Chapter 14 CASE-STUDY PROBLEM: CRUDE UNITS

To illustrate the operation of a fuels refinery and the procedures for making a preliminary
economic evaluation, a material balance will be made on each processing unit in a refinery
and operating and construction costs will be estimated. The material balance for each unit is
located at the end of the chapter that discusses that particular unit, and the evaluation of
operating and construction costs is located at the end of Chapter 17 (Cost Estimation). An
overall economic evaluation is given at the end of Chapter 18 (Economic Evaluation). The
example problem is worked using units of measurement common to U.S. refineries.
In order to determine the economics of processing a given crude oil or of constructing a
complete refinery or individual processing units, it is necessary to make case studies for
each practical processing plan and to select the one giving the best economic return. This is
a very time-consuming process and can be very costly. The use of computer programs to
optimize processing schemes is widespread throughout the refining industry. For the
purpose of illustrating calculation methods, the process flow will not be optimized in this
problem, but all units will be utilized (i.e., delayed coker, fluid catalytic cracker, and hydro-
cracker) even though certain ones cannot be economically justified under the assumed
conditions.
In addition to the basic data contained in the textbook, it is necessary to use industry
publications such as the Oil and Gas Journal, Chemical Week, Oil Daily, and Chemical
Marketing (formerly Oil, Paint, and Drug Reporter) for current prices of raw materials and
products. Chemical Week, for example, has an annual issue on plant sites which lists utility
costs, wages, taxes, etc., by location within the United States.
In many processing units, there is a change in volume between the feed and the products,
so it is not possible to make a volume balance around the unit. For this reason, it is essential
that a weight balance be made. Even though in practice, the weights of individual streams
are valid to only three significant figures, for purposes of calculation it is necessary to carry
them out to at least the closest 100 pounds. For this example, they will be carried to the
nearest pound.
In order to make the balance close on each unit, it is necessary to determine one product
stream by difference. Generally, the stream having the least effect is determined by
difference and, in most cases, this works out to be the heaviest product.
Conversion factors (e.g., lb/hr per BPD) and properties of pure compounds are tabulated in
Appendix B. Properties of products and intermediate streams are given in the chapters on
products and the individual process units.

For the actual design of a specific unit, the yields should be determined by the pilot plant
operation. Values calculated from correlations (of plant and pilot plant operating data) are
for primary economic evaluation studies only.
Bottom line is, material balances are case specific and cannot be generalized.

Statement of the Problem

Develop preliminary estimates of product yields, capital investment, operating costs, and
economics of building a grassroots refinery on the West Coast to process 100,000 BPCD of
North Slope Alaska crude oil.
The major income products will be motor gasoline, jet fuel, and diesel fuel and the refinery
will be operated to maximize gasoline yields within economic limits. The gasoline split will
be 50/50 87 PON regular and 93 PON premium [PON = (RON + MON)/2]. Analysis of the
14-1
crude oil is given in Table 4.6. It is estimated that this crude oil will be available FOB the
refinery at $20.00/bbl. Product prices will be based on the average posted prices for 1999
less the following:

1. $0.005/gal on all liquid products except fuel oil

2. $0.05/bbl on fuel oil
3. $0.50/ton on coke

Utility prices will be those reported in the 1999 Plant Sites issue of Chemical Week (October
1999) for the area in which the refinery will be built. Federal and state income taxes will be
45% (38% U.S. and 7% Calif.) and land cost will be 5% of the cost of the process units,
storage, steam systems, cooling water systems, and offsites.

LSRN (C5 180 F) Isomerization

(X)

CDU Naphtha
(1A) Splitter
(x)

HSRN (180 350 F) Reformer

AR (5)
650 F+ FCC & Coker gas
VGO VGO
VRU 560 850 F GO 560 850 F FCC Alkylation
(1B) 850 1050 F HTU 850 1050 F (2)
LGO
(x)
High S (x) Low S

VR
1050 F+ HGO

Coker HCR
HCGO
(3) (4)

Lt Naphtha
Hv Naphtha

Refinery proecssing scheme for HW problems

List of Material Balance:

1. Crdue Unit Material Balance

2. FCC Unit Material Balance
3. Delayed Coker Unit Material Balance
4. Hydrocracker Unit Material Balance
5. Hydrotreater & Catalytic Reformer Unit Material Balance

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 1. Crdue Unit Material Balance

General Procedure

1. From the crude distillation data given in Table 4.6, plot TBP and gravity-midpercent
curves. These are shown in Figure 4.12.

Figure 4.12 TBP and gravity-midpercent curves, Alaska North Slope crude: gravity,
26.4 API; sulfur, 0.99 wt%. (From Ref. 8.)

2. From TBP and gravity curves, determine percentages and gravities of fractions for the
TBP cut-points of products to be made from atmospheric and vacuum pipe stills.
3. Convert volumes to weights.
4. Determine weight of 1050+F (566C) bottoms stream by difference.
If the volume of 1050+ stream is taken from the TBP curve, then gravity is calculated
from weight and volume. In this case, since the gravity on 1050+ F stream was
determined in the laboratory and the gravity is very sensitive to small changes in weight,
it was decided to use the laboratory gravity and calculate the volume. This gives a total
volume recovery of 100.6%. This is reasonable because there is a negative volume
change on mixing of petroleum fractions, and it is possible on some crudes to obtain
liquid products [more properly liquid-equivalent products because C4 and lighter
products are not liquids at 60F (16C) and 1 atm pressure] having a total volume of up
to 103% on crude.
5. The material balance and utility requirements for the crude units are given in Table 4.7.
6. For crude oils containing significant amounts of sulfur or nitrogen, it is also necessary to
make sulfur and/or nitrogen balances around each unit. The North Slope crude has a
sufficiently high quality of sulfur to require a sulfur balance, but since there is no
nitrogen shown in the analysis, a nitrogen balance is not made. It is assumed that the
North Slope crude is similar to those represented in Figure 4.3.
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7. Compare tyour results with the yeilds from the crude oil assay.

(a)

Figure 4.3a Sulfur content of products from miscellaneous U.S. crude oils. (From
Ref. 5.)

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(b)

Figure 4.3b Sulfur content of products from West Texas crude oils. (From Ref. 5.)

14-5
 (a)

Figure 4.4a Sulfur content of products from California crude oils. (From Ref. 5.)

14-6
 (b)

Figure 4.4b Sulfur content of products from Middle East crude oils. (From Ref. 5.)

