KBC Petro-SIM T2T Training Slide Pack

T2T Distillation Column Workshop –
Crude Units
Ron Sudkamp, KBC
PROPRIETARY
© 2015 KBC Advanced Technologies plc. All Rights Reserved. INFORMATION
11 December 2015
“T2T columns are
difficult and always fail”
True or False?
PROPRIETARY INFORMATION 11 December 2015 2

What is in this Slide Pack?
1. Agenda (sample agenda for a 2-day workshop)
2. Workshop Session Overview
3. Testrun Data Set
4. Testrun Best Practice
5. Columns General
6. Workshop Petro-SIM Sessions
7. CDU Preflash Column – Building and Calibration
8. CDU Atmos Column- Building and Calibration
9. CDU Vacuum Column- Building and Calibration
10. Monitor Page – Active Specifications
11. The Column Sub-Flowsheet
12. Problem Columns
13. Optimisation
PROPRIETARY INFORMATION 3
1. Agenda
Sample Agenda for 2-day Workshop
Agenda – Day 1, Morning Session
• Registration and Petro-SIM installation
• Introduction
• Crude unit testruns
 Best practice
 Data validation
 Mass Balance
• Assay synthesis
 Working session 1: Create a crude assay from testrun data
• Walk through columns in Petro-SIM
 Choice of column solvers
 Rigorous tray-by-tray (T2T)
 Setup options
 Hints and tips
Agenda – Day 1, Afternoon Session
• Build a T2T atmospheric column from testrun data
 Building strategy
 Calibration strategy
 Working session 2: Build a column
 Working session 3: Calibrate a column
• Convert the calibrated column to predict mode
 How to make columns robust
 Specification selection on the Monitor page
 Working session 4: Simple case study
Agenda – Day 2, Morning Session
• Recap of day 1
• Build a T2T vacuum column from testrun data
 Working session 5: Build a column
 Working session 6: Calibrate a column
• Convert the T2T from calibration to predict mode
 Specification selection on the Monitor page
 Working session 7: Simple case study
Agenda – Day 2, Afternoon Session
• Optimisation
 Introduction to optimisation theory
 Petro-SIM optimiser
 Working session 8: Optimisation of distillate yield
• Q&A
 User questions
 Summary and feedback
2. Workshop Session
Overview
• Build complete model from scratch in
15 steps (Preflash, Atmos and Vac
column)
• Step by step sessions
Model Overview
Preflash Column
Atmos Column
Vac Column
Workshop Case Sequence
Session
1 Testrun Feed Synthesis .KSC Construct feed assay from products
2 Preflash .KSC Build preflash column
3 Preflash Tuned .KSC Calibrate preflash column
4 Preflash 2 Drums .KSC Add 2nd drum to condenser section
5 Preflash 2 Drums Tuned .KSC Calibrate the 2 drum column
6 Atmos Column .KSC Build atmos column
7 Atmos Column Tuned .KSC Calibrate atmos column
8 Vac Column .KSC Build vac column
9 Vac Column Tuned .KSC Calibrate vac column
10 Vac Bottom Quench .KSC Add external vac bottoms quench
11 Vac Bottom Quench Inside Column .KSC Move quench inside column flowsheet
12 Atmos Heater Inside Column .KSC Move atmos htr inside column flowsheet
13 Vac Heater Inside Column .KSC Move vac heater inside column flowsheet
14 Full Model_changed to predict mode .KSC Change finished model to Predict mode
15 Full Model_optimisation .KSC Work with a pre-build optimiser
Workshop Methodology
• You don’t have to do every session
• Select the sessions you are most interested in
 Open the start case
 Open the end case for guidance
 Look at the training slide pack for general help
 Look at the session Hints & Tips slide for more help
3. Testrun Data Set
Data to be used throughout the

