REFINERY OPERATIONS

PLANNING

Dunham, Luhila, Odunuga

Overview
 Refinery Overview
 Production Planning
 Linear model with complex and simplified utilities
 Results
 Conclusions
 Model Refinery: Bangchak Refinery
(Thailand) FG

LPG

LN ISO MTBET
ISOU

LN
DCCT
NPU
CDU2 GASOLINE
OM POOL
HN ISOG
CRU
REF
TP
HN
SUPG
LB

SLEB IHSD
HDS

PHET DIESEL
HSD
POOL
Kero
MB

CDU3 Kero
KTU JP1

Kero FO1

FO
FO2

FOVS
FG Kero DO Intermediates
Crudes
LPG Naphtha FO Products
What is Refinery Operations Planning?

How much crude should be purchased?

What kind/quality of crude should be purchased?

How much does the refinery want to produce?

Consists of crude oil unloading, production planning

and distribution
Problems in Refinery Operations
 Uncertainty in prices and demand
 Effects of uncertainty are minimized by using
models
 Historically, models have been linear
 Use of average operating conditions
 Linear models are non-ideal

 Currently
 Non-linear models are ideal
 Linear Model with Complex Utilities
 1996
Shah N
2004
Moro et al.

2002
Gathe-Lundgen et al.

2001
Glismann et al.
2006
Pongsakdi et al
1996
Lee et al.
2001
Zhang et al
Features of Current Models

Crude oil distillation and blending X X X

NLP X X
P.planning, inventory mgt, shipment X X

Coordination of feedstock & pdt with X X X

markets
Uncertainty X X X X

Financial risk X

Decomposition Strategy X X
 Production Planning
 Production Planning
 Processing of crude oil
through different units
 Decisions
 Crude oil
 Purchase
 Processing
 Inventory management

Bangchak
Refinery
Production Planning
 Routine process which guides purchasing
 Departments
 Crude oil acquisition, product sales & refinery
operations
 Based on
 Market demands and prices
 Uncertainty
Production Planning
 Winter  Summer
 High
fuel oil demand  High demand for light
→ more fuel oil crudes → more
produced gasoline produced
Linear Modeling Method

CRU
 Inside Unit is a black
box (inside box F2
doesn’t matter) F1 Light Ends

Reactor
 Input and output can Feed
F3
be related Desulfurized
Product
Linear Modeling Method
 Linear Equation
Relating Inputs and CRU
Outputs:
F2
F3 =α31*F1 F1 Light Ends

Reactor
 What is α31? Feed
F3
Desulfurized
 It depends on the Product

system!
Finding Alpha (α)
 Really, αij is the result of solving an ODE
 Example: Concentration of Aromatics leaving a CRU
dCAro
 rAro  k Aro * C Aro * C H 2
dW
 Thus αij will depend on
 Inlet
concentrations and flows
 Process parameters: Temperature, Pressure
Hydrotreating
 Process to remove impurities in the stream

 Aromatics
Sulfur Nitrogen

 Hydrotreating for sulfur → hydrosulfurization

 Reduces the aromatic content in crudes
 Hydrogenation
Hydrotreating PFD
Hydrotreating Model
 Operating Conditions
 ReactorTemperatures range from 250°F – 550°F
 Main Variables
 Pressure
 Temperature
 Velocity
 H2/HC ratio
KTU Aromatics Flow Rate

Far  f o  W * rar
ƒo = Initial Flow Rate

Aromatic _ weight 1.1E  08

W   5.50 E  5
molecular _ weight _ oil 200
Hydrotreating Empirical Model

Aromatics:
rar  LHSV * Car * Ch
m3
LHSV  2.66
hr
 P * 1000 
 
Car   R *T 
f Total
 P *1000  885000
Ch   *
 R *T  fTotal
KTU Equation Comparison
 Linear Equation: Far =α1*Ftotal

 Actual Equation:
 1000 * P 
 
 R * T   1000 * P   885000 
Far  f o  W * LHSV * *  *  
Ftotal  R * T   Ftotal 
Non linearity
 0.45 
rs  k s * 60 *  Cs * 
C h

 
1  K H 2 S * CH 2 S  2

  132000    P *1000   88500  
ks  4.27 10 exp 
9
 CH 2 S     *   
 R *T    R *T   f *100000  

 P *1000 
Cs    * (1242.5 * f ) * Mw / f 
 R *T  0.45
  P *1000   88500  
Ch     *   
  R * T   f *100000  