14-7
Figure 4.5 Sulfur content of products from Venezuelan crude oils. (From Ref. 5.)

14-8
Figure 4.2 Nitrogen distributions in crude oil fractions.

14-9
Figure 4.7 Crude oil desalting units investment cost: 1999 U.S. Gulf Coast. (See Table
4.3.)

Figure 4.9 Atmospheric crude distillation units investment cost; 1999 U.S. Gulf Coast.
(See Table 4.4.)

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 Figure 4.11 Vacuum distillation units investment cost: 1999 U.S. Gulf Coast. (See
Table 4.5.)

Table 4.3 Desalter Unit Cost Data

Costs included
1. Conventional electrostatic desalting
unit
2. Water injection
3. Caustic injection
4. Water preheating and cooling
Costs not included
1. Waste water treating and disposal
2. Cooling water and power supply
Utility data (per bbl feed)
Power, kWh 0.010.02
Water injection, gal (m 3 ) 13 (0.0040.012) Demulsifier
chemical, lb (kg) a 0.0050.01 (0.0020.005)
Caustic, lb (kg) 0.0010.003 (0.0050.0014)
a
1999 price approximately $1.50/lb.
Note: See Fig. 4.6.

Table 4.4 Atmospheric Crude Distillation Unit Cost Data

Costs included
1. Side cuts with strippers
2. All battery limits (BL) process facilities
3. Sufficient heat exchange to cool top products and side
cuts to ambient temperature
4. Central control system
Costs not included
1. Cooling water, steam, and power supply
2. Desalting
3. Cooling on reduced crude (bottoms)
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 4. Sour water treating and disposal
5. Feed and product storage
6. Naphtha stabilization
7. Light ends recovery
Utility data (per bbl feed)
Steam [300 psig (2068 kPa)], lb (kg) 10.0 (4.5)
Power, kWh 0.9
Cooling water circulation, gal (m 3 ) a 150 (0.58)
Fuel, MMbtu (kJ) b 0.05 (52,750)
a
30F (17C) rise; about 50% of this duty can be used for BFW preheat. b
LHV basis, heater efficiency taken into account. (All fuel data in this text
are on this same basis.)
Note: See Fig. 4.9.

Table 4.5 Vacuum Distillation Unit Cost Data

Costs included
1. All facilities required for producing a clean vacuum gas oil
(single cut)
2. Three-stage jet system for operation of flash zone at 30 to
40 torr
3. Coolers and exchangers to reduce VGO to ambient tem-
perature
Costs not included
1. Cooling water, steam, power supply
2. Bottoms cooling below 400F (204C)
3. Feed preheat up to 670F (354C), 10 (assumes feed is
direct from atm crude unit)
4. Sour water treating and disposal
5. Feed and product storage
6. Multiple cuts or lube oil production
Utility data (per bbl feed)
Steam [300 psig (2068 kPa)], lb (kg) 10.0 (4.5)
Power, kWh 0.3
Cooling water circulation, gal (m 3 ) a 150 (0.57)
Fuel, MMBtu (kJ) b 0.03 (31,650)
a
30F (16.7C) rise.
b
LHV basis, heater efficiency taken into account.
Note: See Figs. 4.10 and 4.11.

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 Crdue Unit Material Balance

Basis: 100,000 PBCD Crude Alaska North Slop Crude Oil

Component Vol% BPCD API (lb/hr)/BPD lb/hr W% W% S lb/hr S W% N lb/hr N
Feed
Crude 100.0 100,000 26.4 13.1 1,307,464 100.0 1.0 14,700

Products
H2S
C2- 0.072 72 5.18 372 0.03
C3 0.317 317 7.39 2,341 0.18
iC4 0.159 159 8.20 1,302 0.10
nC4 0.629 629 8.51 5,353 0.41
LN (C5-180F) 4.3 4,277 63.0 10.61 45,394 3.47 0.00 1
HN (180-350F) 11.7 11,685 49.9 11.38 132,988 10.17 0.01 13
K (350-400F) 4.3 4,332 42.5 11.85 52,534 3.93 0.11 56
LD (400-525F) 12.2 12,200 36.5 12.21 148,906 11.39 0.24 357
HD (525-650F) 12.5 12,500 38.0 12.77 159,653 12.21 0.52 830
AR (650F+) 57.0 54,147 15.5 14.03 759,799 58.11 1.54 11,686

Total 100,317 1,307,464 100.0 12,944

If there are gases (vaporization losses) in the crude oil assigned to you, calculate the composition as follows.
An example, for distillation loss = 1.177 vol% of crude (the text approximates that to 1.2vol%)

Table: Estimation of light ends for CDU

Gas Fraction of distillation loss For distillation loss = 1.177 vol%
Gas Vol% of crude
C2- 0.061 0.072
C3 0.269 0.317
i-C4 0.135 0.159
n-C4 0.535 0.629
total 1 1.177 losses

Vacuum Unit Material Balance

Basis: 100,000 PBCD Crude Alaska North Slop Crude Oil

Component Vol% BPCD API (lb/hr)/BPD Lb/hr W% W% S Lb/hr S W% N Lb/hr N
Feed
AR (650F+) 57.0 54,147 15.5 14.03 759,799 58.11 1.54 11,686

Products
LVGO (650-850F) 20.5 20,500 22.2 13.42 275,119 36.2 0.95 2,614
HVGO (850-1050F) 15.6 15,644 15.5 14.03 219,518 28.9 1.51 3,315
VR (1050F+) 18.0 18,003 8.7 14.73 265,162 34.9 2.17 5,757

Total 54,177 759,799 100.0 11,686

Utility Requirements (per day)

Desalter Atm PS Vac PS Total
Steam (300 psig), lb 400,000 1,000,000 541,000 1,541,000
Power, kWh 1,000 90,000 16,000 107,000
CW circ, gal 15,000,000 8,122,000 23,122,000
Fuel, MMBTu 5,000 1,624 6,624
Water inj., gal 200,000 200,000
Demul. Chem.,lb 500 500
Caustic, lb 100,000 100,000

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Comparison of material balance results
% From crude oil assay (exp) calculated Error
Light gasoline 4.8 4.3 -10.4%
Total gasoline 20.1 4.3 + 11.7 = 16 20.4%
Gasoil 36.9 20.5+15.6 = 36.1 2.1%
Residue 20.3 18 - 11.3%

14-14
 2. FCC Unit Material Balance

YIELD ESTIMATION
Correlations have been developed for estimating FCC typical yields and product
properties (from cracking virgin gas oils).
This is good enough for preliminary studies and to determine yield trends when changes
are made in conversion levels.
The yield structure is very dependent upon catalyst type. Figures 6.11 through 6.16 are
for silica-alumina catalyst and Figures 6.17 through 6.27 are for zeolite or molecular-
sieve catalyst.

