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Abstract—This paper presents a model that uses the crude The property prediction methodology makes use of the
true boiling point curve and other routinely performed crude true boiling point (TBP) curve, available from
laboratory measurements on crude distillation unit (CDU) refinery laboratory, and steady state data such as operating
for product properties prediction. The inputs to the model flow-rates, temperatures and pressures. Based upon the
are different types of crude. Objective of the optimization is draw plate temperatures for different products, the
to minimize the cost of energy consumption per tons of algorithm calculates five equilibrium flash vaporization
crude. The detailed model is based on a real refinery, it is (EFV) temperatures. These EFVs are then converted to
based upon the first-principle, and it is nonlinear. The CDU TBPs which, when superimposed on the crude TBP
model is a non-stage-by-stage, steady-state model and it is curves, allow estimation of five additional product TBP
corrected by real process values. The model calculates yields temperatures. Then, the TBP curves are used as input to
and properties of the products based on the feed the model. Thus, without making the simulation over the
information and product specifications. The proposed model entire column, product properties are determined in an
has following benefits in comparison to commercial easy and instant way. This method is mainly based on
simulation models: it is adapted to real plant conditions, it is proposals in [2] and [3]; and it differs to the one described
an open source solution, and it is flexible and fast in in [1].
execution. The model is useful for comparison of the actual
plant performance to the expectation at the plant design II. CRUDE DISTILLATION UNIT (CDU)
stage and to the optimal case. It can identify operating
changes required to maximize the profit, it can provide for
the highest return on investment for the unit, it can identify Figures 1 - 6 show process flow diagrams of the CDU.
the fouling level and it can be applied for optimal planning The refinery processes blends of REB, Brent, Iraq Kirkuk,
of the unit shutdowns and maintenance. The optimal Libyan EsSider and Syrian light crude oils.
solution obtained shows that the energy consumption could During the unit performance test (test-run), the
be decreased up to 3.2% compared to the actual operating atmospheric bottoms (residue) yield was 42% of crude.
regime. The column's lowest side cut is the heavy gas oil. Light
gas oil and kerosene are side products. Gasoline C5-180,
I. INTRODUCTION LPG and still gas combine the C01 top product.
The CDU is a compound of six sections and it is
presented in the same way as it appears on Honeywell
A model is proposed to minimize the cost of energy TPS distributed control system (DCS) screens. In Fig. 1
consumption in oil refinery depending on the are Desalter (V04) and Preflash columns (C06) with heat
characteristics of different types of crude at input. exchangers for heating crude oil before furnace (F01). Fig.
The oil industry is divided in two parts: upstream, 2 shows the Furnace (F01) and Atmospheric column
concerned with finding oil deposits and getting the crude (C01) section. The Reflux section (V01 and C03) is given
oil out of the ground (exploration & production) and in Fig. 3. Debutanizer (C04) and Stabilizer (C05) sections
downstream, concerned with turning crude oil into usable are given in Fig. 4 and Fig. 5, respectively. Heavy
products and delivering them to customers (refining to distillate cooling section is shown in Fig. 6.
achieve petrochemicals & distribution). Oil industry is An example of optimizing the CDU is given in Fig. 7
among the most prolific and dynamic industries of modern where the results are flow rates (t/h), heat exchangers
civilization where a highly competitive market, stringent energy duty (MJ) and temperatures (°C).
environmental laws and strict quality control of refinery
products are a must. Through the Crude Distillation Unit
(CDU) the entire crude oil entering a refinery must be
processed. III. THE MODEL
Crude oil and all the CDU products are complex
mixtures of hydrocarbons, so it is not convenient to The proposed model operates off-line, it is based on the
characterize them in terms of individual components, see first principle of mass and energy balance, it is validated
in [1], [2] and [3]. by actual data, it is nonlinear and steady-state [4].
Oil refineries are facing an enormous number of options Figure 4. Debutanizer column section
in their operations:
• which crude to refine;
• what processing condition to use;
• how to economize with the energy.
200
Nonlinear Programming is a part of mathematical + 2.698276 · t (°C)
programming. In this project nonlinear programming is + 3.032970 · Ȗ (ton/m3)
used because of inherently existing nonlinearity in
+ 41.86634) · (0.054 · K + 0.352)
description of the CDU equipment [6]. In some papers
Genetic algorithms are used to solve nonlinear Where is: t(°C) - temperature
3
dependencies [7]. Ȗ(ton/m ) - density
Simulation programs are very popular in oil refineries K - Characterization factor [3]
[8] but because of their weaknesses (see [9] and [10]) the
model proposed in this paper gives a better (i.e. closer to Example 2:
real operation) solution for the energy optimization.
Enthalpy of steam (1-12 bars):
The model of CDU is given in Fig. 8. Preprocessing of
input data was performed in MS Excel file named
Technological Preprocessing file (TPP file). Data in this hSteam(t )[MJ/ton]= 2.034506 · t (°C)
file are changed in laboratory when crude oil or basic + 2460.255
properties of crude oil are changing. Data in the file are:
TBP, EFV, density, characterization factor (K), and
volume and mass flows of all crude oil fractions.
1) T-pipe type 1
TPP file Inp ut/Output file T-pipe type 1 is the first element to be modeled. In Fig.
(MS Exc el) 9 an example is given where two similar streams converge
(MS Exc el) into a single one.