2761
K H 2 S  41770  e R T
Catalytic Reforming
 Process of increasing octane number of NPU by
converting napthenes & paraffins
 Outputs
 Aromatics, light hydrocarbons (C1-C5) & hydrogen
 Operating conditions

Variables Range
Temperature °F 900 – 950
Pressure (atm) 30 – 40
Catalytic Reformer PFD
CRU -Empirical Kinetic Model
Conversion of napthenes to aromatics
 W 
 Amount of product X1 Produced  r1    X 1
 T 
F

 3

Reaction Rate
P * P
  r1  k p1  PN  A H 
 K 
 p1 

 34750 
k p1  exp  23.21  
 Kinetic Reaction Constant  T 

PA * PH3  46045 
 Equilibrium Constant K p1 
PN
 exp  46.15 
 T 

Reformer Temperature Modeling
Reactor 1
Mass Flow Rate (lb/hr)
-112
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000

-114

-116

-118
Delta T (R)

-120

-122

-124

-126

-128

-130
 Process Industry Modeling Systems
PIMS
 Allows user to analyze results
graphically and to adjust
variables
 Adds capabilities for global
optimization, solution ranging,
and goal programming
 Requires refinery-specific
inputs to determine an
acceptable starting point
PIMS and Non-linearities
 Benefits
 Identifies the solution that maximizes global
profitability

 Validates solution and enhances planners’ confidence

and gives an estimate on how close results are to
optimal solution

 Eliminates need to manually search for improved

solutions
PIMS and Non-linearities

 SLP is the primary non-linear modeling feature

 Flexibility in the types of equations that can be

used in models

 Builds derivatives which eliminates potential errors

 Non-linear terms can reference existing Aspen PIMs

variables or define new variables
 PIMS Modeling
100
 PIMS finds 90
Objective… Max 2
X
maximum by 80 Max 1
70
calculating 60
X
x
objective function 50
gradient 40
30 x
 Maximum found 20
10
by PIMS depends 0
on initial condition 0 20 40 60
Start 1 Start 2
Alternative Method
Linear Model with Utilities
 Model Super tables