1. Use 75% conversion with Zeolite catalyst

2. Assume sulfur & N removal 90% for LVGO and 80% for HVGO in the HTU
3. Calculate weight of light & heavy gas oil feed from Vacuum Unit (done in previous HW)
4. Calculate Watson characterization factor for each feed then calculate the total using
weight average.
5. Determine yield of all products
Figure 6.18 (for wt% coke). Multiply with total lb/hr for the feed to get lb/hr coke

Figure 6.18 Catalytic cracking yields. Zeolite catalyst (coke).

Figure 6.19 (for wt% C2 & ltr). Multiply with total lb/hr for the feed to get lb/hr C2 & ltr

14-15
 Figure 6.19 Catalytic cracking yields. Zeolite catalyst (fuel gas).

Figures 6.20 (for C3+C4)

Figure 6.21 (for v% C3 and v% C3=). Multiply with total BPD for the feed to get BPD C3
and BPD C3=

Figure 6.21 Catalytic cracking yields. Zeolite catalyst (C 3 ratios).

Figure 6.22 (for v% iC4, v% nC4, and v% C4=). Multiply with total BPD for the feed to get
BPD iC4, BPD nC4 and BPD C4=

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 Figure 6.22 Catalytic cracking yields. Zeolite catalyst (C 4 ratios).

Figure 6.23 (for v% C5+ naphtha). Multiply with total BPD for the feed to get BPD C5+
naphtha

Figure 6.23 Catalytic cracking yields. Zeolite catalyst (C 5 + gasoline).

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6. Determine weight of gasoline by difference. For the C3=, C3, C4=, iC4, and nC4 the
density expressed in (lb/hr)/BPD in the table are constant. Multiply these values with the
BPD to get lb/hr for each one.
7. Using Figure 6.27 (lower part) to estimate gasoline gravity (lb/gal), multiply by 42/24 to
convert to (lb/hr)/BPD, divide (lb/hr)/BPD by 14.59 to get SG, calculate C5+ naphtha
API=141.5/SG-131.5. Multiply [(lb/hr)/BPD] by BPD to get lb/hr C5+ naphtha. calculate
volume of gasoline produced and check against yield estimated by Figure 6.22.

Figure 6.27 FCC product gravity. Zeolite catalyst.

8. From Figures 6.23 and 6.24 and feed rate, calculate the volume of heavy cycle gas oil
(HGO). Calculate the volume of total cycle gas oil (TGO v% =100 conversion =25 v%).
Calculate the lb/hr TGO by subtracting the total lb/hr (feed) lb/hr (coke, C2 & ltr, C3=,
C3, C4=, iC4, nC4, C5+ naphtha). Calculate TGO density in (lb/hr)/BPD, divide to get SG
then calculate the API of TGO

14-18
 TGO

Figure 6.24 Catalytic cracking yields. Zeolite catalyst (heavy gas oil, feed K = 11.8).

9. Subtract volume of HGO from volume of total cycle gas oil to obtain volume yield of light
cycle gas oil (LGO).
10. Use Figure 6.27 (upper part) to estimate HGO gravity (convert as in item 7 above) and
calculate weight yield of HGO.
11. Subtract weight yield of HGO from weight of total cycle gas oil to obtain weight yield of
LGO.
12. Divide weight yield of LGO by volume yield of LGO (step 9) to obtain density of LGO in
(lb/hr)/BPD then convert to SG and API as explained above.
13. Use figure 6.26 to obtain sulfur wt% for C5+ naphtha (C5-390 curve), Coke (Flue Gas
curve), and C2 (C4 and lighter curve). Multiply each with the total lb/he sulfur in the feed
to get individual lb/hr for each product. Obtain TGO (total cycle stock) lb/hr S by
difference, TGO(lb/hr)S = Feed(lb/hr)S - coke(lb/hr)S C2&ltr(lb/hr)S
C5+naphtha(lb/hr)S

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 14. Assume LGO (lb/hr sulfur) = 0.575 of (TGO lb/hr sulfur) and HGO (lb/hr sulfur) =
0.425 of (TGO lb/hr sulfur)

Figure 6.26 Distribution of sulfur in catalytic cracking products. (From Ref. 10.)

15. If sulfur is high in the feed assume the same distribution like sulfur

Product yields and properties are obtained in a similar manner when silica-alumina catalyst
is used in the reactor, except the gravity of the LGO can be obtained from Figure 6.10 and
the yield of HGO from Figure 6.12. It is necessary to find the weight yield of LGO by
difference.

CAPITAL AND OPERATING COSTS

16. Capital construction and operating costs for a FCC can be estimated using Figure 6.28
and its accompanying descriptive material (Table 6.5). Multiplying factors can be
found in Chapter 17 (Cost Estimation).

17. Calculate royalty fees

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 Figure 6.28 Fluid catalytic cracking units investment cost: 1999 U.S. Gulf Coast. (See
Table 6.5.)

Table 6.5 Fluid Catalytic Cracking Unit Cost Data

Costs included
1. Product fractionation
2. Gas compression and concentration for recovery of
95% and fractionation of C 4 s and 80% of C 3
3. Complete reactor-regenerator section
4. Sufficient heat exchange to cool products to
ambient temperatures
5. Central control system
Costs not included
1. Feed fractionation
2. Off-gas and product treating
3. Cooling water, steam, and power supply
4. Initial catalyst charge
Royalty
Running royalty about $0.10/bbl
Paid-up royalty about $110/BPD
Utility data (per bbl feed)
Steam, lb a
Power, kWh b 6.0
Cooling water, gal (30F!::t) 500
Fuel (LHV), MMBtu 0.1
Catalyst Replacement, $ 0.150.50 (take 0.15)
a
Waste heat steam production usually is in excess of consump- tion
by approximately 30 pounds of steam per barrel of fresh feed.
b
Includes electric drive for air blower and off-gas compressor.
Note: See Fig. 6.2.