workshop
Testrun data set for this Workshop
• Spreadsheet with
 Mass balance
 Lab data
 Operational data
• Overview drawing
• Column drawings
Model Overview
Preflash Column
Atmos Column
Vac Column
Preflash Column Configuration
Atmos Column Configuration
Vac Column Configuration
4. Testrun Best Practice
Rubbish IN = Rubbish OUT
Testrun Data Collection
• Make sure the unit is lined out
• Take stream samples of feed and all products, verify exact
sample time
• Minimum lab analysis for tower fitting for all streams:
 density
 Simdist D2887 (avoid D86 & D1160)
 additional tests as appropriate
• Collect average process data (P, T, Flows, etc) over a
minimum period of 1 hour
• Note anything of interest (unusual line-ups, weather
conditions, feed stock details, etc)
Distillation Types #1
• D86
 100 ml flask, evaporation, atmospheric, controlled heating
profile
 Very quick, fully automated
 Can be done by anyone, fill the flask and press the button
• D86 corrected
 As D86
 Corrected for cracking at higher temperatures
• D1160
 250 ml flask, evaporation, under vacuum, controlled heating
profile, reported at 10 or 760 mm-Hg
 Few hours, refinery laboratory
 1 day cleaning in between samples
Distillation Types #2
• TBP vol
 Laboratory column, high reflux ratio, large number of stages
 1 day minimum, research style laboratory
 Needs expert laboratory technicians
• TBP wt
 As TBP vol, reported as wt
• Simdist D2887
 Gas chromatography column
 Very small sample size
 Results in wt, equivalent to TBP wt
 Takes 1 hour, column needs to be flushed between samples
 Has replaced TBP distillations for most operating sites
 Pioneered by Shell in late 70’s
Input Data Checking
• Verify line out status
• Collect process and lab data
• Validate the data
 check for missing data, data out of range, unusual
numbers, etc
• Correct all flow measurements for P, T, and density
• Check mass balance
• Reconcile mass balance (force to 100% closure) – More
later
• Build the simulation model using typical stage efficiencies
• Input data into the simulation model
• Set up model specifications (see step 4)
Mass Balance Reconciliation
• Basic
 Correct all flow meters for density at flowing conditions
 Compare Mass IN versus Mass OUT
 +/- 2% is good
 But even so, force 100% closure by thorough investigation
 Only use mass balance reconciled to 100% for model
calibration
• Advanced
 Check synthesised testrun assay against feed distillation if
available
 See next example for a vacuum column
Mass Balance Reconciliation #1
800 • Hvgo flow adjusted to

achieve 100% mass balance
700
closure
• Note poor agreement, NOT
600 supporting error in Hvgo
flowmeter reading
TBP (C)
500
Flows (m3/hr) Raw Reconciled
Slopoil 1.3 1.3
400 Lvgo 11.5 11.5
Mvgo 83.4 83.4
Feed sample
300 Hvgo 105.2 88.3
Product blend
Vof 18.8 18.8
200 Resid 103.5 103.5

0 10 20 30 40 50 60 70 80 90 100 Total products 323.7 308.0
wt% Distilled Feed 308.0 308.0
Mass Balance Reconciliation #2
800 • Mvgo flow adjusted to

700
closure
• Note poor agreement, NOT
600 supporting error in Mvgo
flowmeter reading
TBP (C)
500
Flows (m3/hr) Raw Reconciled
Slopoil 1.3 1.3
400 Lvgo 11.5 11.5
Mvgo 83.4 65.8
Feed sample
300 Hvgo 105.2 105.2
Product blend
Vof 18.8 18.8
200 Resid 103.5 103.5

0 10 20 30 40 50 60 70 80 90 100 Total products 323.7 308.0
Mass balance Reconciliation #3 - Final
800 • Resid flow adjusted to

700
closure
• Note excellent agreement,
600 supporting error in resid
flowmeter reading
TBP (C)
500 Flows (m3/hr) Raw Reconciled