Product flow of Paraffins

Product flow of Paraffins
(psi) Pressure 400 400 400
(F) Temp. 800 820 840
X=f(C,T,P,F)
Concentration Flow Rate
0.31 15500 2547.928 2547.928 2547.928
Conc = 0.31
0.31 16000 2630.119 2630.119 2630.119 Temp = 800 F
0.31 16500 2712.31 2712.31 2712.31 Pressure = 400 psi
0.31 17000 2794.502 2794.502 2794.502 Flowrate = 16000 m3/day
0.31 17500 2876.693 2876.693 2876.693 X= 2630 bbl/hr
0.31 18000 2958.884 2958.884 2958.884
0.31 18500 3041.075 3041.075 3041.075
0.31 19000 3123.266 3123.266 3123.266
0.31 19500 3205.458 3205.458 3205.458
0.31 20000 3287.649 3287.649 3287.649
Model Super tables
Product flow of Paraffins
(psi) Pressure 400 400 400 400 400 400 400 400 400 400 450 450 450 450 450 450 450 450 450 450 500 500 500 500
(F) Temp. 800 820 840 860 880 900 920 940 960 980 800 820 840 860 880 900 920 940 960 980 800 820 840 860
Concentration Flow Rate
0.31 15500 2571.22 2596.69 2647.74 2747.85 2940.15 3302.30 3971.58 5186.33 7353.35 11155.62 2577.40 2609.65 2674.26 2800.97 3044.36 3502.73 4349.85 5887.40 8630.25 13442.95 2584.32 2624.13 2703.90 2860.34
0.31 16000 2653.41 2678.88 2729.93 2830.04 3022.34 3384.49 4053.77 5268.52 7435.54 11237.81 2659.59 2691.84 2756.45 2883.16 3126.55 3584.92 4432.04 5969.59 8712.44 13525.14 2666.51 2706.32 2786.09 2942.53
0.31 16500 2735.60 2761.07 2812.13 2912.24 3104.53 3466.68 4135.96 5350.72 7517.73 11320.01 2741.79 2774.03 2838.65 2965.35 3208.74 3667.12 4514.24 6051.78 8794.64 13607.33 2748.70 2788.51 2868.28 3024.72
0.31 17000 2817.79 2843.27 2894.32 2994.43 3186.72 3548.87 4218.15 5432.91 7599.92 11402.20 2823.98 2856.22 2920.84 3047.54 3290.93 3749.31 4596.43 6133.97 8876.83 13689.52 2830.89 2870.70 2950.48 3106.91
0.31 17500 2899.98 2925.46 2976.51 3076.62 3268.91 3631.06 4300.34 5515.10 7682.11 11484.39 2906.17 2938.41 3003.03 3129.74 3373.12 3831.50 4678.62 6216.16 8959.02 13771.71 2913.08 2952.89 3032.67 3189.10
0.31 18000 2982.17 3007.65 3058.70 3158.81 3351.10 3713.25 4382.53 5597.29 7764.30 11566.58 2988.36 3020.60 3085.22 3211.93 3455.31 3913.69 4760.81 6298.35 9041.21 13853.90 2995.27 3035.08 3114.86 3271.29
0.31 18500 3064.36 3089.84 3140.89 3241.00 3433.30 3795.44 4464.73 5679.48 7846.49 11648.77 3070.55 3102.80 3167.41 3294.12 3537.51 3995.88 4843.00 6380.54 9123.40 13936.09 3077.46 3117.27 3197.05 3353.48
0.31 19000 3146.55 3172.03 3223.08 3323.19 3515.49 3877.64 4546.92 5761.67 7928.69 11730.96 3152.74 3184.99 3249.60 3376.31 3619.70 4078.07 4925.19 6462.74 9205.59 14018.29 3159.66 3199.47 3279.24 3435.68
0.31 19500 3228.75 3254.22 3305.27 3405.38 3597.68 3959.83 4629.11 5843.86 8010.88 11813.15 3234.93 3267.18 3331.79 3458.50 3701.89 4160.26 5007.38 6544.93 9287.78 14100.48 3241.85 3281.66 3361.43 3517.87
0.31 20000 3310.94 3336.41 3387.46 3487.57 3679.87 4042.02 4711.30 5926.05 8093.07 11895.34 3317.12 3349.37 3413.98 3540.69 3784.08 4242.45 5089.57 6627.12 9369.97 14182.67 3324.04 3363.85 3443.62 3600.06
0.31 20500 3393.13 3418.60 3469.66 3569.77 3762.06 4124.21 4793.49 6008.25 8175.26 11977.54 3399.31 3431.56 3496.17 3622.88 3866.27 4324.65 5171.77 6709.31 9452.17 14264.86 3406.23 3446.04 3525.81 3682.25
0.33 15500 2735.60 2761.07 2812.13 2912.24 3104.53 3466.68 4135.96 5350.72 7517.73 11320.01 2741.79 2774.03 2838.65 2965.35 3208.74 3667.12 4514.24 6051.78 8794.64 13607.33 2748.70 2788.51 2868.28 3024.72
0.33 16000 2823.09 2848.57 2899.62 2999.73 3192.02 3554.17 4223.45 5438.21 7605.22 11407.50 2829.28 2861.52 2926.14 3052.85 3296.23 3754.61 4601.73 6139.27 8882.13 13694.82 2836.19 2876.00 2955.78 3112.21
0.33 16500 2910.59 2936.06 2987.11 3087.22 3279.52 3641.67 4310.95 5525.70 7692.72 11494.99 2916.77 2949.02 3013.63 3140.34 3383.73 3842.10 4689.22 6226.77 8969.62 13782.32 2923.69 2963.50 3043.27 3199.71
