DC SIM+User+Guide

DC-SIM
User Guide
KBC Advanced Technologies, LLC
Ownership of KBC Intellectual Property Rights Software KBC Advanced Technologies plc (KBC) is the owner of and has vested in it the copyright and all other intellectual property rights of a similar nature relating to its software, which includes, but is not limited to, KBCs computer programs, user manuals and all associated documentation, whether in printed or electronic form (the Software), which is supplied by KBC or its subsidiaries to their respective customers. No copying or reproduction of the Software shall be permitted without the prior written consent of KBC, save to the extent permitted by law. Portions of this product are based on HYSYS technology 1998 - 2002 Hyprotech Company. Trademarks Profimatics, Petro-SIM, DC-SIM, REF-SIM, HCR-SIM, VGOHTR-SIM, RHDS-SIM, DHTRSIM and FCC-SIM are trademarks (KBC Trademark) of KBC Advanced Technologies,plc, all rights reserved. The Licensee undertakes not to alter, obscure, remove, conceal, or otherwise interfere with KBC Trademarks or any indications of the source of the Software which may be placed on the Software or its packaging or any part thereof, or use, permit any party to use or authorize the use in any way whatsoever of trademarks that are similar or that may be confused with KBC Trademarks. Microsoft Office, Microsoft Windows, Windows XP, Excel and Visual Basic are registered trademarks of Microsoft Corporation. SentinelPro is a trademark of Rainbow Technologies, Inc. All other company names, products or name brands are trademarks of their respective holders. Use The Licensee shall follow all instructions given to it by KBC from time to time in relation to the use of copyright, the KBC Trademarks, and all similar property rights in the Software. All rights in respect of KBC's Trademarks and all rights in respect of the copyright of the Software are reserved.
Copyright KBC Advanced Technologies plc 2005. All rights reserved.
Registered Office: KBC Process Technology Plc. KBC House 42-50 Hersham Road Walton-on-Thames Surrey KT12 1RZ United Kingdom
Website www.kbcat.com
Contents
Introducing DC-SIM 1-1
Overview................................................................................................................................ 1-2 Whats New in This Release .................................................................................................. 1-3 Optimizer Improvements ......................................................................................... 1-3 New Tuning Factor for Furnace Cracking Temperature.......................................... 1-3 Fractionator Configuration for Extra Low Recycle Operation ................................ 1-4 Predicting Viscosity and Flash Point Product Properties......................................... 1-4 Adjustment of Coker Feed Back End Distillation ................................................... 1-4 Special Once Through Coker Configuration with No HCGO Net Product ............. 1-5 PSV Steam Input to Fractionator ............................................................................. 1-5 Calibration Factors for PONA of Naphtha Range Product...................................... 1-5 Conversion of Old DC-SIM Workbook to Current Version Workbook .................. 1-5 Inter-conversion of Units of Measurement for Data File During IMPORT............. 1-5 Program Security ..................................................................................................... 1-5 Excel Interface Standardization ............................................................................... 1-6 Delayed Coker Refinery Unit................................................................................................. 1-7 Technical Help and Feedback ................................................................................................ 1-9 A Guide to Problem Solving.................................................................................... 1-9 Help and Error Messages......................................................................................... 1-9 Feedback.................................................................................................................. 1-9
DC-SIM Data Requirements
2-1
How DC-SIM Works ............................................................................................................. 2-3 Test Run Data for Model Calibration..................................................................................... 2-4 Drum Dimension Input Data.................................................................................................. 2-5 Calibration Input Data............................................................................................................ 2-7 How the Calibration Case Works......................................................................................... 2-11 Calibration Case Checklist..................................................................................... 2-12 Configuration Guidelines..................................................................................................... 2-13 Zero Natural Recycle Configuration: Once Through............................................ 2-13 Definition of Combined Feed Ratio (CFR)............................................................ 2-17 Velocity Gas Oil .................................................................................................... 2-17 DC-SIM Calibration Guidelines .......................................................................................... 2-20 Predict Input Data ................................................................................................................ 2-22 Quench................................................................................................................... 2-22 Velocity Gas Oil .................................................................................................... 2-23
DC-SIM User Guide KBC Proprietary Contents i
Product Cutpoints Target ....................................................................................... 2-24 Coke Inventory ...................................................................................................... 2-24 How the Predict Case Works ............................................................................................... 2-26 Predict Case Checklist ........................................................................................... 2-26 Product Properties ................................................................................................................ 2-28 Sulfur ..................................................................................................................... 2-28 Nitrogen ................................................................................................................. 2-28 Aniline Point .......................................................................................................... 2-28 Naphtha RON and MON ....................................................................................... 2-28 Diesel Cloud Point, Pour Point and Flash Point .................................................... 2-28 Bromine Number ................................................................................................... 2-28 Naphtha PONA ...................................................................................................... 2-29 Viscosity @ 50 C ................................................................................................... 2-29 Other Properties ..................................................................................................... 2-29 Coke Volatile Matter (VCM)................................................................................. 2-29 Coke Ash Content.................................................................................................. 2-29 Coke HGI............................................................................................................... 2-29 How the Optimizer Works ................................................................................................... 2-30 Optimizer Run Checklist........................................................................................ 2-30
Installing DC-SIM
3-1
PC System Requirements ....................................................................................................... 3-2 Microsoft References ............................................................................................... 3-2 Installation.............................................................................................................................. 3-3 Program Security ..................................................................................................... 3-3 DC-SIM Model Installation ..................................................................................... 3-3 What Is Installed ...................................................................................................... 3-4 Number and Decimal Regional Settings .................................................................. 3-4 Starting the Program .............................................................................................................. 3-7 Opening DC-SIM with the Start Bar........................................................................ 3-7 Starting with the Data Workbook ............................................................................ 3-7 Setting up a Shortcut................................................................................................ 3-8 Starting DC-SIM...................................................................................................... 3-8 Security Settings and Macros................................................................................... 3-9 Testing the Program Execution.............................................................................. 3-10 Problems When Running the Application.............................................................. 3-11
Using the Spreadsheet Interface
4-1
Microsoft Excel...................................................................................................................... 4-3 Data Flow................................................................................................................. 4-3 Gateway Workbook ............................................................................................................... 4-4 Model Workbook and Model Workbook Template ............................................................... 4-5 Getting Started ....................................................................................................................... 4-6 Available Models ..................................................................................................... 4-6 Proceed Button......................................................................................................... 4-6 Cancel Button .......................................................................................................... 4-7 Customizing the Workbook ................................................................................................... 4-8 Model Workbook ................................................................................................................... 4-9
ii Contents KBC Proprietary DC-SIM User Guide
Grouping Feature ..................................................................................................... 4-9 Comments.............................................................................................................. 4-10 DC-SIM Menu ....................................................................................................... 4-11 DC-SIM Options Item ........................................................................................... 4-11 Navigation Item ..................................................................................................... 4-12 Run Item ................................................................................................................ 4-12 Copy Case Data Item ............................................................................................. 4-13 Clear Case Data Item ............................................................................................. 4-13 Text Files Item....................................................................................................... 4-13 Available Results Item........................................................................................... 4-14 Import Case Data Item........................................................................................... 4-14 Export Case Data Item........................................................................................... 4-14 Transfer Workbook Data ....................................................................................... 4-15 Import from Petro-Sim .......................................................................................... 4-15 Export Calibration to Petro-Sim ............................................................................ 4-15 Links ...................................................................................................................... 4-15 Design Worksheet ................................................................................................................ 4-16 Calibration Input Worksheet ................................................................................................ 4-18 Run Button............................................................................................................. 4-18 Import Button ........................................................................................................ 4-19 Copy Button........................................................................................................... 4-20 Clear Button........................................................................................................... 4-21 Predict Input Worksheet....................................................................................................... 4-23 Run Button............................................................................................................. 4-24 Setup Button .......................................................................................................... 4-24 Copy Button........................................................................................................... 4-25 Import Button ........................................................................................................ 4-25 Clear Button........................................................................................................... 4-25 Optimizer Input Worksheet.................................................................................................. 4-26 Run Button............................................................................................................. 4-27 Setup Button .......................................................................................................... 4-27 VGen: LP Vector Generation Tool ........................................................................ 4-28 Result Worksheets................................................................................................................ 4-29 Comparison Worksheet........................................................................................................ 4-31 CaseGen................................................................................................................. 4-31 Summary Worksheet............................................................................................................ 4-33 Charts ................................................................................................................................... 4-34 Charts Worksheet................................................................................................... 4-34 Charts - 2 Worksheet ............................................................................................. 4-37 Worksheet Comments and Model Help ............................................................................... 4-38 Saving Files and DC-SIM Exit ............................................................................................ 4-39
Appendix A - Calibration Factors
A-1
Initialization Factors ............................................................................................................. A-2 DCSIM V2006 Tuning Factors............................................................................................. A-3 DC-SIM V2006 Calibration Factors ..................................................................................... A-6
Index
DC-SIM User Guide KBC Proprietary
I-1
Contents iii
Introducing DC-SIM
Overview................................................................................................................................ 1-2 Whats New in This Release .................................................................................................. 1-3 Optimizer Improvements ......................................................................................... 1-3 New Tuning Factor for Furnace Cracking Temperature.......................................... 1-3 Fractionator Configuration for Extra Low Recycle Operation ................................ 1-4 Predicting Viscosity and Flash Point Product Properties......................................... 1-4 Adjustment of Coker Feed Back End Distillation ................................................... 1-4 Special Once Through Coker Configuration with No HCGO Net Product ............. 1-5 PSV Steam Input to Fractionator ............................................................................. 1-5 Calibration Factors for PONA of Naphtha Range Product...................................... 1-5 Conversion of old DC-SIM Workbook to Current Version Workbook................... 1-5 Inter-conversion of Units of Measurement for Data File during IMPORT ............. 1-5 Program Security ..................................................................................................... 1-5 Excel Interface Standardization ............................................................................... 1-5 Delayed Coker Refinery Unit................................................................................................. 1-7 Technical Help and Feedback ................................................................................................ 1-9 A Guide to Problem Solving.................................................................................... 1-9 Help and Error Messages......................................................................................... 1-9 Feedback.................................................................................................................. 1-9
DC-SIM User Guide
KBC Proprietary
Introducing DC-SIM 1 - 1
Overview
This user guide is for the KBC Profimatics DC-SIM V2006 model for simulating delayed coker units. The guide has five chapters and one appendix. Chapter 1 Introducing DC-SIM Chapter 2 DC-SIM Data Requirements Chapter 3 Installing DC-SIM Chapter 4 Using the Spreadsheet Interface Appendix A Calibration Factors It guides you through the mechanics of setting up and using the model on a personal computer.
1 - 2 Introducing DC-SIM
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DC-SIM User Guide
Whats New in This Release