CASE-STUDY PROBLEM: CATALYTIC CRACKER

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The choice of feedstocks for a catalytic cracking unit should be based on an economic
evaluation of alternative uses of the hydrocarbon streams. This is especially important in the
case of a refinery having both catalytic cracking and hydrocracking units. For this example,
both the heavy gas oil from the atmospheric pipe still and the vacuum gas oil from the
vacuum unit are used as FCC feedstocks, although it is quite possible the vacuum gas oil
might give a better return if used as hydrocracker feed.
The selection of a 75% conversion level was made because of the high boiling characteristics
of the feed. Checks should be made at higher and lower conversion levels to determine the
level of conversion giving the best economic return.
The gravity of the combined charge stock is obtained by dividing the total pounds of charge
by the volume. If the gravity is to be used for the calculation of a characterization factor (KW
) for yield prediction, the weight of sulfur and nitrogen should be subtracted from the
weight of feed before dividing by the volume. If this is not done, the characterization factor
will not be representative of the types of hydrocarbon compounds present in the
feedstocks. (It really does not make any difference)
The yields for the various product streams are obtained from Figures 6.9 through 6.14 for
silica-alumina catalyst and from Figures 6.15 through 6.21 for zeolitic catalyst. The sulfur
distribution in the products is estimated from Figure 6.22. In the case of the C4 and lighter
stream shown in Figure 6.22, it is assumed the sulfur is in the form of hydrogen sulfide (H 2S).
The weight of the total cycle gas oil (TGO) product stream is determined by difference, the
gravity from Figure 6.21, and the volume by dividing the weight by the gravity. This volume
is then used to check the conversion. In this example, the conversion obtained is 75.2%
versus the 75% used as the base. This is a satisfactory check. If it does not check within +1%,
some other method of determining product yields may better fit the characteristics of the
feed.
The material balance is shown below.
Utility requirements are estimated from Table 6.5 and are listed in Table 6.7.

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 FCC Unit Material Balance

Basis: 100,000 BPCD Alaska North Slop Crude oil Severity: 75% Conversion, Zeolite Catalyst
Component Vol% BPCD API (lb/hr)/BPD lb/hr W% W% S lb/hr S W% N lb/hr N Kw

Feed:
HT LVGO (650-850oF) 56.7 20,090 23.2 13.35 268,103 0.10 261 11.65
HT HVGO (850-1050oF) 43.3 15,331 16.5 13.95 213,857 0.29 630 11.73

Total 100 35,421 20.0 13.61 481,960 0.18 891 11.67

Products:
Coke, wt% 27,954 5.80 0.83 232* **
C2 & ltr, wt% 26,508 5.50 1.30 344
C3= 5.30 1,877 7.61 14,286
C3 2.90 1,027 7.42 7,591
C4= 9.50 3,365 8.76 29,477
i-C4 6.10 2,161 8.22 17,718
n-C4 2.70 956 8.51 8,139
C5+ naphtha 56.79 20,117 57.2 10.94 220,115 0.02 40
TGO/TCO 25.0 8,855 8.9 14.70 (130,172) 0.21 (275)
LGO/LCO (18.4) (6,517) 12.6 14.32 (93,352) 0.17 158 10.44
HGO/HCO 6.6 2,338 -0.6 15.75 36,820 0.32 117

Total 38,359 481.960 891

*in flue gas as SO2 ** in flue gas as NO2 ( ) obtained by difference

FCC Catalyst and Utility Requirements

Per bbl feed Per day
Power, kWh/d 6 212,526
Cooling water, gpd 500 17,710,500
Fuel, MMBtu/d 0.1 3,542
Catalyst, $/d 0.15 5,313
Steam, lb/d -30 (1,062,630) generated
Paid-up Royalty $ 110 3,896,310
Royalty fees $ 0.1 3,542

1992 US gulf coast Capital investment (using lower curve for Gasoil feed) = 82 MM $US
Todays price multiply by 1.03n = 1.03(2015-1992) = 1.974
2015 capital cost = 161.83
Building oversease multiply by 3-4 2015 capital cost in kuwait = 485.5 MM $US
Initial catalyst charge cost = ?
Running royalty is about $0.10/bbl = 0.1(35,421) = 3,542 $/d = 1,804(350 days) = 1,239,735 $/yr
Paid-up royalty is about $110/BPD = $100 (35,421) = 3,896,310 $US

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 3. Delayed Coker Unit Material Balance

The feed to the delayed coker is vacuum residue from the vacuum unit material balance, FCC HGO
from the FCC material balance. Neglect alkylation tar since we have not done the Alkylation material
balance.
The delayed coker material balance is calculated from the equations given in Table 5.5.
Use the API calcuated for the feed 7.4 API
Coradson carbon should be calculated by weight avraging the for the feed components but we dont
know how much it is for FCC HGO and Alkylation tar, so we just take it as given in trhe crdue oil assay
CR = 14.2 given in the crude oil assay for vacuum residue

Table 5.5 Coke Yields When Conradson Carbon Is Known

Coke wt% = 1.6 X (wt% Conradson carbon a )

Gas (C 4-) wt% = 7.8 + 0.144 (wt% Conradson carbon a )
Gaso. wt% = 11.29 + 0.343 (wt% Conradson carbon a ) Gas
oil wt% = 100 - wt% coke - wt% gas - wt% gaso.
Gaso. vol% = (131.5 + API) 186.5 (gaso. wt%) b
Gas oil vol% = (131.5 + API) 155.5 (gas oil wt%) b
a
Use actual Conradson carbon when available.
b
All API are those for net fresh feed to coker.
Note: These yield correlations are based on the following conditions:
1. Coke drum pressure 35 to 45 psig.
2. Feed is straight-run residual.
3. Gas oil end point 875 to 925F.
4. Gasoline end point 400F.

