2010 Aspen Technology, Inc.

All rights reserved

November 2010
Refinery Planning with an Integrated Model
for Fluid Catalytic Cracking (FCC)
Presented by: Prof. Y. A. Liu, Kiran Pashikanti
Virginia Tech-Sinopec
Refinery planning with integrated
FCC model
Kiran Pashikanti*
Y.A. Liu**
Yun Shen and Peng Zhang
+
Yanhua Qi and Jianzhang Qiu
+ +
Yushi Chen, Xumei Di and Jianping Wang
+++
AspenTech/SINOPEC Center of Excellence in Process System Engineering
Department of Chemical Engineering
Virginia Polytechnic Institute and State University, Blacksburg, VA 24061
*Email: kpashik@vt.edu; phone: (540) 231-3980
**Email: design@vt.edu; phone : (540) 231-7800
+ SINOPEC Yangzi Petrochemical Corporation, Nanjing
+ + SINOPEC Research Institute for Petroleum Processing, Beijing
+++ SINOPEC Petro-Cyber Works Information Technology Co., Ltd. Shanghai
Overview
Introduction
SINOPEC Yangzi (YZ) FCC process
Model development and results
Case studies: Gasoline yield, feed rate, feed blends
Aspen PIMS LP application
Key business benefits
Conclusions
Yangzi Petrochemical Corporation
(SINOPEC)
Yangzi
Petrochemical
Yangzi Refinery Capacity
(Current) 9.0 million tons/year
180,722 Barrels/day (BPD)
YZPC FCC process
UOP one-riser, one-
regenerator configuration
115 tons/day (19,000 BPD)
Feeds: VR, VGO, CGO
Maximum Gasoline-Diesel
(MGD) Process multiple
feed points in FCC riser
Product
T-102
REGEN
T-101
REACTOR
Lift Gas
Mixed Feed
Dispersion Steam
Lift Gas Steam
Stripping Steam
Steam
Steam
Flue Gas
Air/O2 Mix
Off-Spec and HN Recycle
VR Vacuum Resid
VGO Vacuum Gas Oil
CGO Coker Gas Oil
Available process data
Mixed Feed
Partial D-1160 (up to 70%)
Density (kg/m3)
Concarbon (wt%)
Metals (Na, Ni, V, etc.)
SARA (Saturates, Aromatics, Resins, Asphaltenes) (wt%)
Sulfur and Nitrogen
Available process data
Products
Yields (flowrate) of key products: Dry gas, LPG, gasoline, diesel,
slurry and coke (calculated by difference)
Key properties of liquid products: Density, sulfur content, flash
point, ASTM D-86 distillation (gasoline and diesel)
Complete lab analysis of gas products with full C3 and C4 molar
compositions
Contributions
Extend partial distillation curves with log-
normal and beta statistical functions
Improves prediction of aromatic kinetic
lumps (2% - 4% deviation from plant
measurement)
Contributions
Contributions
Standard petroleum
component list does not
include these
components
Consistent with plant
measurements
cis-2-butene
2M-13-C4==
tr2-Pentene
cis2-Pentene
2M-2-butene
3M-1-butene
Cyclopentene
Cyclopentane
Benzene
Model development
Obtain five months of plant data
(Jan-09 to May-09)
Remove extraneous datasets
Extend distillation curves
Model based on Jan-09 data
Calibrate
Validate model continuously
with updated data sets
Optimization case studies
LP application study
HYSYS/Refining model
Rigorous Tray-by-
Tray simulation of
main fractionation
column
Short-cut separation
with component
splitter for quick
views of plant cuts
FCC with complete gas plant
including overhead
compressors, absorbers and
stabilizers
HYSYS/Refining model
Originally developed in 2006.5
Updated to 7.0
Verified to work well with 7.1
No changes are required from either
2006.5 or 7.0
Model must be solved from scratch
when versions change (5-10 minutes)
Results:
Fractionated product yields
Calibration-case:
LPG shows the largest
deviation (1.5%), so we expect
largest deviations in LPG
Validation-case:
Good agreement with key
plant products (gasoline,
diesel)
Dry gas and slurry are not
significant to the user
Results (Validation):
LPG composition
Model shows good agreement
with measured plant values
NOTE: These values are not
total yields but the
fractionated yields from the
rigorous de-propanizer
column
Results (Validation):
Dry gas
Model shows good agreement
with measured plant values
for key components C1, C2,
C2=
NOTE: These values are not
total yields but the
fractionated yields from the
rigorous de-C2 column
H2 yields deviate because H2
is calculated by difference in
calibration
Results (Validation):
ASTM D-86
Prediction of the distillation curves
for gasoline and diesel are important
to the refinery.