Slopoil 1.3 1.3
400 Lvgo 11.5 11.5
Mvgo 83.4 83.4
Feed sample Hvgo 105.2 105.2
300
Product blend
Vof 18.8 18.8
Resid 103.5 87.8
200
0 10 20 30 40 50 60 70 80 90 100 Total products 323.7 308.0
Feed Characterisation
• Create a single feed assay from products
 Use reconciled mass balance data
• Stream data
 Simdist is best
 If using Simdist, enter as TBP-WT
 Bulk density
 Add light ends data where appropriate
• Avoid using the feed distillation
 Only use this to cross check mass balance reconciliation
5. Columns General
• General
• Tray Efficiencies
Column Solvers
• Default Inside-Out
 General purpose method, which is good for most problems
• Modified Inside-Out
 General purpose method, which allows mixer, tee, and heat exchangers inside the
Column sub-flowsheet
• Newton Raphson Inside-Out
 General purpose method, which allows liquid-phase kinetic reactions inside the
Column sub-flowsheet
• Sparse Continuation Solver
 An equation based solver. It supports two liquid phases on the trays, and its main
use is for solving highly non-ideal chemical systems and reactive distillation.
• Simultaneous Correction
 Simultaneous method using dogleg methods. Good for chemical systems. This
method also supports reactive distillation.
• Distop
 Section-by-section solution method. Good for refinery fractionators. Based on KBC
DISTOP® Column technology
Tray Efficiencies
• Two methods for adjusting column efficiency
1. Equal the number of stages in the model to the number of
real trays
 Modify stage Murphree efficiencies to make the model fit the
plant
2. Adjust number of theoretical stages @100% Murphree
efficiency
 Vary the number of stages in each section to make the model fir
the plant
 Only in exceptional cases manipulate Murphree efficiencies
3. Non-equilibrium distillation
 Stage separation efficiency calculated from droplet and bubble
sizes, heat and mass transfer across phase boundaries
 Binary systems, computing intensive
 Not suitable for multi component petroleum mixtures
Tray Efficiencies
• Murphree stage efficiency
 Based on semi theoretical models assuming that
- the vapour between trays is well-mixed
(uniform composition)
- the liquid in the downcomers is well-mixed
(uniform composition)
- the liquid on the tray is well mixed and is of
the same composition as the liquid leaving
the tray.
 Defined for each tray according to the separation
achieved on each tray
 Based on liquid or vapour
 For a component, equal to the change in actual
concentration in the phase divided by the
change predicted by equilibrium conditions.
Tray Efficiency
• Best Practice
 Do not use Murphree efficiencies, leave at 100%
 Adjust theoretical stages to fit the model to the plant
• Why?
 Especially for large diameter columns, or complex flow
patterns, liquid composition on the tray is not uniform
 Vapour composition may also not be uniform
 It has been proven that best results are achieved by adjusting
the number of theoretical stages
• But
 Using Murphree efficiencies can be very useful for initial
tuning assessment
 Follow up with changing the number of stages
Typical tray efficiencies – initial guess
• Atmos column theoretical stages
 70% at top section
 25 to 50% for side strippers
 25 to 50% for base stripper
 50% above flashzone
 Pumparounds 2 stages
- Purpose is to provide surface area for heat exchange
 Any packed section 2 stages
• Try to calibrate by adding / removing whole theoretical
stages
Typical tray efficiencies – initial guess
• Vac column theoretical stages
 70% at top section
 25 to 50% for side strippers
 25 to 50% for base stripper
 50% above flashzone
 Pumparounds 2 stages
- Purpose is to provide surface area for heat exchange
 Any packed section 2 stages
• Be prepared to use Murphree efficiencies in addition
to removing / adding whole theoretical stages
Calibration Methodology
• Always fix the mass balance
 Set all draw rates except bottoms
• Always fix the heat balance
 Fix heat input to the flashzone (fix heater COT and pressure)
 Set all PA duties
 If top reflux, allow to calculate from heat balance
 If top PA (i.e. vac column), set flow rate and allow duty to be
calculated, or vice versa
• Make initial assessment of distillation matches
• Vary number of theoretical stages to achieve good
match on mainly 5, 10, 90 and 95% points
• In rare circumstances, use Murphree efficiencies if no
other option (mainly for vac columns)
The Monitor Page
• Hints and tips
 Use liberally
 Very useful page to compare model versus testrun
 Create a spec for every bit of plant data you have
- Every available tray temperature
- Every distillation point
- Densities, viscosity, cold properties, sulphur, etc
- Mass flow and volume flows
- All PA specs
- Gaps and overlaps
 You will only use few of these specs
- But it is worth the effort setting up the complete set
List of useful specifications for the Monitor
page
• These will help to assess the fit of the model during
calibration
 Mass and/or volume flows for all gas and liquid products
 Column and side stripper temperature profile
 Product distillation data (D86, D1160, TBP)
- 5%, 10%, 50%, 90%, 95% for distillates
- 1%, 5%, 10%, 50% for bottoms
 Distillation gap / overlaps
- 10% /90%, 5% / 95%
 Pumparounds
- Flow rate
- Duty
- Delta temperature, draw and return temperature
 Top reflux, internal refluxes and pumpdowns
• Lot of work to set up, but worth the time to do up front
How close should it match?
• Do not expect models to be perfect everywhere
• Primary focus is to get good match on fractionation
efficiency
 Gaps/overlaps 1 degC, largest focus on 5/95
• Secondary focus is on
 Temperature profile +/- 10 to 15 degC
 Top reflux +/- 25%
 Don’t expect perfect matches on internal refluxes or
pumpdowns. Readings are often unreliable.
• Fluidpacks and associated property packages are not
perfect
Simulation Basis
• Basis
 Fluidpack
- Peng Robinson for preflash, atmos column and vac column
- Esso Tabular is optional for vac columns. Often better fit, but not
always. Evaluate which provides the best overall fit.
 Component List
- Refinery-large – 106 components
 24 pure components up to C5
 82 hypothetical components
6. Workshop Petro-SIM Sessions
Step by step building and calibration of