The Calculations of yields:

Coke = 1.6 (14.2) = 22.72 wt%.
Gas (C 4-) = 7.8 + 0.144 (14.2) = 9.84 wt%.
Naphtha = 11.29 + 0.343 (14.2) = 16.16 wt%. we calculate this just to get the vol%
Gas oil = 100.0 - (22.7 + 9.8 + 16.2) = 51.3 wt%. we calculate this to get the vol%
Naphtha = [186.5/(131.5 + 7.4)](16.16) = 21.7 vol%.
Gas oil = [(155.5/138.9)](51.3) = 57.4 vol%.
Notice that Naphtha and Gasoil is total for light and heavy
A typical split of coker naphtha is as follows:
Light naphtha = 35.1 vol%, 65 API
Heavy naphtha = 64.9 vol%, 50 API
An approximate split of the coker gas oil can be estimated from the following:
Light gas oil (LCGO) = 67.3 vol%, 30API Heavy
gas oil (HCGO) = 32.7 vol%,
The API for lt and hv naphtha and lt and LCO and HCO are asumed constant. From the API get the SG
then multiply with 14.59 to obtain the density in (lb/hr)/BPD
For the light naptha, heavy naphtha and LCGO multiplying BPD with (lb/hr)/BPD to obtain lb/hr
For HCGO calculate lb/hr by difference = (feed) lb/hr (gas, lt & hv naphtha, LCGO and coke) lb/hr
For HCGO divide mass and volume flow rates to get (lb/hr)/BPD, divide by 14.59 to get SG, calaulate
API
For sulfur and nitrogen distribution in coker prodcts use the following table

Table 5.9 Sulfur and Nitrogen Distribution for Delayed Coking (Basis: Sulfur and Nitrogen in Feed to Coker)

Sulfur (%) Nitrogen (%)

Gas 30
Light naphtha 1.7
Heavy naphtha 3.3 1
LCGO 15.4 2
HCGO 19.6 22
Coke 30 75
Total 100 100

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 Multiply the above wt % with total lb/hr S in feed or lb/hr N in feed to get lb/hr S & N for individual
products
For capital investment use the figure. (Multiply 24/2000 to vonvert lb/hr coke to ton/day);
(68,717)*24/2000 = 824.5 TPD
Devide BPD feed / tonns coke per day to get the ratio to use in the figure below; 20,366 BPD / 824.5
TPD = 24.7 (interpolate between the two figures at 10 and 30) 90 MM$US 1999 (today = 90*1.03 16
= 144$US)

Figure 5.2 Delayed coking units investment cost1999 U.S. Gulf Coast. (See
Table 5.10.)

Calculate the gas composition using below table. Subtract gas lb/hr gas lb/hr S to obtain the sulfur-
free gas then divid by 22.12 (constant MW given) to obtain gas in mol/hr. use the table below to obtain
the detailed gas mol/hr

Table 5.8 Typical Gas

Composition for Delayed
Coking (Sulfur-Free Basis)

Component mol%
Methane 51.4
Ethene 1.5
Ethane 15.9
Propene 3.1
Propane 8.2
Butenm 2.4
i-Butane 1.0
n-Butane 2.6
H2 13.7
CO 2 0.2
Total 100.0
Note: MW = 22.12.

14-25
Sulfur Free Composition:
Sulfur Free Gas: 28,014
Gas Mw 22.12 constant
Total Sulfur Free Gas 1,266.4
Component: Mol% Mol/hr
C1 51.4 650.9
C2= 1.5 19.0
C2 15.9 201.4
C3= 3.1 39.3
C3 8.2 103.8
C4= 2.4 30.4
i-C4 1.0 12.7
n-C4 2.6 32.9
H2 13.7 173.5
CO2 0.2 2.5
Total 100 1,266.4

Calculate the final coker gas balcence adjusted for sulfur; by adding the mol/hr sulfur and subtracting
the same amount from mol/hr H2. Multiply (C3-C4 gases) each by its MW to get the lb/hr then devide
by the density (lb/hr)/BPD to get BPD
Final Coker Gas Balance:
Sulfur flow 1,761 lb/hr 55.0 mol/hr
Sulfur Mw 32
Component: Mol/hr Mw lb/hr (lb/hr)/BPD BPD
C1 650.9 16 10,415
C2= 19.0 28 532
C2 201.4 30 6,041
C3= 39.3 42 1,649 7.61 217
C3 103.8 44 4,569 7.42 616
C4= 30.4 56 1,702 8.76 194
i-C4 12.7 58 735 8.22 89
n-C4 32.9 58 1,910 8.51 224
H2 118.5 2 237
CO2 2.5 44 111
H2S 55.0 34 1,871
Total 1,266.4 29,772 1,341

Get the Utilities from the following table

Table 5.10 Delayed Coking Unit Cost Data

Costs included
1. Coker fractionator to produce naphtha, light gas oil, and
heavy gas oil
2. Hydraulic decoking equipment
3. Coke dewatering, crushing to <2 in. and separation of
material <1/4 in. from that >1/4 in.
4. Three days covered storage for coke
5. Coke drums designed for 50 to 60 psig (345 to 415 kPa)
6. Blowdown condensation and purification of waste water
7. Sufficient heat exchange to cool products to ambient
temperatures
Costs not included
1. Light ends recovery facilities
2. Light ends sulfur removal

14-26
 3. Product sweetening
4. Cooling water, steam, and power supply
5. Off gas compression
Utility data
Steam, lb/ton coke 700
Power, kWh/ton coke a 30
Cooling water, gal/bbl feed (30F !::T) 70
Fuel, MMBtu/bbl feed b 0.14
a
Includes electric motor drive for hydraulic decoking pump.
b
Based on 600F (1110C) fresh feed. LHV basis, heater efficiency
taken into account.
Note: See Fig. 5.2.

Delayed Coker Unit Material Balance

Basis: 100,000 BPCD Alaska North Slop Crude oil Conradson Carbon, 1050+ oF RC = 14.2% (crude
assay)
Component Vol% BPCD API (lb/hr)/BPD lb/hr W% W% S lb/hr S W% N lb/hr N Kw

Feed:
1050+oF VRC 88.4 18,003 8.7 14.72 265,162 2.17 5,757
FCC HGO 11.5 2,338 -0.6 15.75 36,820 0.32 117
Alylation Tar 0.1 25 468

Total 100.0 20,366 7.4 14.85 302,450 1.94 5,875

Products:
Gas (C4-), wt% 29,776 9.84 5.92 1,762
Lt Naphtha 7.6 1,551 65.0 10.51 16,303 0.36 100
Hvy Naphtha 14.1 2,868 50.1 11.36 32,575 0.72 194
LCGO 37.3 7,587 30.0 12.78 96,967 0.93 905
HCGO 20.1 4,103 14.3 14.16 (58,114) 1.98 1,151 10.56
Coke, wt% 68,717 22.7 2.56 1,762

16,110 302,450 5,875

Delayed Coker Utility Requirements

(Basis: 825 tons coke per day)
Steam, lb/d 577,000
Power, KWh/d 25,000
Cooling water, gpd 1,425,600
Fuel, MMBtu/d 2,851

14-27
14-28
 4. Hydrocracker Unit Material Balance

It is necessary to make both weight and hydrogen balances on the unit.