Correlations based on the distillation
and density yield flash point and
associated properties.
The model shows good predictions
for distillation curves (from rigorous
fractionation).
Calculated flash point meets refinery
specification target (<4 C deviation)
Results (Validation):
Density and flash point
HYSYS petroleum components
accurately represent the densities of
the diesel and gasoline product
Refiner is satisfied with the flash
point prediction. It is consistent with
the refiners own internal
correlations.
Results (Validation):
Operating temperature profiles
The model is also a guide to help pin-
point problems with process
equipment.
The prediction of the temperature
profile is critical for optimizing the
cuts from the main fractionator
NOTE: We use rigorous models for all
columns
Case Study 1:
Gasoline optimization
Typical
Operating
range (+-5 C)
Maximum Gasoline
Case Study 2:
Feed rate changes
The curve for 540C is
below that of 510C
because of gasoline
overcracking
We expect the curve for
the 540 C ROT here
Case Study 3:
Blending VR with VGO feed
VR = Vacuum Resid VGO = Vacuum Gas Oil
VR is a cheaper feedstock to use and improves profitability
How much VR can we blend with VGO while meeting sulfur limit of stabilized
gasoline?
Case Study 3:
Blending VR with VGO feed
VR = Vacuum Resid VGO = Vacuum Gas Oil
Case Study 3:
Blending VR with VGO feed
VR = Vacuum Resid VGO = Vacuum Gas Oil
Existing Aspen PIMS table
The base vector comes
from averaged yields
based on historical
data (last quarter,
2008)
The delta-vectors for
SPG (specific gravity),
CON (concarbon) and
SUL (sulfur) are
estimated from plant
experience with the
feed type
LP-vector generation for PIMS
Historical
Current Plant Data
Create model with HYSYS
Calibrate and validate
Repeat until model is
validated
Apply model for different
simulation cases
ASW
New scenarios:
Increase gasoline production
Change feed rate
Updated PIMS vectors
Reflects refinery operation more accurately
Linearizing FCC model
Linearizing FCC model
Use the delta-base utility tool from HYSYS Utilities menu
(Now called Aspen PIMS Support Utility)
* Gasoline Plan
TEXT BA1 SPG CON SUL
FREE 1 1 1
WBALC1F FCC FEED
WBALHS3 FCC Sour Gas -0.0065 -0.0003 -0.0004 -0.0082
WBALGAS Dry Gas -0.0394 -0.0011 -0.0014 0.0000
WBALFCL LPG after de-Sulfur -0.1740 0.0025 0.0041 0.0000
WBALFCN FCC Gasoline -0.3929 0.0098 0.0081 0.0000
WBALFCD FCC Diesel -0.2899 -0.0057 -0.0033 0.0000
WBALFCR FCC Slurry -0.0381 -0.0032 -0.0038 0.0082
WBALCKE FCC Coke -0.0544 -0.0020 -0.0034 0.0000
WBALLOS Loss -0.0048 0.0000 0.0000 0.0000
BA1 SPG CON SUL
-0.00439 0.00068 0.00007 -0.00567
-0.02527 0.00069 0.00033 0.00025
-0.19386 0.02213 0.00271 0.00164
-0.4421 0.09480 0.00621 0.00330
-0.16058 -0.07677 -0.00175 0.00040
-0.11163 -0.10067 -0.00305 -0.00030
-0.06218 0.05913 -0.00453 0.00038
Partial results for a new delta-
base-table computed from the
rigorous model. This table
correctly reflects current unit
operation.
The old table consistently
underestimates gasoline and LPG
yields, thus underestimating the
actual product profits.
Updated PIMS vectors from Common Model Utility
Key benefits
Improved yield and property predictions (less <
2.0% deviation for key products). Earlier
standard was 5% based on historical data.