These enhancements include: You can now specify either a maximization or minimization optimization run. The list of available dependent variables has been expanded. New furnace cracking temperature adjust factor to improve furnace cracking calculation during calibration. Fractionator Open Wash Zone option to allow simulation of extra low recycle (CFR < 1.05) operation. Add Flash Point and Viscosity (@ 50 C or 122 F) calculation for liquid products. The viscosity of furnace feed is also calculated when fresh feeds viscosities are specified. Automatic correction of feed distillation 90% and 99% points to avoid flat pseudocomponent profile on the back end. Special coker configuration for simulation of Once Through coker with HGO recycled to extinction. Input of PSV steam to the fractionator. Calibration factors for PONA of naphtha range products. Conversion of old DC-SIM workbook to current version workbook. Inter-conversion of units of measurement for data file during IMPORT. New KBC Profimatics security mechanism, which replaces the old parallel port security dongle with either network or local License file/USB dongle combination. Standardization of model Excel interface with other KBC Profimatics SIM models.
Optimizer Improvements
The capability to run the Optimizer for objective function minimization has now been added. Additional dependent yields variables are now available to use as objective function or constraints.
New Tuning Factor for Furnace Cracking Temperature

During the DC-SIM calibration mode, the cracking temperature inside the furnace is set at 75% of the process fluid temperature rise. With the furnace outlet temperature fixed, the furnace inlet temperature is calculated by heat balance during the calibration convergence loops. The amount of cracking occurring in the furnace tube is based on this furnace cracking temperature.
DC-SIM User Guide
KBC Proprietary
NOTE: Even though the calibration may have converged, you are cautioned to review some of the calibration parameters to potential problems. Under some situations, the calibration data may result in too high a level of cracking in furnace. The normal range of furnace cracking should be less the 25%. If the initial calibration results calculate too high a furnace cracking level, you can use this Furnace Cracking T Adjust Factor to shift the furnace cracking temperature to reduce the furnace cracking amount to a more acceptable level.
Fractionator Configuration for Extra Low Recycle Operation

For operation at extra low recycle ratio operation (CFR < 1.05), setting HGO draw tray as either tray 4 (default) or tray 3, will likely result in column simulation failure. There is often insufficient liquid traffic in the wash zone trays. By specifying the HGO draw tray to be tray 2, the fractionator is configured as open wash zone, so that the column model will solve even at extra low recycle operation. For this configuration, feed 4 and feed 5 are no longer allowed as there are no intermediate wash zone trays for those feeds.
Predicting Viscosity and Flash Point Product Properties

For liquid products, the viscosity (at 50 C or 122 F) and flash point properties are now calculated by the model using API procedures. If the fresh feeds viscosities are specified on the input sheets, the model will calculate the furnace feed viscosity, blending from fresh feeds and recycle streams. The furnace feed viscosity is required data for the Petro-SIM furnace model. If the gasoil range products have calibration flash point input specified, calibration factors will be calculated comparing the prediction from API procedure vs plant data. The API flash point procedure requires the product stream D86 10% point to be > 150 F.
Adjustment of Coker Feed Back End Distillation

The lab measurement of coker feed distillation goes up to about 700 C (1300 F). This covers about 70% of the feed materials. DC-SIM requires entry of 7 distillation points including the 90% and 99% points. The backend distillation is normally extrapolated from the other distillation points. However, the extrapolated backend distillation, in conjunction with the feed gravity, may result in a flat pseudo-component profile tail. This could cause non-smooth responses in predict case parametric studies. The model now adjusts the 90% and 99% feed distillation points automatically when it came up with a flat pseudocomponent profile tail.
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DC-SIM User Guide
Special Once Through Coker Configuration with No HCGO Net Product

DC-SIM has been adapted to simulate a coker in Once Through mode but with normal HCGO range product recycled to extinction. This type of coker is constrained by the lack of downstream HCGO processing capability such as FCC unit. To simulate this operation, enter the HCGO yields as 0.0001 wt% in the calibration. The HCGO product quality information is provided in the calibration as this stream is still present in the unit as recycles.
PSV Steam Input to Fractionator

In some coker units, PSV steam are present in the fractionator. Entry of this PSV steam to DC-SIM lets you study its impact on the tower vapor liquid equilibrium.
Calibration Factors for PONA of Naphtha Range Product

On the Calibration Input worksheet, you can enter the plant test data for olefin, naphthenes, and aromatics vol% content in naphtha range products. The paraffins are calculated by difference. These factors allow better matching between calculated PONA values from correlations and the measured PONA data. In Predict cases, these calibration factors are applied to each of these naphtha components.
Conversion of Old DC-SIM Workbook to Current Version Workbook

A new utility has been added to the DC-SIM Tool menu to let you read in an older version DC-SIM workbook which is automatically converted to the current version workbook format.
Inter-conversion of Units of Measurement for Data File During IMPORT

During the IMPORT data file process, an option is now available to convert the data to a different set of units of measurement. This tool will help you evaluate data from different sources.
Program Security
A new security system has been implemented. This system lets you attach a security key to your USB port, the parallel port, or network system. Contact KBC for details.
Excel Interface Standardization