Calculation Procedure:
1. Obtain the feed to the HCR process in this example is Coker gasoil and FCC LCO from previous HWs
2. Calculate the total BPD, lb/hr for the feed and the lb/hr S and N
3. Calculate the (lb/hr)/BPD for the feed, divide by 14.59 to get SG then calculate the feed API
4. Use coker GO Tb = 616 F and FCC LCO Tb = 617F to calculate watson K for each (Kw = 10.56 & FCC
LCO = 10.44) then for the feed by weight average (in this example Kw = 10.52)
5. Use severity = 2,000 Hydrogen, scfb
6. With the Watson characterization factor (Kw ) of the feed and the hydrogen consumption in scf/bbl
feed proceed as follows:
7. Use Figure 7.3 to determine the vol% (C5-180F) naphtha.

Figure 7.3 Approximate hydrogen required for hydrocracking. (From Ref. 11.)

8. With Figure 7.5 use the vol% (C5-180F) naphtha and feed KW to obtain vol% (180 to 400F) naphtha.
9. If the yield of C5-180F naphtha is greater than 25 to 30 vol%, the yield of heavy hydrocrackate (180
to 400F naphtha) will be determined from a curve having a negative slope. This indicates an
economically unattractive situation because heavy hydrocrackate is being cracked to lighter materials.
A less severe operation should be used.

14-29
Figure 7.4 Relationship between yields of C 5-180F and 180400F hydrocrackates.

10. Calculate the liquid volume % butanes formed from:

LV% iC4 = 0.377 [LV% (C5-180F)]
LV% nC4 = 0.186 [LV% (C5-180F)]
11. Use the given density in (lb/hr)/BPD which is constant for iC4 and nC4 to obtain lb/hr for each
12. Calculate the wt% of propane and lighter from:
wt% C3 and lighter = 1.0 + 0.09 [LV% (C5-180F)]
then multiply with the feed lb/hr (total oil without H2) to obtain 2,603 lb/hr
13. Obtain KW factors of the product streams from Figure 7.5 using average boiling point below

Product average mid-boiling points (F) Kw Calculated SG

(Given) (given) (from Figure 7.5)
C5-180F naphtha 131 12.37 0.6785
180 to 400F naphtha 281 11.40 0.7923
400+F streams 460 11.25 0.8643

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 Figure 7.5 Characterization factor of hydrocracker products. (From Ref. 12.)

14. The gravities of the product streams can be calculated using the KW factors of the product streams
using the floowing equation SG =(Tb+460)(1/3 / Kw. Use SG to calculate the API. Multiply SG with 14.59
to obtain (lb/hr)/BPD. Use (14.59)( SG)( BDP) to obtain lb/hr for C5-180F naphtha and 180 to 400F
naphtha
15. Because all the sulfer in the feed is removed as H2S, the lb/hr H2S is obtained by multiplying 1,309
lb/hr S with 34/32 which is the atio of the MW of H2S over MW of S. this gives 1,391 lb/hr H2S.
16. The chemical hydrogen consumed should be included with the total weight of the feed. Since we
assumed severity of 2,000 scf/bbl we multiply that with feed 10,620 BPD and devide by 4554
conversion factor (conversion from day to hr and scf to lb) to obtain 4,671 lb/hr H2 to be entered with
the feed for the reaction.
17. The weight of the 400+F stream is obtained by difference from the feed oil & H2 (lb/hr) minus all
other products (lb/hr). Divide this by the density in (lb/hr)/BDP to obtain vol flow rate in BPD. Divide
by total BPD feed oil to obtain the vol %.

HYDROGEN BALANCE
18. Hydrogen contents of the streams can be estimated using the wt% hydrogen for each stream, except
the liquid products,
19. Subtract lb/hr H2S lb/hr S = 1,391 - 1,309 to obtain the amonut of H2 = 82 lb/hr
20. The w% of H2 in C4 is constant at 17.2%.
21. The composition of the C3 and lighter stream will vary depending upon feedstock properties and
operating conditions. For the purpose of preliminary studies, the following composition can be
assumed (average from experimental data). For this gas composition the H2 wt% for C3 & ltr is 20%.
for.
mol% wt%
C1 20 8.8
C2 15 12.4
C3 65 78.8
Total 100 100.0

22. For the liquid feeds and products Hydrogen contents is obtained from Figure 7.6 which requires Kw
and Tbave

14-31
 Figure 7.6 Hydrogen content of hydrocarbons. (From Ref. 21.)

23. For the feed, use the given Tb and the above calculated Kw in Figure 7.6 to get w% H2
24. For the products, use the tabulated results for Kw and the Tb (from step 13 above) in Figure 7.6 to get
w% H2
25. Multiply the H2 wt% of each product with the products mass flow in lb/hr to obtain the lb/hr for each
products.
26. Assume hydrogen loss by solution in products of 1 lb/bbl feed (range 0.8 to 1.3 lb H2 /bbl feed).
Convert from lb/day to lb/hr
27. The difference in hydrogen between the in and out is 904 lb/hr which is H2 that should be added. This
is equivalent to 904(4554/10,621 BPD) = 387 SCFB (making H2 consumption 2,000+387 = 2,387
scf/bbl)
28. Capital investment costs for catalytic hydrocracking units can be estimated from Figure 7.7.
29. Table 7.4 lists the utility requirements (interpolate for utility requirements corresponding to the
calculated hydrogne conasumption 2,387 scf/bpd not the assumed 2,000 scf/bpd)
30. Calculate the intital cataklyst cost and royalties cost

Table 7.4 Catalytic Hydrocracking Unit Cost Data

Costs included
1. Stabilization of gasoline
2. Fractionation into two products
3. Complete preheat, reaction, and hydrogen circulation facilities
4. Hydrogen sulfide removal from hydrogen recycle
5. Sufficient heat exchange to cool products to ambient temperature
6. Central control system
7. Electric motordriven hydrogen recycle compressors
Costs not included
1. Initial catalyst charge, approximately $150/BPD of feed
2. Hydrogen generation and supply facilities
3. Spare hydrogen recycle compressors
4. Recovery of butanes, propane, etc., from gas
5. Feed fractionation
6. Conversion of hydrogen sulfide to sulfur
7. Cooling water, steam, and power supply
14-32
 8. Paid-up royalty
Royalty
Running royalty is about $0.15 to 0.25/bbl.
Paid-up royalty is about $150 to 250/BPD.
Utility data (per bbl feed)
Hydrogen consumption, scf. 1000 2000 3000
Steam, lb 50 75 100
Power, kWh a 8 13 18
Cooling water, gal crclt. (30F!::t) 300 450 600
Fuel (LHV), MMBtu 0.1 0.2 0.3
Catalyst replacement, $ 0.05 0.1 0.2
a
Includes electric drive for hydrogen recycle compressors.
Note: See Fig. 7.8.