a typical CDU/VDU model in 15 steps
Workshop Case Sequence
Session
1 Testrun Feed Synthesis .KSC Construct feed assay from products
2 Preflash .KSC Build preflash column
3 Preflash Tuned .KSC Calibrate preflash column
4 Preflash 2 Drums .KSC Add 2nd drum to condenser section
5 Preflash 2 Drums Tuned .KSC Calibrate the 2 drum column
6 Atmos Column .KSC Build atmos column
7 Atmos Column Tuned .KSC Calibrate atmos column
8 Vac Column .KSC Build vac column
9 Vac Column Tuned .KSC Calibrate vac column
10 Vac Bottom Quench .KSC Add external vac bottoms quench
11 Vac Bottom Quench Inside Column .KSC Move quench inside column flowsheet
12 Atmos Heater Inside Column .KSC Move atmos htr inside column flowsheet
13 Vac Heater Inside Column .KSC Move vac heater inside column flowsheet
14 Full Model_changed to predict mode .KSC Change finished model to Predict mode
15 Full Model_optimisation .KSC Work with a pre-build optimiser
Session 1 – Testrun Feed Synthesis
• Start case
 New refining case
• End case
 Session_01_Testrun feed synthesis.ksc
• Objective
 Learn how to create a testrun assay from laboratory data and
mass balance
• Learnings
 Importance of good quality mass balance and lab data
 Oil environment
 Default fluid pack and component list
Session 1 – Hints & Tips
• Create new refining case
• Go to Oil Environment and create new assay from testrun data
provided
• Add one single plant data group
• Append 8 cuts (use names provided), all are Contiguous
• Add these 15 properties
 Mass flow [tonne/hr]
 Distillation TBP wt% 1, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 95, 99 [C]
 Liq. Mass density (Std. Cond) (Dry) [SG @Std. Cond.]
• Copy and paste values direct from Excel
• Optional
 Methane, Ethane, i_Butane, n-Butane, i-Pentane, n-Pentane composition by wt%
 No lights end data provided, but if added you will see the calculated values from the
synthesis
• Don’t forget to synthesise
• In PFD: Add Feeder operation and link to the assay created
• Set P, T, and flow rate
Session 2 - Preflash
• Start case
 Session_01_Testrun feed synthesis.ksc
• End case
 Session_02_Preflash.ksc
• Objective
 Learn how to build a T2T Preflash column from scratch
• Learnings
 Use wizard for initial setup
 Typical tray efficiencies
 Specify mass balance and heat balance
 Initial review of column
• For guidance refer to section 7 of this slide pack “CDU Preflash Column – Building and
Calibration”
• Create new column from Refluxed Absorber Column template
• Use Wizard (activate in Preferences)
• Default Inside-Out solver
• Data as per Excel spreadsheet
• Don’t forget the water draw option from the overhead condensor
• There is no offgas stream (use the wizard to specify)
• Simplify the actual 2 drum overhead system by having just 1 drum and use 2nd actual
drum for setting P&T of your single drum model
 We will add the second drum later
• Add full list of recommended specifications on the Monitor page
• In the Oil Environment
 Clone the testrun assay and rename as Preflash Bottoms, Exclude the preflash naphtha stream
• Create a calibration stream and link to the PF Bottoms assay
• Look at Stream Properties > TBP wt and use these values as specs on the monitor page
(manually or via a spreadsheet import/export link)
• When completely finished, update and lock profiles. Save the case.
Session 3 – Preflash Tuned
• Start case
• End case
 Session_03_Preflash tuned.ksc
• Objective
 How to calibrate a simple T2T column
• Learnings
 Key properties to match
• For guidance refer to section 7 of this slide pack “CDU Preflash Column –
Building and Calibration”
• Review gap/overlap between naphtha and bottoms and decide on calibration
strategy
• Enter the column flowsheet and add/remove stages until you achieve a good
match on distillation gap/overlap.
• Make small adjustments to the column at a time
 Update and lock the profiles regularly. Don’t forget to save.
• Document calibration progress.
Session 4 – Preflash 2 Drums
• Start case
• End case
 Session_04_Preflash 2 drums.ksc
• Objective
 Make changes to the column flowsheet
 Change 1 drum in to 2 drum overhead system
• Learnings
 Use the Modified Inside-Out solver
 Make changes and add complexity to the column flowsheet
• For guidance refer to section 11 of this slide pack “The Column Sub-Flowsheet”
• Change the solver to Modified Inside-Out
• Make sure profiles are updated and locked before you start
• Make a plan for the changes to the column flowsheet you are going to make.
• Enter the column flowsheet and make the changes.
• Leave the boundary stream in tact, otherwise you loose connectivity to the main PFD
• Adjust the pressure profile
• Create 2 new specs
 Temperature of drum 1
 Offgas of drum 2 (set to zero, there is no offgas for this case)
• Run the column
• Check the specs on the monitor page for anything that is no longer working, reconnect
anything that is shown as <empty>
• Note that the gap/overlap specs are no longer valid. These can only be linked to
equilibrium stages in the model. The naphtha now comes from a mixer. In the next
exercise you have to calibrate against distillation points, not gap/overlaps.
• When completely finished, update and lock profiles. Save the case. ise you should tune
against distillation curves, not gap/overlaps.
Session 5 – Preflash 2 Drums Tuned
• Start case
 Session_04_Preflash 2 drums.ksc
• End case
 Session_05_Preflash 2 drums tuned.ksc
• Objective
 How to calibrate a complex T2T column
• Learnings
• For guidance refer to section 7 of this slide pack “CDU Preflash Column –
• Repeat the Hints & Tips of session 3. These are:
• Review gap/overlap between naphtha and bottoms and decide on calibration
strategy
match on distillation gap/overlap.
• Review the differences in calibration results when comparing the simple 1