As part of the interface standardization effort for KBC Profimatics SIM models, some changes have been made to DC-SIM Excel interface. The
DC-SIM User Guide KBC Proprietary Introducing DC-SIM 1 - 5
old Profdc.xls gateway file has been replaced with a SIM universal gateway DLL. While the appearances on some of the worksheets have been modified or improved, the basic functionalities are maintained.
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DC-SIM User Guide
Delayed Coker Refinery Unit

Delayed coking is an established and widely used bottoms upgrading process. It uses severe thermal cracking in a low space velocity vessel in which the feedstock is allowed to soak at high temperature. The combination of time and temperature promotes thermal cracking reactions. A key design parameter of the delayed coking process is how to delay the formation of coke in the charge furnace and to concentrate the thermal reactions in the coke drum in such a way as to maximize liquid product conversion. The feed to delayed cokers is traditionally a vacuum residue, but petrochemical byproduct tars and catalytic cracker decanted or clarified oil can also be processed. Delayed coking rejects carbon from the residual oil leaving cracked products that are somewhat more enriched in hydrogen and significantly lower in average molecular weight. However, because the feedstock is highly hydrogen deficient to begin with, and some of that hydrogen is lost to H2S or gas, the raw coker liquid products tend to be olefinic and aromatic. Coker products are typically treated chemically to be stabilized or sent to hydroprocessing units to further increase the hydrogen content. Cokers are often built in conjunction with Fluid Catalytic Crackers (FCCUs), which are sized and designed to handle the converted coker products. Traditional delayed coke comes in at least two quality grades (anode or fuel), and several recognizable compositional forms (needle, sponge, or shot), each with a different end use, market value, physical property set, and handling requirements. The coke type is largely predetermined by the properties of the feedstock. For example, the coke produced by nonresidual stocks is more crystalline and less amorphous than typical vacuum resid feed coke. Coker operations have only a limited or marginal effect on what type of coke is produced. DC-SIM focuses on predicting the yield and property shifts from changes in process conditions and from changes in feedstock within a class of feeds. DC SIM is not designed to predict behavior of coke quality across different classes of feeds. However, it can directionally indicate where certain key properties, like sulfur, nitrogen and metals, are likely to go with an entirely different feedstock. DC-SIM is based on a standard representation of a typical fuel or anode grade delayed coker unit as shown in the following figure.
DC-SIM User Guide
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DC-SIM User Guide
Technical Help and Feedback

A Guide to Problem Solving
The SIM Series of models provides assistance in a variety of ways. This document includes information on the DC SIM V2006 model covering Excel interface topics, as well as specific DCSIM model operation. Excel Comments on each worksheet provide valuable information on the cell in which they are located. Model help and error messages are reported in the DC SIM message log. If you need additional assistance in using the process modeling software, please contact your KBC modeling specialist.
Help and Error Messages

Help and error messages are available to provide guidance. The error messages are reported in the DCMSG.OUT file. To view these messages: 1. 2. 3. 4. Select DC-SIM on the toolbar. Click Text Files to open the View Text Files view. Select Messages Select OK to exit.
Error messages are numbered for easier identification, and provide hints on error cause or correction guidelines, where appropriate.
Feedback
KBC Advanced Technologies, Inc. is constantly upgrading and enhancing its software. Your feedback is important to this process. You can contact KBC directly through your modeling specialist or local account representative. Alternately, you can contact KBC Profimatics Software Support (email: software@kbcat.com) or through your regional office.
DC-SIM User Guide
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DC-SIM User Guide
DC-SIM Data Requirements

How DC-SIM Works ............................................................................................................. 2-3 Test Run Data for Model Calibration..................................................................................... 2-4 Drum Dimension Input Data.................................................................................................. 2-5 Calibration Input Data............................................................................................................ 2-7 How the Calibration Case Works......................................................................................... 2-11 Calibration Case Checklist..................................................................................... 2-12 Configuration Guidelines..................................................................................................... 2-13 Zero Natural Recycle Configuration: Once Through............................................ 2-13 Calibration as a Once Through Unit........................................................ 2-13 Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit...................................................................... 2-15 Definition of Combined Feed Ratio (CFR)............................................................ 2-16 Conventional Recycle Coker ................................................................... 2-16 Once Through Coker ............................................................................... 2-16 Velocity Gas Oil .................................................................................................... 2-16 DC-SIM Calibration Guidelines .......................................................................................... 2-19 Predict Input Data ................................................................................................................ 2-21 Quench................................................................................................................... 2-21 Velocity Gas Oil .................................................................................................... 2-22 Product Cutpoints Target ....................................................................................... 2-22 Coke Inventory ...................................................................................................... 2-23 How the Predict Case Works ............................................................................................... 2-25 Predict Case Checklist ........................................................................................... 2-25 Product Properties ................................................................................................................ 2-26 Sulfur ..................................................................................................................... 2-26 Nitrogen ................................................................................................................. 2-26 Aniline Point.......................................................................................................... 2-26 Naphtha RON and MON ....................................................................................... 2-26 Diesel Cloud Point, Pour Point and Flash Point .................................................... 2-26 Bromine Number ................................................................................................... 2-26 Naphtha PONA...................................................................................................... 2-27 Viscosity @ 50 C................................................................................................... 2-27 Other Properties ..................................................................................................... 2-27 Coke Volatile Matter (VCM)................................................................................. 2-27
DC-SIM User Guide KBC Proprietary DC-SIM Data Requirements 2 - 1
Coke Ash Content.................................................................................................. 2-27 Coke HGI............................................................................................................... 2-27 How the Optimizer Works ................................................................................................... 2-28 Optimizer Run Checklist........................................................................................ 2-28
2 - 2 DC-SIM Data Requirements
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DC-SIM User Guide
How DC-SIM Works

DC-SIM is a generalized kinetic model that is tuned to an actual unit to model its behavior. Following this tuning, or calibration, the model can be used to predict unit behavior. The model can also predict the specific optimum for a given unit. The three models, called modes, that DC-SIM runs are: Calibration mode Predict mode Optimization mode The model is tuned by making a run in Calibration mode. In this run, plant data from a delayed coker unit test run is entered into the model. The model forces a fit between the theoretical model and the real-world unit, automatically calculating a series of parameters called Calibration factors. Kinetic rate constants for the key reactions of cracking and polymerization are calculated during the Calibration procedure. Once the model is calibrated, it can be run in Predict mode. This mode lets you predict model behavior. Calibration factors determined from the Calibration runs are used as inputs to Predict mode. For Predict runs, input the feed rates and qualities and unit operating conditions. You can vary any of a number of process variables, including: Feed rates (including adding a new feed or feeds) Feed qualities Combined feed ratio (furnace feed/fresh feed) Furnace outlet temperature Drum pressure Product fractionation cut-points Given these inputs, the model predicts how the unit will behave. Results include: Yields Product properties Drum fill time Quench rates
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DC-SIM User Guide
Test Run Data for Model Calibration

The suggested general procedure for gathering and organizing calibration data for a delayed coker is based on the following. The best interval of time for establishing a mass balance is one complete drum cycle. This is from drum swing to the next drum swing, normally a period of between twelve to twenty-four hours, depending on local operating procedures. The model is calibrated as a steady state operation taken at the mid-point of the drum cycle. The coke inventory is set to 50% of the final inventory or just 50% of maximum if the final outage is not available. The mass balance is closed around the fractionator tower and includes all residue feeds, light slops, external quenches, and the recovered products from these feeds. It should not include any internal slops, blowdown oils or quench which is taken from tower product streams. Any rich oils or commingled naphthas, light ends, or gases that pass through the coker tower overhead or gas plant should be backed out of the balance. The measured flows should be averaged and validated on a consistent basis. If the crude slate that generated the coker feed is known and laboratory data is incomplete or unavailable, residue feed distillations and properties can be generated using a Crude Assay Library tool such as KBCs Crude Assay Management System (CAMS). Light ends and naphtha should be adjusted for C4- in naphtha and C5+ in butane. DC-SIM is calibrated using the mass flows of the gases, light ends and liquid product streams. If necessary, the lightest liquid stream gravity should be adjusted for the C4/C5 transfers. However, if the amount of C4- in the naphtha remains about the same in most operations, this C4- adjustment may be skipped. DC-SIM assumes the reported C4- yields do not include the amount included in the naphtha. Coke yield is calculated by DC-SIM as the difference between the sum of the feed weights and the sum of the product weights.
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DC-SIM User Guide
Drum Dimension Input Data

