Refinery Planning Presentation

Refinery Modeling
Aaron Smith, Michael Frow,

Joe Quddus, Donovan Howell,
Thomas Reed, Clark Landrum,
Brian Clifton
May 2, 2006
The
Big
Black
Box
The
Big
Black
Box
Demand
Crude B
Crude C
Crude A
Costs
Profit
The
Big
Black
Box
Demand
Crude B
Crude C
Crude A
Costs
Profit
Hydrotreating
INPUT:
Temperature
Pressure
H
2
/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
Hydrotreating
Removal of sulfur, nitrogen, and
aromatics.
Government regulations are leading to
increased sulfur removal requirements.
Typical Processing
Conditions
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
(
o
C)
H
2
Pressure
(psia) H
2
/HC
Space
velocity
Hydrotreating
Cracking is assumed to be insignificant.
Therefore, properties such as density and
molecular weight are assumed to be
constant.
Hydrotreating
Cracking is assumed to be insignificant.
Therefore, properties such as density and
molecular weight are assumed to be
constant.
Hydrotreating Model
For MoCo catalyst reaction rates are:
Rate
s
= k
s
C
s
2
C
H2
.75
Rate
n
= k
n
C
n
1.4
C
H2
.6
Rate
ar
= k
ar
C
ar
C
H2
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
Delayed Coking
Used to process
bottoms from the
vacuum distillate.
Breaks down this
portion into usable
napthas, gas, and
gas oil.
Delayed Coking
Coke Products
Shot Coke
Sponge Coke
Needle Coke
Delayed Coking Model
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
Effect of Pressure on
Product
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%)
Delayed Coking Model
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
New Correlation
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%)
Catalytic
Reforming
INPUT:
Temperature
Pressure
% Napthenes
% Aromatics
% Paraffins
OUTPUT:
Hydrogen
LPG
Reformate
MODEL:
PBR
Catalytic Reforming
Catalytic Reforming
Hydrogen Intensive Process Units
Xylenes Isomerization
Boilers
Catalytic Reforming
Simplified reactions and equations from
Case Study 108 by Rase
( )
( )
( )
( ) napthenes of ing Hydrocrack
paraffins of ing Hydrocrack
H napthenes Paraffins
H aromatics Napthenes
_ _ 4
_ _ 3
2
* 3 1
2
2
+
+
Catalytic Reforming
( )
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
+

Catalytic Reforming
[ ]
( )( )( ) atm cat lb hr
moles
T
k
P
. _
,
34750
21 . 23 exp
1
=
|
\
|
=
)
[ ]
( )( )( )
2
2
. _
,
59600
98 . 35 exp
atm cat lb hr
moles
T
k
P
=
|
\
|
=
)
[ ]
( )( ) . _
,
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
Catalytic Reforming
[ ]
( )( ) . _
_ _ _ _
*
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
=
|
\
|
=
)
)
Catalytic Reforming
Catalytic Reforming
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
C
9
+ Aromatics
Blending
O-Xylene
Chemical Feedstock
Mixed Aromatics
Blending
P-Xylene
Chemical Feedstock
Reaction driven by equilibrium
Temperature dependence of equilibrium
modeled in Kirk-Othmer Encyclopedia of
Chemical Technology
ne EthylBenze Xylene p Xylene o Xylene m
Solvent
Extraction
INPUT:
Temperature
S/F Ratio
OUTPUT:
Lube Oil
Aromatics
MODEL:
Correlation
Solvent Extraction
Solvent Extraction
Paraffinic Oils - Solvent Dewaxing
Mixed Aromatics
Blending
Solvent Extraction
Furfural Extraction Averaged K Values
Benzene from Cyclohexane
Benzene from Iso-octane
1,6-diphenylhexane from Docosane
Temperature (R) dependence of K correlated from this
=
=
N
n
n
E
Extracted
0
1
1 %
F
S
K E * =
( ) 371 . 7 * 0259 . 0 5 2
2
+ = T E T K
Solvent Extraction
Correlations developed from Institut Franais
du Ptrole data
( ) 9318 . 0 0426 . 0 * % +
|
\
|
=
F
S
ield RaffinateY
( ) 9229 . 0 ) 0073 . 0 ( * 0004 . 0 * . .
2
+
|
\
|
\
|
=
F
S
F
S
G RaffinateS
Solvent Extraction
Solvent Extraction
Visbreaker
INPUT:
Temperature
OUTPUT:
Gas
Gasoline
Gas Oil
Residue
MODEL:
PFR
Visbreaking
Visbreaking
Carbon chains cracking into smaller chains of varying
carbon numbers
Visbreaking
S
i-2
+ O
2
S
i-3
+ O
3
S
i-j
+ O
j
S
2
+ O
i-2
S
1
+ O
i-1
S
i
S
i
forms all components with carbons less than i-1
Visbreaking
S
i
is formed from all components with carbons greater
than i+1
S
i-2
+ O
2
S
i-3
+ O
3
S
i-j
+ O
j
S
2
+ O
i-2
S
1
+ O
i-1
S
n
S
n-1
S
k
S
i+3
S
i+2
O
n-i
O
n-1-i
O
k-i
O
3
O
2
S
i
S
i
forms all components with carbons less than i-1
Visbreaking
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
2
4
1
=
i
i
ro
F dz
dCo
2
4
1
=
Visbreaking
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 0 ,
[ ] ( )
2
3
4
2
1
2
2 1 0 ,
|
|
|
|
\
|