drum column with the more complicated 2 drum column
 Why are the results different?
Session 6 – Atmos Column
• Start case
 Session_05_Preflash 2 drums tuned.ksc
• End case
 Session_06_Atmos Column.ksc
• Objective
 How to build a T2T Atmos column from scratch
• Learnings
 Use wizard for initial set up
 Specify mass and heat balance
• For guidance refer to section 8 of this slide pack “CDU Atmos Column –
• Create new column from Refluxed Absorber Column template
• Don’t forget the water draw option from the overhead condensor
• There is no offgas stream (use the wizard to specify)
• In the Oil Environment
 Clone the testrun assay and rename as Atres, Exclude these streams: preflash
naphtha, Lt naphtha, Hv naphtha, Kero, Diesel.
• Create a calibration stream and link to the Atres assay
• Look at Stream Properties > TBP wt and use these values as specs on the
monitor page (manually or via a spreadsheet import/export link)
Session 7 – Atmos Column Tuned
• Start case
 Session_06_Atmos Column.ksc
• End case
 Session_07_Atmos Column tuned.ksc
• Objective
 How to calibrate a T2T atmos column
• Learnings
 Removing and adding stages
• For guidance refer to section 8 of this slide pack “CDU Atmos Column –
match on distillation gap/overlap for each section.
Session 8 – Vac Column
• Start case
 Session_07_Atmos Column tuned.ksc
• End case
 Session_08_Vac Column.ksc
• Objective
 How to build a T2T vac column from scratch
• Learnings
 Use wizard for initial set up
 Specify mass and heat balance
• For guidance refer to section 9 of this slide pack “CDU Vacuum Column –
• Create new column from Absorber Column template
• Specify overhead system as pumparound
Session 9 – Vac Column Tuned
• Start case
 Session_08_Vac Column.ksc
• End case
 Session_09_Vac Column tuned.ksc
• Objective
 How to calibrate a T2T vac column
• Learnings
 Removing and adding stages
 Work with tray efficiencies
• For guidance refer to section 9 of this slide pack “CDU Vacuum Column –
match on distillation gap/overlap for each section.
• As it is a vacuum column, be prepared to also use Murphree tray efficiencies
for fine tuning.
Session 10 – Vac Bottom Quench
• Start case
 Session_09_Vac Column tuned.ksc
• End case
 Session_10_Vac bottom quench.ksc
• Objective
 Add simple bottoms quench in the main flowsheet external to
the column
• Learnings
 Simple solutions are sometimes best
• In the main PFD add a simple external quench system as per overview
drawing and operating data provided in the spraedsheet
• There is no interaction between the boot of the column where the quenching
takes place, and the base stripping section and flashzone above. The
quenched liquid in the boot is kept below the bubble point, so there is no
vapour travelling upwards.
• You need to install
 Mixer, cooler, splitter
 Recycle operation to allow for the recycle stream
 An adjust operation to vary the quench flow rate to achieve the desired quenched bottoms
temperature
Session 11 – Vac Bottom Quench Inside
Column
• Start case
 Session_10_Vac bottom quench.ksc
• End case
 Session_11_Vac bottom quench inside column.ksc
• Objective
 Move external bottoms quench outside to inside of vac
column flowsheet
• Learnings
 Work with Modified Inside-Out column solver
 Create a quench pumparound below flashzone
 Create dummy steam feed stream to avoid non-convergence
• For guidance refer to section 11 of this slide pack “The Column Sub-
Flowsheet”
• Change the column solver to Modified Inside-Out
• In the column flowsheet
 Create space at the bottom of the column for adding the additional quench PA by adding 1 stage
below stage 2
 Move all connections to stage 1 (main feed and base steam) to the new stage 2, leaving nothing
connected to stage 1
 Back to the PFD environment
• Add a dummy steam feed flow of 0.001 tonne/hr and connect this to stage 1
• Enter the column operations view and add a new PA from stage 1 to stage 1
• On the Monitor page add these active specs for the new quench PA
 Quench PA rate Calculated
 Quench PA Dt Calculated
 Quench PA T return Active
 Tray 1 temperature Active
• Run the column
Session 12 – Atmos Heater Inside Column
• Start case
 Session_11_Vac bottom quench inside column.ksc
• End case
 Session_12_Atmos Heater inside column.ksc
• Objective
 Move atmos heater from outside to inside of atmos column
flowsheet
• Learnings
 Work with Modified Inside-Out solver
 Advantages of creating a specification for heater outlet
temperature on the monitor page
Flowsheet”
• Before you start, make sure that you update and lock the column profiles
• Change the column solver to Modified Inside-Out
• Make a new connection from the heater feed stream direct to the column and
disconnect the heater outlet stream
 Add a simple heater (change the icon so that it looks like a heater if you wish)
 A flash drum for the COT flash (remember to delete the 0 pressure drop)
 Connect everything up
 Connect flash drum vapour to stage 3 and liquid to stage 2
• In the column operations view
 Update the pressure profile
 Monitor page: add stream property temperature spec for the heater COT (active)
 Check for any specs that are empty and need to be fixed
• Run the column
Session 13 – Vac Heater Inside Column
• Start case
 Session_12_Atmos Heater inside column.ksc
• End case
 Session_13_Vac Heater inside column.ksc
• Objective
 Move vac heater from outside to inside of vac column
flowsheet
• Learnings
 Work with Modified Inside-Out solver
 Advantages of creating a specification for heater outlet
temperature on the monitor page
Flowsheet”
• Before you start, make sure that you update and lock the column profiles
• The column solver should already be Modified Inside-Out
• Make a new connection from the heater feed stream direct to the column and
disconnect the heater outlet stream
 Add a simple heater (change the icon so that it looks like a heater if you wish)
 Add a valve to reflect the transfer line pressure drop (set to 130 mbar)
 A flash drum for the COT flash (remember to delete the 0 pressure drop)
 Connect everything up
 Connect flash drum vapour to stage 3 and liquid to stage 2
• In the column operations view
 Update the pressure profile
 Monitor page: add stream property temperature spec for the heater COT (active)
 Check for any specs that are empty and need to be fixed
• Run the column
Session 14 – Full Model changed to Predict
mode
• Start case
 Session_13_Vac Heater inside column.ksc
• End case
 Session_14_Full Model_changed to predict mode.ksc
• Objective
 Change active spec selections from Calibrate to Predict
• Learnings
 Choose robust active spec combinations
 Check robustness for different feed rates