2) T-pipe type 2
A. Process Equipment Model
In Fig. 10 an example is given where a single stream
All process equipment in the CDU is modeled based on forks in two.
the first principle (energy and mass balance) and validated
by actual data. Equations are nonlinear and the model
represents steady-state. F1,t1,h1 F3 ,t3 ,h 3
Energy balance is based on heat contents (enthalpy) of
petroleum fractions; see [2] and [3]. An USER@ function
is defined in LINGO for calculating enthalpy of petroleum
fractions and H2O (for both: liquid and vapor state).
F2,t2,h2
Example 1: Figure 10. T-pipe type 2
Enthalpy (h) of liquid petroleum fractions:
F3 = F1 - F2
hHC(t, Ȗ, K )[MJ/ton]= (0.00295682247 · t2(°C) t3 = t1 = t2
- 17.1523 · Ȗ2(ton/m3) h3 = h2 = h1
- 0.0010328 · t2(°C) · Ȗ(ton/m3)
- 0.437829 · t (°C) · Ȗ2 (ton/m3)
- 0.607645 · t (°C) · Ȗ (ton/m3)
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3) Exchanger
(Ak2,f%)
In Fig. 11 an example of a typical exchanger is given.
F11,t 11,h11 t 12,h1 2
F2,t21,h 21
Q1 = F1 · (h11 - h12)
F1,t 1,h 1 F2,t 2,h2
Q2 = F2 · (h22 - h21)
LMTD = [(t11 - t22) - (t12 - t21)]
/ ln [(t11 - t22) - (t12 - t21)]
Q1 = Q2 = Ak · f% · LMTD
t11 > t22 +1
t12 > t21 + 2
F3,t3,h3
Model of the exchanger is based on [3] and [6]. Fouling
is discussed in [11] and [12]. Figure 14. Vessel
F2 ~ 0
4) Distillate cooling fan F3 = F1, t3 = t1, h3 = h1
Q1 = F1 · (h1 - h2)
Q1 < max Duty
t2 < t1 - 1 F01
5) Distillate-Water cooler
FFG FFO FSte a m_12b ar
In Fig. 13 an example is given of a typical distillate-
water cooler.
Figure 15. Furnace
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Q1 = FCrude · (h12 - h11) + FSteam_5bar · (h22 - h21)
Q2 = QFG · FFG + QFO · FFO min(Cost/Crude) = Cost($) / Crude(ton)
Q1 = ȘF01 · Q2 Cost($) = PriceChemicals($/ton) · Crude(ton)
Q2 < maxDutyF01 + PriceH2O_Desalter($/ton) · H2O(ton)
FSteam_12bar = FFO · Steam_12bar_% + PriceSteam_5bar($/ton) · Steam_5bar(ton)
+ PriceSteam_12bar($/ton) · Steam_12bar(ton)
Where
+ PriceH2O_Cool($/ton) · H2O_Cool(ton)
FG stands for “Fuel Gas”
+ PriceFuel _Oil($/ton) · Fuel_Oil(ton)
FO stands for “Fuel Oil”
+ PriceFuel_Gas($/ton) · Fuel_Gas(ton)
+ PriceElect_Power($/MW) · Elect_Power(MW)
8) Stabilizer column
In Fig. 16 an example is given of the Stabilizer column. A typical value of performance function was 2.5~3.5
($/ton) depending on the CDU capacity and crude oil type.
F2,t2,h2 (V03,E20,E31)
C. Initial values
F1,t1,h 1 F4,t4,h4 F7 ,t4,h4 In particular for nonlinear models, the initial values for
the solver search may influence the quality of solution and
the speed of reaching it.
In the CDU model initial values are put very close to a
C05 "guessed or expected" value. It is necessary to try a few
values before the solver finds the optimal solution.
Otherwise, the solution is usually far from optimum or
F5,t5,h5
even infeasible.
(QE22)
IV. TEST RESULTS
F6,t6,h6 F3,t3,h3
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TABLE 1: A possible saving in energy of 3.17% is valuable
because CDU is among the biggest energy consumers [13]
Crude oil: Iraq Kirkuk DCS CDU Model
in a typical refinery and it rises the opportunity to improve
the energy management.
Crude oil fractions % %
In addition, the model can be used for testing different
Still Gas 0.07 0.05
revamping scenarios and to solve production bottlenecks
LPG 1.15 1.25 in the CDU.
Gasoline C5- 78°C 5.94 5.32 Finally, the model presented in the paper could be
Gasoline 78 - 180 °C 15.70 15.68 useful in production planning when using a new type of
Kerosene 9.69 9.75 crude oil. Accounting to more than 85% of the typical
Light Gas oil 18.17 18.29 refinery's operating cost structure, the crude is a key
Heavy Gas oil 6.99 7.48 "operating parameter" that must be set early in the
planning process [14]. The benefit of using the CDU
Residue 42.29 42.19 model for that purpose is even higher than presented in
ENERGY this paper.
Steam 5 bar (ton/h) 6.34 7.11
Steam 12 bar (ton/h) 1.98 2.26
Cooling water (ton/h) 603.90 441.53 REFERENCES
Desalter water (ton/h) 16.91 24.00 [1] S. Bhat, T. Chatterjee, and D. N. Saraf, “On-line Data Processing
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Electrical Power (MJ) 3.47 3.50 [2] J. B. Maxwell, Data Book on Hydrocarbons, Fourth printing, D.
PROCESS DATA Van Nostrand Company, Inc, Princeton, New Jersey, 1957.
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The CDU model provides answers to questions related September 1998.
to equipment condition in the CDU; it helps in shutdown
planning for maintenance and in the crude oil
management.
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