+ + =
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
Visbreaking
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
Isomerization
INPUT:
Temperature
H
2
/HC Ratio
OUTPUT:
Hydrocarbons
C
4
-C
6
MODEL:
PFR
Isomerization
Isomerization
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.
Isomerization
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 . 0
2
5
2 5
1 0000197 . 0
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
Isomerization
Model inputs
Temperature, mass flow rate, and H
2
/HC ratio
Model Product form
Weight percents of the individual isomers
Hydrocracking
INPUT:
API
K
w
H
2
/BBL
OUTPUT:
Naptha
Light
Heavy
C
3
Up
i-Butane
n-Butane
Gas Oil
MODEL:
Correlation
Hydrocracking
Convert higher boiling point petroleum fractions
into lighter fuel products
Hydrocracking
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 + H
2
R-C-C + heat
Hydrocracking
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
Hydrocracking Model
Development
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
Hydrocracking Model
Hydrocracking Model
y =0.84165e
0. 00096x
R
2
=0.99872
y =0.91507e
0. 00099x
R
2
=0.99903
y =1.03077e
0. 00102x
R
2
=0.99873
y =1.17542e
0. 00105x
R
2
=0.99820
y =1.35330e
0. 00110x
R
2
=0.99840
y =1.48461e
0. 00120x
R
2
=0.99938
y =1.64851e
0. 00129x
R
2
=0.99707
y =1.80073e
0. 00143x
R
2
=0.98730
y =2.20169e
0. 00147x
R
2
=0.98763
y =2.67927e
0. 00153x
R
2
=0.98715
y =3.40926e
0. 00157x
R
2
=0.98555
0
10
20
30
40
50
60
70
80
90
100
0 500 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
Hydrocracking Model
y = 1.852E-05x
4
- 1.206E-03x
3
+ 2.920E-
02x
2
-
2.531E-01x + 1.546E+00
R
2
= 9.992E-01
0
0.5
1
1.5
2
2.5
3
3.5
4
0 10 20 30 40
API of Feed
A

C
o
n
s
t
a
n
t
y = 6.024E-11x
6
- 6.539E-09x
5
+ 2.738E-
07x
4
- 5.600E-06x
3
+ 5.935E-05x
2
- 2.996E-
04x + 1.509E-03
R
2
= 9.982E-01
0
0.0002
0.0004
0.0006
0.0008
0.001
0.0012
0.0014
0.0016
0.0018
0 10 20 30 40
API of Feed
B

C
o
n
s
t
a
n
t
Hydrocracking Model
Vol% of light naptha
Hydrogen Rate(SCFB) 7.5 10 12.5 15 17.5 20 22.5 25
2500 K
w
=12.1 9.25 11 13 16 21 30 45 80
diff. from K
w
=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 K
w
=12.1 3.4 4 4.8 5.8 7.3 9.1 11.25 14.25
diff. from K
w
=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 K
w
=12.1 1.4 1.55 1.7 2 2.3 2.8 3.4 4.2
diff. from K
w
=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
Hydrocracking Model
y = -0.7691x + 11.739
R
2
= 0.9916
0
0.5
1
1.5
2
2.5
3
3.5
4
10.5 11 11.5 12 12.5
Kw
s
l
o
p
e
Hydrocracking Equations
H B
w
Ae K p vol

= ) 00833 . 0 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 + =
Hydrocracking Model
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 K
w
vol% p
1
vol% p
2
9%
25%
7%
1%
27%
9%
Solvent
Dewaxing
INPUT:
Composition
Temperature
OUTPUT:
Wax
Lube Oil
MODEL:
Correlation
Solvent Dewaxing
Separate high pour point waxes from
lubricating oils
Solvent Dewaxing
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
Dewaxing Model
Development
Correlation from Energy and Fuels
Krishna et. al.
3 experimentally determined parameters
3 inputs
2 outputs
2 / 1 ) / 100 log( 0 A CL A PC A PPT + + =
( )
( ) ) ( 100
) ( 100
%) (
product PC
feed PC
wt OilYield
=
Dewaxing Model Error
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
Alkylation PFD
http://www.prod.exxonmobil.com/refiningtechnologies/pdf/AlkyforWR02.pdf
Exxon-Mobil Autorefrigeration H
2
SO
4
alkylation
Alkylation
*Lots of side reactions
Alkylation
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
olefin space velocity, v/hr/v
Progress in Petroleum Technology AV Mrstik et al. ACS Publications
Polymerization
INPUT:
Iso-butane
Butylene /
Propylene
OUTPUT:
Gasoline
Diesel
MODEL:
Correlation
Polymerization Polymerization Polymerization Polymerization
Converts Propylenes and butylenes into saturated
carbon chains
1
st
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
Zeolite Zeolite Zeolite Zeolite Polymerization Polymerization Polymerization Polymerization
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]
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
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
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 .1lb
m
acid
consumed per gallon
product
++Typical octane number =
96(RON)
VS
Deasphalting
INPUT:
%Heavies
Temperature
Pressure
OUTPUT:
%Heavies
Lube oil
MODEL:
Correlation
Propane Deasphalting - PFD
http://www.scielo.br/scielo.php?script=sci_arttext&pid=S0104-66322000000300012&lng=pt&nrm=iso
Typical Propane Deasphalting
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
Sub Critical Propane
Deasphalting
2
1
|
|
\
|