DC-SIM processes certain drum dimensions so the coke inventory can be translated to an outage value.
The premises of the model are: Outage is measured from the top head flange. The total volume of the drum includes: The bottom cone The cylindrical portion The top head volume to the flange.
Drum outages are estimated subtracting out the top head volume and referencing coke level in the drum to the top tangent line (with appropriate offsets and adjustments). Coke inventory is tracked in the model in terms of percent of maximum volume where maximum volume is defined by the coke level at minimum outage. Knowing the volume of coke in inventory, the weight accumulation rate of new coke, the run time interval, and the density of the coke, it is possible to profile the accumulation of coke and the outage level through a drum cycle. The model assumes a uniform diameter over the entire vertical range of the drum cylinder (from top tangent line to bottom tangent line). The bottom cone area is represented as a virtual cylinder having the same diameter as the main drum and the actual volume of the cone area to the bottom head. This should be kept in mind when analyzing outage estimates in the first few percent of the drum cycle. Many cokers consist of multiple trains, or cells, made up of a furnace and drum pair running in parallel looping from and back to a single fractionator. In these cases we aggregate the drums into a conceptual drum made up of the individual drums stacked
KBC Proprietary DC-SIM User Guide
on top of each other and a combined furnace. The drum diameter is kept the same as the physical diameter of the drums (which assumes they are all the same). This allows for outage and coke accumulation calculations, which are a simple multiple of the number of cells.
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DC-SIM User Guide
Calibration Input Data
c = Required; blank = optional Note: Input data will be shown as screen captures from the actual model. The units shown are British/USA; you can select metric units on the Design worksheet. The operating conditions entered represent the average conditions in effect consistent with the material and property balance data.
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DC-SIM User Guide
c = Required; c* = Conditional on presence of stream selection on design worksheet; blank = Optional The coker unit product yields are entered as mass flow or weight percent.
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DC-SIM User Guide
c = Required; c* = Conditional on presence of stream selection on design worksheet; blank = Optional The initialization factors can normally be left blank initially. The two Distribution Factors and the Converge Tolerance Initial Factors can be used during Calibration in accordance with DC-SIM Calibration Guidelines on page 2-19. Liquid Stream properties are shown below. Even though product sulfur, nitrogen and metals are not required input, that information is used to calculate their distribution in the Predict cases.
c = Required; c* = Conditional on presence of stream selection on design worksheet; blank = Optional
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DC-SIM User Guide
c = Required; c* = Conditional on presence of stream selection on design worksheet; blank = Optional Economic prices and costs can be assigned for a net profit calculation. All economic entries are optional.
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DC-SIM User Guide
How the Calibration Case Works

The general sequence of Calibration Case calculations is: 1. Feeds are identified and broken up into volatile oil pseudocomponents and a non-volatile back-end defined as the weight % concarbon residue. The mass yield and gravity data are interpreted to establish the calibration basis for product streams. This sets the weight and volume targets against which the reaction equations are calibrated. The liquid product TBP distillations are interpreted to calculate volume-weighted cutpoints. Distillation overlaps and offsets are calculated and stored as Calibration factors. The cutpoints are stored as Calibration references. Sulfur and nitrogen are balanced based on distributions to gas, liquid products, and coke. The fractionation tower is initialized to provide an initial estimate of the furnace feed composition. The furnace, drum and quench operations are simulated and iterated until the weight yield of gas, liquid products, and coke is converged at the measured process conditions by manipulating the yield and distribution Calibration factors. The fractionator tower is re-calculated with the equilibrium drum vapor to separate the heavy gas oil and lighter from the recycle. The furnace feed is recalculated and step 6 repeated until all sections are converged. Having established the back-end of heavy gas oil in step 7, the front-end cutpoint is manipulated until the heavy gas oil weight is converged with the measured calibration weight within the rigorous fractionation procedure. The tower is resolved and all steps from step 6 are repeated. The remaining tower liquid streams are distributed by weight using a simple column TBP procedure.
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10. Each of the liquid stream volumes are adjusted to the measured target volume by adjusting the K-Factors of the pseudocomponents until both the weights and volumes agree. The K-Factor shift from feed to products is recalculated and the model resolved from step 6 again. 11. The converged model then compares estimated properties against the measured inputs and calculates property Calibration factors, or saves the Calibration gross property values as points of reference.
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Calibration Case Checklist

While calibrating the model, check the following: 1. Retrieve an existing Calibration Case to load into the Calibration Input Worksheet or enter the required data manually. Check that the model configuration and static data on the Design Worksheet are correct and consistent with the Calibration Input Worksheet data. Run the model using the Run button on the Calibration Input Worksheet or the DC-SIM menu. If the model fails, an error message appears above the case that failed on the Calibration Result worksheet. You are prompted to go to the Message Log Report. The cause of the failure is listed at the bottom of the file and will provide information for you to correct the problem. After correcting, run the model again. If the model runs successfully, then the Model Messages should be checked to ensure there are no abnormal warnings. The results will be loaded into the Calibration Result Worksheet. View output files using the Text Files selection on the DC-SIM menu. Review the Summary Worksheet to check Calibration Case data quality. Review the Charts 2 Worksheet to inspect the feed and product breakups and distillations.
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DC-SIM User Guide
Configuration Guidelines
Zero Natural Recycle Configuration: Once Through
Conventional coker technology mixes the bubble tower bottom with fresh feeds to add recycle to the furnace. While this recycle helps the resid flow through furnace, it also contributes to additional coke yields. In recent years, a different coker configuration has been implemented at some refinery. The fresh feeds are no longer mixed with the tower bottom. Depending on the resid quality, distillates such LGO or HGO are mixed in just before furnace inlet to provide the dilution needed. To differentiate this zero natural recycle technology from the conventional recycle mode, this alternative is labeled as Once Through Configuration. Selection of the Once Through Configuration removes the fresh feeds from the tower bottom. The fresh feeds are sent directly to the furnace bypassing the fractionator bottom. In this configuration, there is no natural recycle where the feed is not picking up any recycle from the tower bottom tray. It is still feasible to send Distillate recycle by taking a tower product stream (such as LGO or HGO) and mixing that with the fresh feed just before furnace inlet using the Velocity Gas Oil slot. The Once Through Configuration can be applied in two types of situations: Calibration as a Once Through Unit Prediction of Once Through Unit performance using a calibrated Conventional Recycle Unit
Calibration as a Once Through Unit