Figure 7.7 Catalytic hydrocracking unit investment cost: 1999 U.S. Gulf Coast. (See
Table 7.4.)

14-33
 Hydrocracker Material Balance

Basis: 100,000 BPCD North Slope, Alaska, Crude oil Severity 2,000 scf H2/bbl) Assmued (will be corrected)
Component Vol% BPCD API (lb/hr)/BPD lb/hr W% W% S lb/hr S W% N lb/hr N Kw Tb F

Feed:
Coker HGO 38.6 4,103 14.3 14.16 58,114 1.98 1,151 10.56 616
FCC LCO 61.4 6,517 12.6 14.32 93,352 0.17 158 10.44 617
total 100.0 10,621 13.3 14.26 151,456 1,309 10 10.49 617

Hydrogen, scfb 2,000 4,671

Assumed for
example
Total with H2 156,137
You must
calculate
Products:
from before
NH3 12 10
H2S (wt%) 1,391 0.89 1,309
C3 & ltr (wt%) 2,603 1.72
iC4 2.89 307 8.22 2,523
nC4 1.43 151 8.51 1,289
Lt N (C5-180F) 8.98 817 77.1 9.90 8,096 12.37 131
Hv N (180-400F) 28.12 2,937 47.1 11.56 34,519 11.42 281
Dist (400-520F) 79.5 8,441 32.2 12.61 (105,716) 11.25 460

120.9 12,841 156,137

S and N in product is assumed zero because of hydrocracking. Any N in the feed come out as NH3 gas
lb/hr NH3 = 10 (lb N /hr) (17/14) = 12.14 lb/hr , hydrogen in NH3 is the difference between NH3 and N = 12.14 10 = 2.14
( ) obtained by difference,

Hydrogen Balance wt % H2 lb/hr lb/hr H2

Out:
NH3 2.14
H2S 1,391 82
C3 & ltr 20.0 2,603 521
C4 17.2 3,805 654
C5-180 F 15.3 8,053 1,231
180-400 F 13.9 34,519 4,798
400-520 F 12.1 106,439 12,870
H2 in soln. (1 lb/bbl feed) 443
20,601
In:
Coker GO 10.0 58,114 5,791
FCC LCGO 9.9 93,352 9,235
Hydrogen 100.0 4,671 4,671
19,697
Added H2* 904
20,601

*Increase H2 consumption by 904 lb/hr to give 2,387 scfb H2 used.

Hydrocracker Utility Data (per bbl feed)

Hydrogen Consumption, scf 1,000 2,000 3,000
Steam, lb 50 75 100
Power, KWh* 8 13 18
Cooling Water, gal crclt (30 F t) 300 450 600
Fuel (LHV), MMBtu 0.1 0.2 0.3
Catalyst Replacement, $ 0.05 0.1 0.2
* Includes electric drive for hydrogen recycle compressors.

Hydrocracker Catalyst and Utility Requirements

Steam, Mlb/day 797
Power, MKWh/d 138
Cooling water, gpd 4,750
Fuel, MMBtu/d 2,124
Catalyst, $/d 1,062

14-34
Capital cost 1999 = 90 MM $US , Today = 90 (1.03)16 = 144.4 MM $US
Initial catalyst charge cost is approximately $150/BPD of feed = 150(10,621) = 1,593,150 $US
Running royalty is about $0.15 to $0.25/bbl = 0.25(10,621) = 2,655 $/d = 2,655(350 days) = 929,338 $/yr
Paid-up royalty is about $150 to $250/BPD = $250 (10,621) = 2,655,250 $US

14-35
 5. Hydrotreater & Catalytic Reformer Unit Material Balance

YIELDS AND COSTS

Catalytic reforming yields can be estimated using Figures 10.4 through 10.7. These simplified yield correlations
are approximations only and are not specific for any catalyst, operating parameters, or process configuration.
Actual yields are functions of reactor pressure, catalyst type and activity, and feed quality.

CASE-STUDY PROBLEM: NAPHTHA HYDROTREATER, CATALYTIC REFORMER, AND

ISOMERIZATION UNIT

The feed to the catalytic reformer consists of the heavy straight-run (HSR) gasoline (180 to 350F)
from the crude unit and the coker gasoline (C5-380F).

1. Calculate the characterization factor (KW ) of the feed. Assume the boiling point C5 is 90F
HSRN; Tb = (180+350)/2 = 265F, Kw = (265+460)1/3 / 0.7800 = 11.52
Coker LN; Tb = (90+180)/2=135F, Kw = (135+460)1/3 / 0.7204 = 11.68
Coker HN; Tb = (180+380)/2=280F, Kw = (280+460)1/3 / 0.7786 = 11.62

Ave. KW = [(11.52)(132,988) + (11.68)(16,303) + (11.62)(32,575)]/ 181,886 = 11.55

2. Assume severity of 94 RONC (clear) initially.
3. Determine C5+ gasoline volume yield from Figure 10.4 (dahsed line). Extrapolate using curves for 11.9
and 11.7 if out of range. If vol% is greater than 87.5 assume higher RON say 95 or 96, etc. until C5+
gasoline volume yield becomes 87.5 or slightly less. Here 94 RON gave 88.6 vol% so we try 95 RON.
This gives 87.3 vol% C5+ gasoline which is ok.

Figure 10.4 Catalytic reforming yield correlations.

4. Multiply vol% of C5+ reformate with feed BPD to get reforamte BPD
5. Determine weight or volume yields
Fig 10.5 gives vol% C4 total = 4.44, then iC4 = 0.415 (4.44) = 1.8 v% and nC4 = 0.585 (4.44) = 2.6 v%
Multiply vol% of each with feed BPD to get BPD for iC4 anf nC4.