Provide accurate product yield and property
predictions for PIMS and production planning
Quantify alternative feed blends that improve
unit profitability
Guide for monitoring plant equipment and
sensors
Examples of beneficial changes in
process operations
Improving equilibrium catalyst activity (MAT)
from 66% to 68.5% results in more profitable
product distribution (10.2 million RMB/yr),
while coke yield remains under 6.5%
Increasing riser outlet/reactor pressure from
300 kPa to 310 kPa promotes higher LPG and
gasoline yield (3.0 million RMB/yr)
Economic payback
Million RMB/yr Million USD/yr
FCC 13.23 1.94
MP HCR 24.36 3.57
HP HCR 7.29 1.07
Reformer 3.46 0.51
Total 48.34 7.08
Through changes in process operations without new investment as identified
by Apsen HYSYS Petroleum Refining modeling and optimization
Evaluated by SINOPEC ,Yangzi Petrochemical Corporation (March 2010)
Related work
Our group has also modeled:
Catalytic Reformer
High-Pressure Hydrocracker
Medium-Pressure Hydrocracker
Complete plant-scale models for Yangzi
Petrochemical Corporation with
downstream fractionations
Thank you!
AspenTech
Steven Dziuk
Darin Campbell
Glenn Dissinger
Zhiming Huang
Chau-Chyun Chen
Vikas Dhole
John Adams
Maurice Jett

SINOPEC
Dai Houliang
Cao Xianghong
Li Defang
Pan Xinrong
Guan Xinhu
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35
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Accelerate
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http://support.aspentech.com/training
Consider a training class from AspenTech
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Aspen HYSYS Training
Process Modeling (Refining Industry Focus) (EHY102)
December 13, 2010 Houston, Texas
January 4, 2011 Virtual - Americas
January 31, 2011 Houston, Texas
February 22, 2011 Houston, Texas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY102
Optimize engineering work processes using the full power and flexibility of
Aspen HYSYS to build, evaluate and optimize flowsheets.
Learn the shortcuts for efficient use of the software to build steady state
simulations for refining processes.
2010 Aspen Technology, Inc. All rights reserved |
38
Aspen HYSYS Training
Aspen HYSYS Petroleum Refining:
Refinery Modeling (Aspen RefSYS) (EHY341)
December 15, 2010 Houston, Texas
January 27, 2011 Virtual - Americas
March 21, 2011 Houston, Texas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY341
Gain experience on the use of the most advanced technology for rigorous
refinery simulation
Utilize flowsheet and FCC reactor model to understand refinerys true
operating window
Explore the data generation tools which enable improved planning and
scheduling decisions
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Aspen HYSYS Training
Aspen HYSYS: Using Aspen Simulation Workbook (EHY121)
December 3, 2010 Houston, Texas
January 7, 2011 Virtual - Americas
May 7, 2011 Houston, Texas
May 9, 2011 Virtual - Americas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY121
Embed and link an Aspen HYSYS Simulation case and variables within
MS Excel

without using any programming languages.
Link models with process data and create plant data tables.
Learn how to publish and deploy models using ASW.
Prepare a standard basis project.
2010 Aspen Technology, Inc. All rights reserved |
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Aspen PIMS Training
Aspen PIMS: Introduction to Refinery Planning (RPA101)
December 6 , 2010 Houston, Texas
January 10, 2011 Houston, Texas
January 10, 2011 Reading, UK
January 31, 2011 Houston, Texas
http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=RPA101
Build refinery LP planning models in PIMS to generate optimum plans
including evaluating alternative crudes, intermediate feedstocks, outside
blendstocks, process unites, products, and markets.
Develop LP structure in order to solve optimization problem including
interpreting and analyzing the LP solutions.
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Contact Information
Prof Y.A Liu
Virginia Tech
Email: design@vt.edu
Kiran Pashikanti
Virginia Tech
Email: kpashik@vt.edu
Steve Dziuk
AspenTech (Aspen HYSYS family Product Manager)
Email: steve.dziuk@aspentech.com
Ken Dooley
AspenTech (Industry Marketing)
Email: ken.dooley@aspentech.com
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Thank you.