A standard Calibration run can be performed by specifying the Once Through option in the Configuration menu on the Design sheet.
In the Once Through configuration, only fresh feeds 1 to 3 are available as furnace feed. Feeds 4 and 5 are not applicable in this mode.
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DC-SIM User Guide
In addition to the product streams present in the conventional recycle coker, a sixth product, Flash Zone Gas Oil (FZGO), is produced from the tower bottom. For the Velocity Gas Oil option, it is also possible to use FZGO as part of the velocity gas oil. This can be done is two ways. FZGO (Flash Zone Gas Oil) used as velocity gas
OR Both HGO and FZGO mixed together to be used as velocity gas
Refer to Velocity Gas Oil for the flow rates of the new Velocity Gas Oil. When HGO + FZGO mixture is used, both Recycle Gas Oil Volume Rate and Recycle FZGO Oil Volume Rate are required (Calibration or Predict input worksheet rows 235 through 238.)
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DC-SIM User Guide
In DC-SIM V2006, a special Once Through configuration where there is no net HGO product streams can be simulated by setting the HGO yields to be .0001 wt% on the Calibration Input worksheet. The Converge Tolerance Initial Factor in row 291 should be specified as 0.005 or less in order to converge on the near zero yields target used for HGO. If the default kinetics can not converge on the yields profile you want, you can enable the special modified kinetics by setting the Cracking Rate Factor (row 458 of Calibration Input) to 1.01. Before running the model, you should also set the Once Through flag for the selected case. (Calibration Input worksheet row 490; Predict Input worksheet rows 345.)
Predict runs of the Once Through configuration can be done either as Primed Predict or Cold Predict.
Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit
You can calibrate as a conventional recycle unit, and then switch to a Once Through configuration for Predict mode. This allows a conventional recycle coker to simulate coker performance, if the tower bottom is modified to separate the fresh feeds from the tower bottom liquids. To simulate the Once Through configuration, perform the calibration of the Conventional Recycle base case with Open Wash Zone configuration. As described above in the section about the new Open Wash Zone configuration, this allows simulation of extra low recycle operation. By setting the CFR to 1.001 in the Predict mode, the operation is now a Once Through operation. The yields, including coke yields, would now reflect what one would get in Once Through operation. There is one missing piece of information in this type of simulation. The program is going to predict a combined HGO and FZGO product stream since the configuration is kept as Conventional Recycle. You can use a flowsheet such as Petro-SIM to simulate the coker fractionator. By recombining the products predicted by DC-SIM into a column feed stream, you can get the individual product separation expected. Using this technique, the HGO and FZGO products can be obtained as separate product streams. By using the approach described above (i.e. running at CFR of 1.001), you can identify the benefits of converting from a conventional recycle unit to Once Through operation. DC-SIM is not configured to perform conventional recycle Predict from the Once Through Calibrated case.
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Definition of Combined Feed Ratio (CFR)

Various definitions of combined feed ratio (CFR) are used by the model.
Conventional Recycle Coker

Type
CFR CFR Natural (CFRN) CFR Distillate (CFRD)
Definition
(Tower Bottoms Volume + Velocity Gas Oil) / Sum of Feeds 1 to 5. Tower Bottoms Volume / Sum of Feeds 1 to 5. (Sum of Feeds 1 to 5 + Velocity Gas Oil) / Sum of Feeds 1 to 5.
Once Through Coker

Type
CFR CFR Natural (CFRN) CFR Distillate (CFRD)
Definition
(Sum of Feeds 1 to 3 + Velocity Gas Oil) / Sum of Feeds 1 to 3. (Sum of Feeds 1 to 3 + FZGO recycle as Velocity Gas Oil) / Sum of Feeds 1 to 3. (Sum of Feeds 1 to 3 + Distillate Velocity Gas Oil (non-FZGO)) / Sum of Feeds 1 to 3.
Velocity Gas Oil

Velocity gas oil is defined as a stream that is added to the furnace feed to increase the velocity in the furnace. This stream can be either external to the unit or a recycled oil within the coker system. It is expected that where a fractionator stream is recycled for use as drum quench, that same stream will be used as furnace Velocity Gas Oil. Although you can configure the model to put, for instance, heavy coker gas oil into the drum overhead and light coker gas oil into the furnace feed, this configuration has not been validated and the results may be unreliable. The velocity gas oil can be formulated with several schemes: 1. Flow Control You can specify a fixed volume of velocity gas oil. For external feeds, the volume is entered as the feed rate for Feed Number 7 in the Feedstock section of the Input worksheet. For recycled feeds the volume is specified in the Operating Conditions section under Furnace as Recycle Gas Oil Volume Rate. 2. Ratio Control in Predict Cases At the bottom of the Furnace section on the Predict Input worksheet is a target entry that lets you specify a volume percentage of total furnace feed. If this is left blank, the model uses the flows specified above. If it contains a value, it overrides either the external Feed Number 7 rate or the recycle volume rate, whichever is active.
2 - 16 DC-SIM Data Requirements KBC Proprietary DC-SIM User Guide
3.
Ratio Control Defaults There is a complex system of defaults, allowing quick setup of Predict case studies and optimization runs. The scheme logic is shown below. This lets you set up a Calibration Case and go directly to a Predict case study without any additional set-up of inputs or controls on gas oil to furnace feed. When calibrating with either recycle or external gas oil to the furnace, the model saves the percent of total furnace feed (based on the CFR as defined above) as a Calibration Factor. If you go directly to a Predict Back case without any other inputs, the calibration volume will be passed through and used in the Predict series until it is changed. If you expect to change the fresh feed rate and want to maintain the furnace feed gas oil ratio, enter a zero (0) into the Predict Input Recycle Gas Oil Volume Rate. It will then follow the default logic and use the calibration ratio to set gas oil volume. You can change this ratio by putting any sensible number into the % Furn Feed Target cell. The model determines the mode of operation (external or recycle) from the selector list box on the design sheet.
A consequence of this scheme is that if you set recycle feed rate and the % target to zero, the model will default to the calibration ratio. There is no way to turn the recycled Velocity Gas Oil completely off with this scheme. External feed can be shut off by simply setting the Feed Number 7 rate to zero. The default logic for setting Velocity Gas Oil rate and ratio is shown in the following diagram.
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Create XKUP (108) = 100*VelGO/ (CFR*Feeds 1-5)
VelGO = Calibration Volume Rate of Gas Oil to Furnace Feed
Yes
Calibration Case?
No Yes
No Input?
Yes No
Set % Target = XKUP (108)
Recycle On?
Yes No Yes
Set Recycle GO from Target
Target > 0?
Recycle On? Set Feed #7 from Target
No
No
Use User Inputs for Feed #7 or Recycle GO
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DC-SIM User Guide
DC-SIM Calibration Guidelines

The following guidelines apply to typical delayed coker units. However for special feeds or unit operations, the guidelines may not all apply: 1. If the model does not solve: Check all temperature and pressure profile numbers. Check that the amount of quench is consistent with the recycle rate (CFR). Too much quench relative to CFR can cause the wash zone to become infeasible. Check that the feed distillation is reasonable and that the KFactor is consistent with the products. When the data is uncertain make sure that the feed 50% point is set to yield a K-Factor approximately equal to (or slightly greater than) the K-Factor of the heavy gas oil stream. The Converge Tolerance Initial Factor on row 291 of Calibration Input can be used to loosen or tighten the target convergence errors on the internal iteration loops. Check the H2S and NH3 yields on Calibration Result. If it is off, use the Distribution Factors on Calibration Input rows 287-288 to adjust and re-run Calibration Check the Coking Calibration factor XKUP(03). It should be approximately 1.0. The normal range is 0.6 to 1.2. Values at the extremes of this range or outside of it indicate an unusual coking pattern relative to the ConCarbon of the feed. If the number is low, the input ConCarbon value of the feed may be high (relatively more coke from ConCarbon means that the coke from polymerization requirement to close the coke balance is less). If it is high, the ConCarbon may be low. Also, any error in recovered product yields shows up in coke yield and that, in turn, can impact this Calibration factor. Look at the Heat of Cracking Calibration factor XKUP(102). It should be approximately 15 to 25. Above that range indicates that the drum delta temperature is low for the amount of cracking going on in the drum. Low values indicate the opposite. This may create a problem in Predict runs. Check the overall cracking profile (found at the bottom of the Summary sheet and the fraction of volatile oil cracked in the furnace (found in the Operating Conditions Furnace section of the Calibration Results sheet). There should be a reasonable balance between the various cracking modes. There is no typical profile, but a rough guideline is that the
2.
When the model solves:
fraction cracked in the furnace should be between 0.05 and 0.25. The tuning factor, Furnace Cracking T Factor, can be used to shift some of the cracking from furnace to the drum. Check the Notional Depth of Drum Liquid Holdup found on the Operating Conditions Drum section of the Calibration Results should be a reasonable number. Again, there is no typical number, but it usually falls between 1-4 feet (0.3 to 1.3 meters). Check the Tower Temperature Profile for reasonableness. Check that Calibration factors XKUP(118) and (119). XKUP(118) are completely data driven and indicate the measured difference between the front end of the heavy gas oil distillation and the heavy gas oil process temperature. The bigger this number is the worse the fractionation or the more suspect one or more of the data points. XKUP(119) is a measure of the internal adjustments needed to be made by the model to bring the pseudocomponent bubble points into balance with the measured temperatures. As this number grows, it indicates that the model has to make a larger correction. As the value exceeds 50, it indicates possible problems with the process data or yield data. Check the K-Factor profile for reasonableness. Typically, the K-Factor of the light and heavy gas oil will be approximately the same as the feed, the distillate will be somewhat lower, and the light naphtha will trend upward. A typical profile of product K-Factor vs. TBP (in deg F) looks like:
1 2.5 12 1 1 .5 11 1 0.5 10 9.5 9
500
1000
1500
2000
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Predict Input Data