0.33 17000 2998.08 3023.56 3074.61 3174.72 3367.01 3729.16 4398.44 5613.20 7780.21 11582.49 3004.27 3036.51 3101.13 3227.83 3471.22 3929.60 4776.72 6314.26 9057.12 13869.81 3011.18 3050.99 3130.77 3287.20
0.33 17500 3085.57 3111.05 3162.10 3262.21 3454.51 3816.65 4485.94 5700.69 7867.70 11669.98 3091.76 3124.01 3188.62 3315.33 3558.72 4017.09 4864.21 6401.75 9144.61 13957.31 3098.68 3138.49 3218.26 3374.70
0.33 18000 3173.07 3198.54 3249.60 3349.70 3542.00 3904.15 4573.43 5788.19 7955.20 11757.48 3179.25 3211.50 3276.11 3402.82 3646.21 4104.58 4951.70 6489.25 9232.11 14044.80 3186.17 3225.98 3305.75 3462.19
0.33 18500 3260.56 3286.04 3337.09 3437.20 3629.49 3991.64 4660.92 5875.68 8042.69 11844.97 3266.75 3298.99 3363.61 3490.32 3733.70 4192.08 5039.20 6576.74 9319.60 14132.29 3273.66 3313.47 3393.25 3549.68
0.33 19000 3348.06 3373.53 3424.58 3524.69 3716.99 4079.14 4748.42 5963.17 8130.19 11932.46 3354.24 3386.49 3451.10 3577.81 3821.20 4279.57 5126.69 6664.24 9407.09 14219.79 3361.16 3400.97 3480.74 3637.18
0.33 19500 3435.55 3461.03 3512.08 3612.19 3804.48 4166.63 4835.91 6050.67 8217.68 12019.96 3441.74 3473.98 3538.60 3665.30 3908.69 4367.07 5214.19 6751.73 9494.59 14307.28 3448.65 3488.46 3568.24 3724.67
0.33 20000 3523.04 3548.52 3599.57 3699.68 3891.98 4254.12 4923.41 6138.16 8305.17 12107.45 3529.23 3561.48 3626.09 3752.80 3996.19 4454.56 5301.68 6839.22 9582.08 14394.77 3536.14 3575.95 3655.73 3812.16
0.33 20500 3610.54 3636.01 3687.06 3787.17 3979.47 4341.62 5010.90 6225.65 8392.67 12194.94 3616.72 3648.97 3713.58 3840.29 4083.68 4542.05 5389.17 6926.72 9669.57 14482.27 3623.64 3663.45 3743.22 3899.66
0.35 15500 2899.98 2925.46 2976.51 3076.62 3268.91 3631.06 4300.34 5515.10 7682.11 11484.39 2906.17 2938.41 3003.03 3129.74 3373.12 3831.50 4678.62 6216.16 8959.02 13771.71 2913.08 2952.89 3032.67 3189.10
0.35 16000 2992.78 3018.25 3069.30 3169.41 3361.71 3723.86 4393.14 5607.89 7774.91 11577.18 2998.96 3031.21 3095.82 3222.53 3465.92 3924.29 4771.41 6308.96 9051.81 13864.51 3005.88 3045.69 3125.46 3281.90
0.35 16500 3085.57 3111.05 3162.10 3262.21 3454.51 3816.65 4485.94 5700.69 7867.70 11669.98 3091.76 3124.01 3188.62 3315.33 3558.72 4017.09 4864.21 6401.75 9144.61 13957.31 3098.68 3138.49 3218.26 3374.70
0.35 17000 3178.37 3203.85 3254.90 3355.01 3547.30 3909.45 4578.73 5793.49 7960.50 11762.78 3184.56 3216.80 3281.42 3408.13 3651.51 4109.89 4957.01 6494.55 9237.41 14050.10 3191.47 3231.28 3311.06 3467.49
0.35 17500 3271.17 3296.64 3347.69 3447.80 3640.10 4002.25 4671.53 5886.28 8053.30 11855.57 3277.35 3309.60 3374.21 3500.92 3744.31 4202.68 5049.80 6587.35 9330.20 14142.90 3284.27 3324.08 3403.85 3560.29
0.35 18000 3363.96 3389.44 3440.49 3540.60 3732.90 4095.04 4764.33 5979.08 8146.09 11948.37 3370.15 3402.40 3467.01 3593.72 3837.11 4295.48 5142.60 6680.14 9423.00 14235.70 3377.07 3416.88 3496.65 3653.09
0.35 18500 3456.76 3482.24 3533.29 3633.40 3825.69 4187.84 4857.12 6071.88 8238.89 12041.17 3462.95 3495.19 3559.81 3686.51 3929.90 4388.28 5235.40 6772.94 9515.80 14328.49 3469.86 3509.67 3589.45 3745.88
0.35 19000 3549.56 3575.03 3626.08 3726.19 3918.49 4280.64 4949.92 6164.67 8331.69 12133.96 3555.74 3587.99 3652.60 3779.31 4022.70 4481.07 5328.19 6865.74 9608.59 14421.29 3562.66 3602.47 3682.24 3838.68
0.35 19500 3642.35 3667.83 3718.88 3818.99 4011.28 4373.43 5042.72 6257.47 8424.48 12226.76 3648.54 3680.78 3745.40 3872.11 4115.50 4573.87 5420.99 6958.53 9701.39 14514.08 3655.45 3695.26 3775.04 3931.47
0.35 20000 3735.15 3760.63 3811.68 3911.79 4104.08 4466.23 5135.51 6350.27 8517.28 12319.56 3741.34 3773.58 3838.20 3964.90 4208.29 4666.67 5513.79 7051.33 9794.19 14606.88 3748.25 3788.06 3867.84 4024.27
0.35 20500 3827.95 3853.42 3904.47 4004.58 4196.88 4559.03 5228.31 6443.06 8610.08 12412.35 3834.13 3866.38 3930.99 4057.70 4301.09 4759.46 5606.58 7144.13 9886.98 14699.68 3841.05 3880.86 3960.63 4117.07
 Linear Model with Utilities
100