 Introduce new assays to the case and check for robustness
Session 14 – Hints & Tips #1
• For guidance refer to section 10 of this slide pack “Monitor Page – Active
Specifications”
• Preflash Column
 Modify active specs like this
• Atmos Column
Session 14 – Hints & Tips #2
• Vacuum Column
• You will notice that in the Preflash column we changed drum1 temperature
from 119 C (testrun value) to 100 C
 This is for handling crude assays with a much lighter front end. At 119 C there is no liquid from
drum 1 and the column fails. At 100 C the column is more robust.
• Test robustness
 Change the main crude feed rate
 Change some of the column quality specs
 In the oil environment, add sample crude A and B and add these to the Feeder operation
 Then change crude assay or the mix in the Feeder
Session 15 – Full Model_optimisation
• Open case
 Session_15_Full Model_optimisation.ksc
• Objective
 Learn to work with the optimiser using the prebuild optimiser
in this case
• Learnings
 Make the flowsheet and the columns robust
 Choose logical Optimiser variables
 Choose logical Optimiser constraints
 Decide on Optimiser objective function
 Choose best Optimiser solver settings
• Tighten column solver tolerances
 Equilibrium Error Tolerance = 1.000e-008 (default = 1.000e-005)
 Heat / Spec Error Tolerance = 5.000e-006 (default = 5.000e-004)
 These are not settings that always work, you need to try out to see what works best for your
model
• Flashzone
 Better to use overflash as a variable and heater COT as constraint
• It is OK to use PA rate/duty as a variable, provided you have already ensured
the column profile is robust and there is no risk of running dry.
• Test robustness by manually changing some of the variables you have chosen
• Select suitable constraints to ensure the optimiser does not get ahead of itself
• For the variables start with small allowable movement, open up when things go
well
• For a model like this, it typically takes a lot of work to achieve perfect
robustness. Be patient.
• When the optimiser fails, try to understand why and adjust constraints and
variables
• Ultimately, you will achieve 100% robustness
7. CDU Preflash Column
Building and Calibration
Building a New Preflash Column #1/4
• Use wizard (optional – see preferences)
• Start with
 Refluxed absorber template
 Nr of stages based on expected efficiencies
 Set pressure profile
 Feed to flashzone at correct P&T (use split feed option)
 Base steam to bottom stage
 Spec cond temperature to testrun value (if offgas > 0)
 Alternatively spec off gas rate to 0 flow and allow temperature
to be calculated
 Spec distillate rate
 Allow reflux to be calculated
• Add column draws step by step from top down
 Not required, this column has no side draws
• Add column pa’s step by step from top down
 Not required, this column has no pumparound
• After each addition
 Update and lock profiles
 Save the case
• What to do if during a step it goes wrong and the
column fails to converge?
 When adding the distillate draw
- Set draw rate to very small value
- Make sure it solves
- Make small steps and bring the column to just before failing to
converge
- Look at performance > Column Profiles and understand why it is
close to non-convergence
- Fix the problem by
 Increase heater outlet temperature
page
calibration
 Column temperature profile
- 5%, 10%, 50%, 90%, 95% for distillate
- 1%, 5%, 10%, 50% for bottoms
- 10% /90%, 5% / 95%
 Top reflux
Calibrate the Preflash Column #1
• Work from top to bottom
• Easiest if you add/remove stages from within the column flowsheet
 Much easier to make sure you are making the correct change
 Once done, verify what you have done
• After each configuration change
 You need to Run the column from the column operation view in the main
flowsheet. It will not happen automatically.
• Vary number of whole stages in each section to get a good match on
distillation tails. Look at
 5%, 10% of the heavy stream
 90%, 95% of the light stream
 Much easier if you look at gap/overlap between 10/90 and 5/95
 If you cannot match both, give more weight to the 5/95% gap
• Avoid using Murphrees efficiencies unless no other option
 More likely needed on vac column rather than atmos column or preflash column
 Use mainly for 2 stage or less sections
- If 1 stage is too little, and 2 stages too much
- Or if you only have 1 stage left and the fractionation is still too good
 Do not use at all if there is a boundary product stream connected to the main
flowsheet. You will get a warning if you do.
• After each step
 Remember to always update and lock profiles and save the case (under a new
name)
8. CDU Atmos Column
Building a New Atmos Column #1/4
• Start with
 Refluxed absorber template
 Spec cond temperature to testrun value (if offgas > 0)
 Alternatively spec off gas rate to 0 flow and allow temperature
to be calculated
 Spec distillate rate
 Straight side draws
 Stripped side draws (steam stripped or reboiled)
 Create a spec for the draw rate and make active
 Set PA rate and make active
 Set PA dt or duty and make active
 Save the case
 When adding a product draw
converge
 Changing draw rate spec to “nil” internal reflux spec
 When adding a pumparound
- Set pa duty to very small value
converge
 Change pa duty spec to a lower value
 At the point where the column is drying up, introduce an internal
reflux spec and set to “nil” value (i.e. 1 tonne/hr)
page
calibration
- 5%, 10%, 50%, 90%, 95% for distillates
- 1%, 5%, 10%, 50% for bottoms
- 10% /90%, 5% / 95%
 Pumparounds
- Flow rate
- Duty
Calibrate the Atmos Column #1
 More likely needed on vac column rather than atmos column
• Side strippers
 Use stripper delta T for calibration (if data available)
• After each step
name)
9. CDU Vacuum Column
Building a New Vac Column #1/4
• Start with
 Absorber template
 Top stage reflux = pumparound option
 Make allowance for transfer line pressure drop
 Ignore bottoms quench effect
 Spec top temperature to testrun value
 Spec vac distillate rate
 Straight side draws
 Stripped side draws (steam stripped or reboiled)
 Create a spec for the draw rate and make active
 Set PA rate and make active
 Set PA dt or duty and make active
 Save the case
 When adding a product draw
converge
 Changing draw rate spec to “nil” internal reflux spec
 When adding a pumparound
- Set pa duty to very small value
converge
 Change pa duty spec to a lower value
 At the point where the column is drying up, introduce an internal
reflux spec and set to “nil” value (i.e. 1 tonne/hr)
page
calibration
- 5%, 10%, 50%, 90%, 95% for distillates
- 1%, 5%, 10%, 50% for bottoms
- 10% /90%, 5% / 95%
 Pumparounds
- Flow rate
- Duty
Calibrate the Vac Column #1