Predict cases require many of the same inputs as the Calibration case for feed and operating conditions. Yield information is not required, since it will be calculated by the program.
Quench
When external source quench is encountered in the Predict mode, DCSIM always requires the presence of a Temperature Control Quench stream to adjust the amount of quench needed to achieve the drum vapor quenched delta temperature target. If only external Flow Control Quench is used during Calibration, DC-SIM assumes the same quality external quench will be used to satisfy the Temperature Control Quench during Predict, unless you specify a separate external Temperature Control quench stream (row 200 on Predict Input worksheet). When calibrated with only external Flow Control quench in Predict mode, reduce the Predict Input Flow Control quench input (Predict Input row 176) by at least 10% from the Calibration value. This amount is then used as the initial value for the Predict Input Temperature Control quench (Predict Input row 200). In this situation, both the Flow Control and Temp Control quench streams are the same external quench stream. This gives the model flexibility of adjusting the total external quench flow needed to meet the specified Predict drum vapor quenched delta temperature target. This approach is required in situations when less total quench flow is needed to meet the delta temperature target. This can happen when the drum vapor quench delta enthalpy requirement is less than that used during Calibration due to either lower delta temperature target or less drum vapor enthalpy. The total external quench flow is reported on line 471 of the Results worksheet.
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When LGO or HGO is used as recycle quench, the amount required is calculated by the model in the Predict cases. The quench target can be specified in two ways. In the Quench Targets section, on row 253, there is a Quench Delta T Override Selector. When this is set to 0, the Quench Delta T Override Value on row 254 is used by the model as the quench delta T target for the drum vapor. When the Quench Delta T Override Selector is set to 1, then the Drum Vapor Inlet Temperature to Fractionator is used as the target for how much the drum vapor should be quenched.
Velocity Gas Oil

In the Furnace section, the recycle Velocity Gas Oil (for example, LGO or HGO used as velocity gas oil) can be specified in several different schemes. A detailed discussion of how velocity gas oil are handled in the Predict cases can be found in the Velocity Gas Oil section.
Product Cutpoints Target

For the naphtha range products (product streams 1 to 3), use D86 values for cutpoint specification by entering a new value in the Alternative Cut Point Spec section. Any value entered here will override the value in the corresponding TBP cutpoint.
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Coke Inventory
In the Predict mode, DC-SIM can be set up to predict a history of coke buildup in the drum during a cycle. There are two approaches to keeping track of coke inventory. In the first method, you specify a Run Time Interval in row 247.
The model calculates the amount of coke made in that time interval starting at the Calibration case or first Cold Predict case drum coke level conditions. Each Predict case is a separate run that is not affected by the other Predict cases in the stack.
In the second method, you set up a series of Predict cases and set the Coke Inventory Sequence in Feature Selections section to 1.
Each of the Predict cases will calculate the amount of coke made in the specified Run Time Interval (row 247) starting with the existing drum coke inventory established in the previous Predict case. In this manner, the drum coke inventory history during a cycle can be viewed on the Predict Results worksheet.
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How the Predict Case Works

The Predict Case works as follows: 1. 2. Feeds are identified and broken up the same as in the Calibration case. The fractionator is initialized at the specified recycle (CFR) and product distillation cutpoints. If no distillation cutpoints are supplied, the model will default to the calibration reference. The furnace, drum, and quench sections are solved based on the Calibration factors, independent variables, and any quench temperature targets. The fractionator tower is re-calculated with the equilibrium drum vapor as in the Calibration case. The furnace feed is recalculated and step 3 repeated until all sections are converged. The converged model then estimates properties for the liquid product streams and sulfur, nitrogen, and metals distributions across all products based on Calibration factors.
3.
4.
5.
Predict Case Checklist

Before running a model Predict Case, check the following items: 1. 2. Select the Predict Input worksheet. Select the run mode, primed or cold. If running a primed mode case, select a Calibration case to start the model from. If running a cold Predict, make sure that a Calibration factor set has been copied into the Predict case column from the Calibration Result Worksheet. If necessary, set the quench temperature target mode and setpoint. If desired, set product stream cutpoints. Set other independent variables. If running a cold Predict, all required data must have a value. In a primed case, no independent variable entries are required. Any blank entries will cause the model to use the value supplied in the Calibration case. Change tuning factors and other selection items as desired. Run the model using the Run button. If the model does not run because of a fatal error, the error will be reported. All messages are stored in the Message Log. The information provided in the message should be enough to troubleshoot the problem. Once the problem has been fixed, rerun the program. When the model runs successfully, please view Messages to ensure that there are no serious non-fatal run errors.
3. 4.
5. 6.
7.
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DC-SIM User Guide
Product Properties
The product properties in Calibration cases are based either on your input or correlations. When user-supplied product properties are available from Calibration runs, this information is taken into account during Predict runs to adjust calculated product properties from correlations.
Sulfur
In a Calibration case, you enter the sulfur content of feed and product streams. The distribution of sulfur to liquid products is based on a correlation between sulfur concentration and API gravity of the streams, calibrated to the measured sulfur distribution.
Nitrogen
Nitrogen is distributed using the same procedure as sulfur.
Aniline Point
Aniline points are calculated and compared to the measured input in the Calibration case. The Calibration factor for aniline point is represented by an additive correction term, which is applied to the calculated value in Predict runs.
Naphtha RON and MON

Octanes (RON and MON) are predicted for the coker naphtha range products. RON and MON predictions require plant measured RON and MON values to be specified during Calibration. The calibrated value is then adjusted during Predict mode to reflect changes in cracked product properties.
Diesel Cloud Point, Pour Point and Flash Point

Cloud Point, Pour Point and Flash Point properties are calculated for gas oil and diesel range products. These properties are calculated using API procedures, and are based on the product stream average boiling point and specific gravity. The flash point procedure requires the stream D86 10% point to be > 150 F. If Cloud Point, Pour Point or Flash Point data is available in the Calibration run, Calibration factors are calculated comparing the laboratory data to calculated values. These Calibration factors are then applied to the calculated values in the Predict runs.
Bromine Number
Bromine numbers are input to the model and saved as reference calibration data. In Predict runs, the reference Bromine Numbers are adjusted for feed K-Factor and product stream cutpoint to estimate the
Predict case value. Olefins Content is calculated from the Bromine Number for each stream. Calibration Bromine value is required for Naphtha range products in order to predict PONA.
Naphtha PONA
PONA properties for naphtha range products are predicted from coker naphtha data, using the TBP midpoints, bromine number and API.
Viscosity @ 50 C
The viscosities at 50 C are calculated for the liquid product streams
Other Properties
Olefins content, refractive index, cetane index, and molecular weight are estimated by defined correlations, based on various forms of distillation and gravity.
Coke Volatile Matter (VCM)