 Our model finds 90

Objective Function

the maximum by 80

70

testing many 60

discrete points 50

40

30

20

 Optimum value 10

0
will be close to 0 10 20 30 40 50 60

the global
optimum
GAMS Software
 Algebraic modeling
interface capable of
solving linear and
mixed integer models

 Non-linear equations
cause problems
Comparison

Linear Model (in GAMS) PIMS

 Linear or Mixed  Successive Linear

Integer Programming Programming
 Discretizes continuous  Uses gradient of
values objective function
 Always finds best test  May find local
point (near global maximum (depends on
maximum) starting point)
Utility Calculations
 Steam and Power are produced within the refinery

 Steam is produced by fired steam boilers, which

burn refinery fuel gas and fuel oils to create steam

 Electricity is produced by running high pressure

steam through a turbine
Utility Table Equations
 Water Cost (Heat exchangers)
$  m p  Cpp  Tp $ m  vap
  
coolers 
lb
TW  Cpw
  
condensers 
lb 
Tw  Cpw

 Unit Fuel Gas Consumption (Heaters)

 p  Cp p  T
m
 H fg
Utility Equations in GAMS
Results
Linear Model Development

LP Model
(Individual
Units)

CRU Reactor
Temperature Utilities

Isothermal Non- No Utilities Simplified Complex

Isothermal Utilities Utilities
Utility Models
Linear Model with Complex Utilities:
 Uses tables to coordinate output values with

functions of Temperature, Pressure, and Flow rate

Linear Model with Simplified Utilities:
 Assumes Temperature and Pressure to be the
average of operating conditions
Linear Model without Utilities:
 Does not calculate utility cost
 Results - Gross Refinery Margin

Model GRM
Linear Model with Complex Utilities $34,103,151
Linear Model with Simplified Utilities $31,168,455
 Results - Total Utility Cost

Model Utility Cost

Linear Model with Complex Utilities $2,980,761
Linear Model with Simplified Utilities $3,411,319
 Purchasing Recommendations
Linear Model with Simplified Utilities Linear Model with Complex Utilities
Crude Purchasing Recommendations Crude Purchasing Recommendations
(m3/day) (m3/day)
Month Month
1 2 3 1 2 3
OM 244486 262303 267899 OM 250361 265445 267700
TP 32853 41126 47392 TP 35313 42245 43073
LB 0 0 12997
LB 0 0 9041
SLEB 95392 95392 95392
SLEB 95392 95392 95392
PHET 57235 57235 57235
PHET 57235 57235 57235
MB 95392 95392 95392 MB 95392 95392 95392
Unit Operating Conditions

No Utility Model Complex Utility Model

Month: 1 2 3 1 2 3
NPU2 NPU2
Temperature 600 600 600 600 600 600
Pressure 600 600 600 600 600 600

NPU3 NPU3
Temperature 700 700 700 700 700 700
Pressure 600 680 680 680 680 680

ISOU ISOU
Temperature N/A 275 275 275 275 275
Pressure N/A 1.9 1.9 2 2.1 2.1

CRU2 CRU2
Temperature 980 980 980 980 980 980
Pressure 850 850 800 850 850 400

CRU3 CRU3
Temperature 980 980 980 980 980 980
Pressure 500 800 550 400 600 750
Discussion
Catalytic Reforming Unit

Isothermal Model Varying Temperature Model

 Reactors are  Each reactor operates

isothermal at a different
 All reactor temperature
temperatures are the  Temperature changes
same in each reactor
 Produces more Fuel  Produces more
Gas Hydrogen
 Produces almost 50%
more Reformate
Hydrogen and Refinery Fuel Gas
 Both utility models calculated a net production of
Hydrogen and Refinery Fuel Gas

 Assume these are usable and can be transported

around the refinery where make-up is needed

 Since excess is produced, no Hydrogen or RFG is

purchased
Conclusions
The Linear Model with Complex Utilities processes
more crude and gives a larger GRM than a model
with Simplified Utilities and a model with no utility
cost calculation

The Non-isothermal CRU model produces more

reformate and increases overall GRM

Linear models in GAMS always find a value close to

the global optimum, where PIMS may find only a
local optimum depending on starting point
Questions?