 More likely needed on vac column rather than atmos column

• Side strippers
 Use stripper delta T for calibration (if data available)
• After each step
name)
• Finally
 Normally Esso-Tabular is recommended for vacuum columns instead of Peng-
Robinson
 Investigate if Esso Tabular fluidpack provides a better fit.
 If the column fits better choose Esso-Tabular for the vac column only
 Consider the fit for
- Overflash
- Pumpdown refluxes
- Temperature profile
 Use the Basis environment to clone the PR basis (Basis-1) to create Basis-2 and
change the fluidpack from PR to ET
 Use the Basis Environment to select Basis-2 for the vac column

10. Monitor Page –
Active Specifications
• For Calibration
• For Predict

What spec combinations to use?
• Matching plant data
 Fix product flows
 Fix heat balance
• Switching to predictive mode
 Fix product qualities, like distillations
 Fix internal refluxes
 Rigorous columns can be made to be 100% robust in
predictive mode

Monitor Page – VDU Testrun Specs

Changing column specs from Calibration to
Predict
• How to make T2T columns robust in Predict?
 Avoid using too many draw rate specs
 Alternatives for column draw rate specs
- Distillation spec, i.e. 95% ASTM D86
- Internal reflux at draw location
 Alternatives for pumparound specs
- Internal reflux above pumparound section
 Flashzone
- Spec overflash rate and allow freedom on heater temperature
- Spec heater temperature and allow freedom on heaviest
distillate

Monitor Page – VDU Predict Specs

11. The Column Sub-Flowsheet
For Experienced Users

Column sub-flowsheets
• Beginners, don’t even look at it
 Almost everything can be done from the normal column
operation view
 The wizards are pretty good and helpful for setting up new
columns
• Advanced users
 The column sub flowsheet opens many possibilities
 Very complex and unusual columns configurations can be
represented
 But you need to know what you are doing
 The only limit is you imagination