14-36
 Figure 10.5 Catalytic reforming yield correlations.

Fig 10.6, C1 + C2 = 0.7 w%, and C3 = 1.6

Figure 10.6 Catalytic reforming yield correlations.

Fig 10.7 gives H2 = 1.4 wt%

Figure 10.7 Catalytic reforming yield correlations.

14-37
6. Calculate weight yield lb/hr of H2, C1+C2 and C3 by multiplying wt% with feed mass flow in lb/hr.
Divide lb/hr C3 by the given constant desnity of C3 which is 7.42 (lb/hr)/BPD to obtain BPD C3
7. Calculate the mass flow of iC4 and nC4 by multiplying BPD with the given constant desity of each in
(lb/hr)/BPD
8. Make sulfur balance to determine H2S made. Multiply total feed sulfur 307 by 34/32 to obtain 326
lb/hr H2S. Calculate the difference 326 307 to obtain the amount of H2 = 19 lb/hr consumed to
make H2S.
8. Make nitrogen balance (if there is N in the feed) to determine NH3 made. Multiply total feed nitorgen
20 by 17/14 to obtain 24 lb/hr NH3. Calculate the difference 24 20 to obtain the amount of H2 = 4
lb/hr consumed to make NH3.
9. Subtract these amounts of hydrogen from the H2 produced = 2,518 19 4 = 2,494 lb H2 (net)
10. Determine weight yield of C5+ gasoline by difference; lb/hr (feed) lb/hr (N, S, H2, C1+C2, C3, iC4 and
nC4). We count the lb/hr S and N and not the lb/hr H2S and NH3 bacause the H2 produced already
accounts for the hydrogen contained within the NH3 and H2S.
9. Divid lb/hr C5+reforamte by BPD to get the desnity in lb/hr/BPD, divide by 14.59 to get SG, then use
SG to calculate API gravity of C5+ gasoline.
10. Estimate Catalyst & Royalties from Table 10.2.

Table 10.2 Catalytic Reforming Unit Cost Data

Costs included
1. All battery limit facilities required for producing 102 RON unleaded reformate
from a HSR naphtha sulfur-free feed
2. Product stabilizer
3. All necessary control and instrumentation
4. Preheat and product cooling facilities to accept feed and release products at
ambient temperatures
Costs not included
1. Cooling water, steam, and power supply
2. Initial catalyst charge
3. Royalty
4. Feed fractionation or desulfurization
Catalyst charge
Initial catalyst charge cost is approximately $200/BPD of feed.
Royalties
Running royalty is about $0.05 to $0.10/bbl.
Paid-up royalty is about $50 to $100/BPD.
Utility data (per bbl feed)
Steam,a lb 30
Power, kWh 3
Cooling water, gal 400
Fuel gas (LHV), MMBtu 0.3
Catalyst replacement, $ 0.10

a
With some configurations, a net steam production is realized.
Note: See Fig. 10.8.

11. Estimate chemical and utility requirement data from Table 10.7.

Table 10.7 Hydrotreaters, Catalytic Reformer, and Isomerization Unit Chemical and Utility Requirements

Reformer and HT Isomerization

Per barrel Per barrel

Utility feed Per day feed Per day

Steam, Mlb 0.036 631

Power, MkWh 0.005 88 0.001 6
CW, Mgal 0.9 15,786 0.8 4,662
Fuel, HMBtu 0.4 7,016 0.2 1,166
Catalyst, $ 0.12 2,105 0.05 291
H 2 makeup, Mscf 0.04 233

14-38
12. Capital and operating costs can be obtained from Figure 10.8

Figure 10.8 Catalytic reforming unit investment cost: 1999 U.S. Gulf Coast. (See Table
10.2.)

14-39
 Table 10.5: Hydrotreater & Catalytic Reformer Unit Material Balance

Basis: 100,000 PBCD North Slop, Alaska, Crude oil Severity: 95 RON Clear Kw = 11.55
Component Vol% BPCD API (lb/hr)/BPD lb/hr W% W% S lb/hr S W% N lb/hr N

Feed:
CDU HSRN (180-350F) 72.56 11,685 49.9 11.38 132,988 13
Coker L Naphtha (C5-180F) 9.63 1,551 65.0 10.51 16,303 100
Coker H Naphtha (180-380F) 17.81 2,868 50.1 11.36 32,575 194

100.0 16,104 50.2 11.29 181,866 0.17 307 20 Assumed for

example
Products: You must
NH3 24 20 calculate
H2S 326 307 from before
H2, wt%, total 2,518 1.4
C1+C2, wt% 1,317 0.7
C3, wt% 385 7.42 2,855 1.6
iC4 1.8 297 8.22 2,441
nC4 2.6 419 8.51 3,563
C5+ Reformate 87.3 14,054 40.3 12.01 (168,846)

Total 15,154 181,866

H2S = 326 (lb/hr) / 34 (lbm/lbmol) = 9.59 lbmol/hr NH3 = 24 (lb/hr) / 17 (lbm/lbmol) = 1.412 lbmol/hr
H2 in H2S = (9.03 lbmol/hr)(2 lbm/lbmol) = 19 lb/hr H2 in NH3 = (1.412 lbmol/hr)(2 lbm/lbmol) = 4.236 lb/hr
Net Hydrogen produced = 2,518 19 4 = 2,494 lb/hr
( ) calculated by difference

Hydrotreater & Catalytic Reformer Units

Chemical & Utility Requirements
Utility Per bbl feed Per day
Steam, lb 36 579,744
Power, kWh 5 80,520
CW, gal 900 14,493,600
Fuel, MMBtu 0.4 6,442
Catalyst, $ 0.12 1,932

Capital cost 1999 (fixed bed) = 29 MM $US

Today = 32 (1.03)16 = 46.5 MM $US
Initial catalyst charge cost is approximately $200/BPD of feed = 200(16,104) = 3,220,800 $US
Running royalty is about $0.05 to $0.10/bbl = 0.1(16,104) = 1,610 $/d = 1,610(350 days) = 563,640 $/yr
Paid-up royalty is about $50 to $100/BPD = $100 (16,104) = 1,610,400 $US

14-40
 6. Overall refinery material balance

1. Add the products from all the units in a table in BPD and lb/hr
2. Add all the utilities, then calculate their cost
3. Calculate the total cost and running of the refinery including capital cost, catalyst and royalties

14-41