The VCM of the coke is based on the amount of liquid holdup in the drum. Liquid holdup is affected by changes in operating conditions, primarily drum temperature and cycle length, coke VCM responds accordingly.
Coke Ash Content

Since a significant portion of the ash in coke consists of metals, the ash content of coke is assumed to be proportional to the metal content. An ash/metals weight ratio is calculated from the data you supply in the Calibration case. This factor is used to estimate ash content in subsequent Predict cases.
Coke HGI
The Hardgrove Grindability Index (HGI) property for coke is estimated in DC-SIM. HGI is a measurement of the propensity of the coke to break into fines, which may cause problems during coke cutting calcinations or other final use. This coke hardness is likely to be related to the level of asphaltenes in the coker feed. Feed alphaltenes level is not routinely measured in the refinery. However, the coke sulfur is usually proportional to the asphaltene level. DC-SIM calculates the HGI using a correlation to coke sulfur. If the coke HGI is specified in calibration input, this lab HGI value is compared to the calculated value from correlation to obtain a Calibration factor. If no calibration HGI is specified, this Calibration factor is set to 1. In the Predict mode, the newly calculated coke HGI from correlation is adjusted by this Calibration factor to arrive at the predicted coke HGI.
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How the Optimizer Works

The Optimizer works as follows: The Optimizer maximizes or minimizes a variable you select producing the Objective Function. Profit, product yield, or fresh feeds are examples of variables that can be maximized or minimized. Up to eight constraints with minimum/maximum limits can be defined. These are typically furnace duty and a fractionator tower constraint. Up to nine manipulated (independent) variables with minimum/maximum limits can be defined. The Optimizer manipulates these to maximize/minimize the desired function while staying inside constraint limits. Typically, these include furnace coil outlet temperature, feed rate, recycle rate (CFR), etc. Enter maximum step sizes for each manipulated variable. These keep the Optimizer from moving too far in one step. The Optimizer starts by running the selected Predict case. This is the initial case for the Optimization run. If the initial case is outside of constraint limits, the Optimizer will force the model to be inside of the constraint limits. If the initial case is too far outside of the constraint limits, the model will abort. The Optimizer maximizes/minimizes the objective by moving the manipulated variables. Each move will be limited by maximum step sizes. The Optimizer stops when the objective moves by less than 0.1% (default value) from case to case.
Optimizer Run Checklist

An Optimizer run is a series of Predict cases. This checklist highlights items specific to the optimizer. Before running the model optimizer, check the following items. 1. 2. Select the Optimizer Input Worksheet. Check that the model contains the results of an earlier Predict Case run. Processing of the optimization case does not start until the Calibration Case used to prime the Predict Cases and all the Predict Cases with a non-blank Run Status are run. Select an optimizer starting point by using the Reference Case Number spinner. By setting up the Predict Cases appropriately, you control the initial starting point of the optimizer. Choose Maximize or Minimize mode on the Setup dialog box using the Minimization Option selection. Use default tolerances that are displayed on the Settings dialog box. Typically, no inputs are required for tolerances.
3. 4.
5.
Select up to nine independent variables. The Optimizer will manipulate these to maximize or minimize the Objective Function. Select the variable that will be maximized or minimized (the Objective Function) with an x. Use a non-x, non-blank character to select up to eight constraints with minimum and maximum limits on the dependents variable list. Run the Optimizer using the Run button on the worksheet. If the model does not run because of a fatal error, the error will be reported in the Optimizer Log or the Message Log. The message should provide enough information for you to fix the problem. Once the problem is fixed, run the program again.
6. 7.
8. 9.
10. If the model runs successfully, scan the messages in the Optimizer Log to ensure there are no serious non-fatal run errors. The independent and dependent variable results from the final Optimization run are displayed in the Optimized Value column on the Optimizer Input Worksheet To be thorough, also review the Predict Case checklist.
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DC-SIM User Guide
Installing DC-SIM
PC System Requirements....................................................................................................... 3-2 Microsoft References............................................................................................... 3-2 Installation.............................................................................................................................. 3-3 Program Security ..................................................................................................... 3-3 DC-SIM Model Installation ..................................................................................... 3-3 What Is Installed ...................................................................................................... 3-4 Number and Decimal Regional Settings.................................................................. 3-4 Starting the Program .............................................................................................................. 3-7 Opening DC-SIM with the Start Bar ....................................................................... 3-7 Starting with the Data Workbook ............................................................................ 3-7 Setting up a Shortcut................................................................................................ 3-8 Starting DC-SIM...................................................................................................... 3-8 Security Settings and Macros .................................................................................. 3-9 Testing the Program Execution.............................................................................. 3-10 Problems When Running the Application ............................................................. 3-11
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Installing DC-SIM 3 - 1
PC System Requirements
Minimum system configurations required to run DC-SIM are Microsoft Excel 97 or Excel 2000 Intel Pentium processor or better Microsoft Windows XP, Windows 97, Windows 98, Windows 2000 or Windows NT CD-ROM drive, to load the installation CD USB port to attach a software security key or network connection to use network version of software security system
Microsoft References
The software package provided by KBC uses many Microsoft products to perform user interface, file editing and file management tasks. This approach was taken to make the model as open and universally portable as possible. However, it is your responsibility to have and maintain valid licenses for any Microsoft application needed to operate this model.
3 - 2 Installing DC-SIM
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DC-SIM User Guide
Installation
A single model installation package for one standalone PC is contained on the CD provided in the installation package. To install DC-SIM: 1. 2. Place the CD in the disc drive, select Setup to bring up the installation screen. Follow the instructions.
Before installing the DC-SIM software, follow the procedures in the stand-alone or network Security Key Installation Instruction documents to install the license file (delivered separately via email) on your PC.
Program Security
DC-SIM operates with a security scheme based on either a network license or local PC license. A software security key (dongle) is used to protect against unauthorized use of the model. This security key is a small device with USB connector on one end. It contains a custom microprocessor, nonvolatile memory, and other support circuitry. The security key must be connected to the USB port either locally or on a network server for the model to run. The instructions for network license users are provided in a separate documentation on network license. With network license, you can run DC-SIM whenever you are connected to your network. For local PC licenses, place the KBC license file, License.kbclic, in the C:\Program Files\Common Files\KBC folder. A USB dongle specific to that license file should be attached to the USB port of that PC. Each license file is set up to run only with its own specific USB key. Presently, KBC Profimatics SIM Series models use a security key manufactured by Rainbow Technologies, called SuperSentinelPro. The parallel port dongle used with Version 96 to Version 2003.2 is not compatible with this version of the model. That dongle can be used only to run those older versions. Refer to the Model Installation Instructions Single User manual if you are using a stand-alone PC or Network Security Key Installation Instructions manual if you are running DC-SIM on a network.
DC-SIM Model Installation

The model is loaded using InstallShield, which creates program folders and loads program files into those folders. InstallShield guides you through the installation process. Program Folder or Directory Selection: The default program folder or directory into which InstallShield places its files is C:\Program Files\KBC Profimatics\SIM Suite 3.0\Profsim. It can be placed either as
DC-SIM User Guide KBC Proprietary Installing DC-SIM 3 - 3
the root directory or as the subdirectory of a user-defined directory. It can also be placed on any of your local drives. The only restriction is that the DC-SIM directory must be a subdirectory of PROFSIM. Windows NT Users: To successfully install the model, the person performing the installation (the person logged on as the current user) must have Supervisor/Administrator privileges. This is necessary because the procedure includes installation of the dongle driver software and registration of the model DLL.
What Is Installed
The files programs loaded onto the PC hard disk during the model installation are:
Program Folders
\Program Files\KBC Profimatics\SIM Suite 3.0\Profsim
Description
Version Definition \SIMSUITE.INI DCSIM Executable \DCSIM.EXE SIM Interface Executable \KBCProfSIMGATEWAY.DLL \KBC_Gateway.EXE
..\Profsim\DCSIM
Variables mapping table \DCUnitsConversin.xls \DCMAP.xls Help files
..\Profsim\DCDATA
Model Workbook Template \DCSIMV2006MASTER.XLS Example Case Data \TEST_DCSIM.XLS Example Case Test Data \*.DAT
\Program Files\Common Files\KBC
License File \LICENSE.KBCLIC
Number and Decimal Regional Settings