=
V
T R H
g
=
= 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]
Super Critical Propane
Deasphalting
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:
K
w
Temperature
OUTPUT:
Gas Oil
Gasoline
LPG
Dry Gas
Coke
MODEL:
PFR
Fluidized Catalytic Cracking
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
Different yields of products will
occur 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
of the reactor
2
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
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
A B C
D E
Ancheyta-Juarez, Jorge, Estimation of Kinetic Constants., Energy & Fuels, 2000, 14, 1226-1231
A B C
D E
A B C
D E
A B C
D E
A B C
D E
8 kinetic constants
One catalyst deactivation
Gas Oil considered as a second order reaction
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
Change
Temperature
Inlet Feed
Mass Balance:
dt
dt
dC
C C
i
i
*
0
+ =
i
C
L i
r
WHSV dz
dy
= ) (
1
Change
Temperature
Inlet Feed
Mass Balance:
dt
dt
dC
C C
i
i
*
0
+ =
i
C
L i
r
WHSV dz
dy
= ) (
1
TEMPERATURE:
480, 500, 520 C
Constant C/O Ratio of 5
Varying space velocity (WHSV)
6 48 h
-1
Gas Oil Conversion ~ 70 %
Gasoline ~ 50%
LPG ~ 12 %
6 48 h
-1
Gasoline ~ 50%
LPG ~ 12 %
6 48 h
-1
Gasoline ~ 50%
LPG ~ 12 %
Blending
INPUT:
35 streams
OUTPUT:
Gasoline
Regular
Premium
LPG
Coke
Lube Oil
Wax
Asphalt
Blending
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
Blending Indexes
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 of fraction volume the is
Index Blending the is Where
i
x
BI
Blending Indexes
|
\
|
=
08 . 0
1
p p
T BI
Pour Point
10
10
log 3
log
+
=
v
BI
Viscosity Index
|
\
|
=
05 . 0
1
CL CL
T BI
Cloud Point
6 . 42
2414
1188 . 6 log
10
+ =
F
F
T
BI
Flash Point
( ) [ ] AP BI
AP
00657 . 0 exp 124 . 1 = Aniline Point
( )
25 . 1
RVP VPBI =
Reid Vapor Pressure
Gasoline Blending
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
Gasoline Blending
Vapor pressure blending can be
improved by using thermodynamically
based methods
Raoult's Law
=
*
i i
P x P
Blending
Other possible products
Fuel oils
Lube oils
Diesel fuel
Blending requires data for aniline point,
pour point, cloud point, flash point, and
diesel index
Refinery Planning
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
Refinery Planning
Max Profit

=
T t C c T t C c
t c t c t c t c t c
T t C c
t c
o p p
cl AL co AC cp MANU
, , , , , ,
Pongsakdi, Arkadej, et. al, Financial risk., Int. J. Production Economics, accepted 20 April 2005
Refinery Planning
Max Profit

=
T t C c T t C c
t c t c t c t c t c
T t C c
t c
o p p
cl AL co AC cp MANU
, , , , , ,
Product Sales
Amount of product produced
in that time period multiplied by
unit sale price of product c
Refinery Planning
Max Profit

=
T t C c T t C c
t c t c t c t c t c
T t C c
t c
o p p
cl AL co AC cp MANU
, , , , , ,
Product Sales
Crude Oil Costs
Amount of crude oil refined in
that time period multiplied by
unit purchase price of crude oil
Refinery Planning
Max Profit

=
T t C c T t C c
t c t c t c t c t c
T t C c
t c
o p p
cl AL co AC cp MANU
, , , , , ,
Product Sales
Crude Oil Costs
Amount of crude oil refined in
that time period multiplied by
unit purchase price of crude oil
Discounted Expense
Amount of product volume
that cannot satisfy demand
multiplied by discounted price
Modeling
A Visual Basic macro in Excel was used
to help Solver find the optimal crude
selection
Modeling
A Visual Basic macro in Excel was used
to help Solver find the optimal crude
selection
Model Inputs
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
Model Results
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
Future Work
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.
Questions?

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Refinery Modeling

Aaron Smith, Michael Frow,

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