH, AVG0.7037 D86
STREAMNAPH, DATA10,74/30,88/50,104/70,122/
90,146/95,153/100,162 LIGHTEND
STREAMNAPH, PERCENT(WT)7.1,
COMP(LV)2,0.05/3,1.5/4,0.95/5,4.6,NORM PROP
STRMHSR,TEMP15,PRES5.033,RATE(WT)38413,
ASSAYLV SPGR STREAMHSR, AVG0.7836 D86
STREAMHSR, DATA0,138/5,165/10,172/30,179/50,183/
70,187/ 90,193/95,196/100,204
File Name Short-BK10.bkp
49
PROP STRMKERO,TEMP15,PRES5.033,RATE(WT)55563,
ASSAYLV SPGR STREAMKERO, AVG0.8034 D86
STREAMKERO, DATA0,168/5,198/10,203/30,210/50,215
/70,221/ 90,229/95,235/100,251 PROP
STRMLGO,TEMP15,PRES5.033,RATE(WT)159250,
ASSAYLV SPGR STREAMLGO, AVG0.8456 D86
STREAMLGO, DATA0,218/5,246/10,254/30,268/50,283/
70,301/ 90,328/95,337/100,378 PROP
STRMRESID,TEMP15,PRES5.033,RATE(WT)473899,
ASSAYLV SPGR STREAMRESID, AVG0.9713 D1160
STREAMRESID, DATA0,319/5,368/10,381/30,454/50,53
3/70,684/ 90,874 PROP STRESTM1,
PRES4.533, PHASEV, COMP(WT)1,1313 PROP
STRESTM2, PRES4.533, PHASEV, COMP(WT)1,1243
PROP STRESTM3, PRES4.533, PHASEV,
COMP(WT)1,3418 PROP STRESTM4, PRES45.33,
PHASEV, COMP(WT)1,11603 OUTPUT FORMATREFINE
50
UNIT OPERATIONS DATA SHORTCUT UIDS01 FEED
NAPH,HSR,KERO,LGO,RESID,STM1,STM2,STM3,STM4
PROD STREAMLSRP,PHASEM,PRES2.443,CUTP(WT)16.9
PROD STREAMHSRP,PHASEL,PRES2.563,CUTP(WT)21.
29 PROD STREAMKERP,PHASEL,PRES2.713,CUTP(WT)
27.64 PROD STREAMLGOP,PHASEL,PRES2.793,CUTP(W
T)45.84 PROD STREAMRESP,PHASEL,PRES2.85
COND TYPEMIXED,TEMP123 EVALUATE MODELREFINE
SPEC STREAMLSRP,D86(95),VALUE153 SPEC
STREAMHSRP,D86(5),MINUS,STREAMLSRP,D86(95),VALUE
12 SPEC STREAMHSRP,D86(95),VALUE196 SPEC
STREAMKERP,D86(5),MINUS,STREAMHSRP,D86(95),VALUE
2 SPEC STREAMKERP,D86(95),VALUE235 SPEC
STREAMLGOP,D86(5),MINUS,STREAMKERP,D86(95),VALUE
11 SPEC STREAMLGOP,D86(95),VALUE337 SPEC
STREAMRESP,RATE(WT),VALUE473958 FLASH UIDF01
FEED LSRP PROD VVLSR,LLLSR ISO
TEMP123,PRES2.003 END
51
------------- TOTAL STREAM
RATES ------------- MOLES
WEIGHT LIQUID VOL NORM VAPOR(1) NUM
STREAM PHASE KG-MOL/HR KG/HR
BBL/HR M3/HR SECTION TRAYS ------------
- ---------- ---------- ---------- ----------
------- ----- LSRP M 2476.76
163394.87 1414.45 55514.09 1 5.38
HSRP L 272.16 39702.12
322.00 6100.16 2 7.19 KERP
L 305.78 51593.78 404.72 6853.78
3 5.08 LGOP L 716.74
163928.31 1222.79 16065.08 4 3.86
RESP L 859.14 473957.84
3071.43 19256.75 TOTALS
4630.58 892576.92 6435.39 103789.85
21.51