Example – 2 drum Preflash Column

Example – Vac Heater inside column

Hints & Tips
• Before you start
 Update and lock column profiles, save the case. If you don’t, you may loose
profiles all together and it will be difficult to recover from column failure.
 Change the column solver from Default Inside-Out to Modified Inside-Out.
This allows maximum flexibility for working in the column flowsheet.
• Make a plan
• Add complexity step-by-step
• Leave boundary streams in tact, otherwise you loose connections to
the main flowsheet
• Once happy with the new lay-out, check degrees of freedom and add
new specifications on the Monitor page if required.
• Make sure your new specifications are logical to the solution.
• On the Monitor page check if all previous specifications still work (i.e.
are not shown as <empty>).
• Finally, Run the column

12. Problem Columns
Common Problems and their Solutions

Typical causes of column solver failure
• Mass & heat balance problems
 Draw too much side draw
 Very small side stripper steam flow rate
 Take out too much PA heat
 Insufficient vaporisation in the flashzone
• Other
 Did not update and lock column profiles and save the case
 Illogical or impossible combination of active specs
 Forgot to include a water draw for the ovhd condensor
 Profiles far away from desired solution
 Profile corruption

Problem Columns
• How do get myself out of a hole?
 Diagonal Matrix, your worst nightmare!
- Focus on getting a converged solution no matter how far from reality
- Switch to total reflux
 Nil or very low PA duties
 Nil or very low side draws
- Once the column solves the first time
 Results look strange, don’t worry
 Save the profiles
 Don’t forget to save the case!
- Next make VERY small changes and work your way slowly to the
solution you want
 Go from top to bottom
 Product draw rates first
 PA’s next
 Save the case as you go along
- When done, update the profiles and save the case
Problem Columns #1/3
• The dreaded diagonal matrix!!!
• Or the column simply does not converge
• Most problems occur on multi side draw columns like crude or vacuum
columns
 Vacuum columns are the biggest culprits
• Possible causes
 Impossible question
 Inappropriate solver settings
- Damping could help
- Often seen on columns with hardly any temperature gradient
 Lack of profile data for initialisation
- Often with newly build columns
- Always good to update and save column profiles once a first converged
run has been achieved
 Sometimes the solution exists, but the solver cannot get there
without a little help
• How do get myself out of a hole?
 Review your specs and spec combinations
- Does it make sense?
- Is the solution possible?
- Unwise or impossible column specification selection?
- Think about it and choose a more sensible combination of active
specs

• Case corruption
 Very rare
 Last resort
 Save case as XML
 Then read in the XML case
 This will rebuild the case from scratch
 And if the case is corrupted, this will get rid of the corrupted
element

13. Optimisation
Hints & Tips

Optimisation robustness
• Column in predict mode must be robust
 One single column solver fail at any time may destroy a complete optimisation
 You must understand the column and foresee where it may fail
• Make sure you
• Tighten up on column solver tolerances
 To provide clear direction to the optimiser
 Reduce solution noise
• Optimiser Solver
 You need to try different settings, one setup is not always best for everything
 Try Cobyla and iPopt
 Try Autoscale before Solve: On or Off
 Use Best Feasible Iteration: Always On
 Leave all other settings to default

“T2T columns are
difficult and always fail”
True or False?
PROPRIETARY INFORMATION 11 December 2015 121

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T2T Distillation Column Workshop –

Ron Sudkamp, KBC

PROPRIETARY INFORMATION 11 December 2015 2

Sample Agenda for 2-day Workshop

Data to be used throughout the

Rubbish IN = Rubbish OUT

800 • Hvgo flow adjusted to

200 Resid 103.5 103.5

800 • Mvgo flow adjusted to

200 Resid 103.5 103.5

800 • Resid flow adjusted to

500 Flows (m3/hr) Raw Reconciled

Step by step building and calibration of

• Review the differences in calibration results when comparing the simple 1

Building and Calibration

Building and Calibration

Building and Calibration

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PROPRIETARY INFORMATION 101

PROPRIETARY INFORMATION 102

PROPRIETARY INFORMATION 103

PROPRIETARY INFORMATION 104

PROPRIETARY INFORMATION 105

PROPRIETARY INFORMATION 106

PROPRIETARY INFORMATION 107

For Experienced Users

PROPRIETARY INFORMATION 108

PROPRIETARY INFORMATION 109

PROPRIETARY INFORMATION 110

PROPRIETARY INFORMATION 111

PROPRIETARY INFORMATION 112

Common Problems and their Solutions

PROPRIETARY INFORMATION 113

PROPRIETARY INFORMATION 114

PROPRIETARY INFORMATION 117

PROPRIETARY INFORMATION 118

Hints & Tips

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PROPRIETARY INFORMATION 11 December 2015 121

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