Both the DC-SIM core code and the Excel user interface are configured to accept and report numbers in a standard format. When running DC-SIM adjust your Windows operating system settings. 1. 2. Select Control Panel from the Start menu. Select Regional and Language Settings. The following Dialog box appears.
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DC-SIM User Guide
3.
Click Customize.
4. 5. 6. 7.
DC-SIM User Guide
Set Decimal symbol to: Set Digit grouping symbol to: Set List separator to: Click on the Currency tab
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. , ,
(decimal period) (comma) (comma)
8. 9.
Set Decimal symbol to: Set Digit grouping symbol to: ,
(decimal period) (comma)
10. Click OK. You may need to adjust other settings, depending on local conditions.
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Starting the Program

After DC-SIM V2006 has been installed, KBC recommends that you start the program and run the example problem to test it. You can start the program in several ways. You can use the Start bar, open the gateway workbook file, or create a shortcut for your desktop.
Opening DC-SIM with the Start Bar

To begin with the Start bar, select KBC Profimatics as shown:
Starting with the Data Workbook

In the past, the Gateway Workbook, Profdc.xls, is required to be active before opening the data workbook. In DC-SIM V2006, this is now replaced with a Gateway executable. You can also select the data workbook from Windows Explorer to start the DC-SIM model. The interface executables are now automatically initialized when the data workbook is opened.
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Setting up a Shortcut
You can set up a shortcut to KBC_Gateway.exe in the C:\Program Files\KBC Profimatics\Sim Suite 3.0\Profsim directory using standard Microsoft methods.
Starting DC-SIM
When you start DC-SIM through the Gateway executable, the KBC Profimatics Simulation window appears:
Select Proceed. This dialogue box opens so you can select the Excel data file you want.
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To test the installation, select TEST_DCSIM.XLS. To create a new DCSIM workbook, open the template file, DCSIMV2006Master.xls. Next this dialogue box appears.
This dialogue box refers to the macros in the applications. To continue with the start up, select Enable Macros.
Security Settings and Macros

The Gateway contains macro files that are used to run the program. Depending upon your security settings in Excel, you may get a warning message regarding macros. If your security message is set to Medium (which is the most typical) you will see the message shown in Starting DC-SIM on page 8: If your Excel security is set to Low, you will not get a message. If your security setting is High, you will get the following message:
Change the security setting to Medium to use DC-SIM. To set or change your Excel security: 11. Open the Tools menu. 12. Select Macros and then select Security. When the Security window opens, select the setting you want.
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Testing the Program Execution

To test the running of the program, go to the DC-SIM menu, and select Run for one of the cases, as shown:
When the program runs, it searches for the security key or dongle that needs to be attached to your USB port. If you are using network security, then you must connect through your network to a server with the license file and network security key installed. It then executes the program. If the security key is found, the spreadsheet opens with DC-SIM active.
3 - 10 Installing DC-SIM KBC Proprietary DC-SIM User Guide
Problems When Running the Application

If the dongle is not attached or the license file not found, this message appears:
After you press the Enter key, you return to the program. A message appears asking you to load the results. This opens a message stating that the results are not available:
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If you get this message, first check that the dongle is connected to the USB port or the license file is in the correct folder. If the program still does not run properly, follow the procedure in the Security Key Installation manual to identify the problem. If DC-SIM still does not work, contact KBC additional assistance.
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Using the Spreadsheet Interface

Microsoft Excel...................................................................................................................... 4-3 Data Flow ................................................................................................................ 4-3 Gateway Workbook ............................................................................................................... 4-4 Model Workbook and Model Workbook Template ............................................................... 4-5 Getting Started ....................................................................................................................... 4-6 Available Models..................................................................................................... 4-6 Proceed Button......................................................................................................... 4-6 Cancel Button .......................................................................................................... 4-7 Customizing the Workbook ................................................................................................... 4-8 Model Workbook ................................................................................................................... 4-9 Grouping Feature ..................................................................................................... 4-9 Comments.............................................................................................................. 4-10 DC-SIM Menu ....................................................................................................... 4-11 DC-SIM Options Item ........................................................................................... 4-11 Navigation Item ..................................................................................................... 4-12 Run Item ................................................................................................................ 4-12 Copy Case Data Item ............................................................................................. 4-13 Clear Case Data Item ............................................................................................. 4-13 Text Files Item....................................................................................................... 4-13 Available Results Item........................................................................................... 4-14 Import Case Data Item........................................................................................... 4-14 Export Case Data Item........................................................................................... 4-14 Transfer Workbook Data ....................................................................................... 4-15 Import from Petro-Sim .......................................................................................... 4-15 Export Calibration to Petro-Sim ............................................................................ 4-15 Links ...................................................................................................................... 4-15 Design Worksheet ................................................................................................................ 4-16 Calibration Input Worksheet ................................................................................................ 4-18 Run Button............................................................................................................. 4-18 Import Button ........................................................................................................ 4-19 Copy Button........................................................................................................... 4-20 Clear Button........................................................................................................... 4-21 Predict Input Worksheet....................................................................................................... 4-22 Run Button............................................................................................................. 4-23
DC-SIM User Guide KBC Proprietary Using the Spreadsheet Interface 4 - 1
Setup Button .......................................................................................................... 4-23 Copy Button........................................................................................................... 4-23 Import Button......................................................................................................... 4-24 Clear Button........................................................................................................... 4-24 Optimizer Input Worksheet.................................................................................................. 4-25 Run Button............................................................................................................. 4-26 Setup Button .......................................................................................................... 4-26 VGen: LP Vector Generation Tool ........................................................................ 4-27 Result Worksheets................................................................................................................ 4-28 Comparison Worksheet........................................................................................................ 4-30 CaseGen................................................................................................................. 4-30 Summary Worksheet............................................................................................................ 4-32 Charts ................................................................................................................................... 4-33 Charts Worksheet................................................................................................... 4-33 Setup Button ............................................................................................ 4-33 Update Button.......................................................................................... 4-34 Select Button .......................................................................................... 4-34 Series /X Variable.................................................................................... 4-35 Save ......................................................................................................... 4-35 Load......................................................................................................... 4-36 Charts - 2 Worksheet ............................................................................................. 4-36 Worksheet Comments and Model Help ............................................................................... 4-37 Saving Files and DC-SIM Exit............................................................................................. 4-38
4 - 2 Using the Spreadsheet Interface
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Microsoft Excel
The spreadsheet environment provides one of the most flexible, powerful and easy-to-use engineering application interfaces available. Microsoft Excel includes Visual Basic, a sophisticated high level programming language. Visual Basic has been used extensively to enhance Excels functionality to support the specific tasks needed to operate DC-SIM.
Data Flow
When you run DC-SIM, you remain in the Excel workbook while the application runs. Information flows between the Excel worksheets and the model executable as follows:
Excel Input Worksheet
DC.DAT
Model Execution
DCSIM.CSV
Excel Results Worksheet
When running the model from Excel, the file DC.DAT is created in the default directory from the data entered in the Excel Input worksheets. This text file includes all the input data necessary for the model to run. If multiple cases are being run, then the data for each case are appended to the DC.DAT file. The model executable, DCSIM.exe, is run in a batch mode loading the DC.DAT file and processing each case sequentially. Once the model has processed all the cases, it generates a text file containing the results, called DCSIM.CSV. The output data in the DCSIM.CSV file is then loaded into the Result worksheet. If one of the model cases fails, processing is stopped and those cases successfully completed are loaded into the Result worksheet and the Error flag is displayed at the top of the failed case. Model messages are logged in a Message file that you view from the Model Workbook using a menu item.
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Using the Spreadsheet Interface 4 - 3
Gateway Workbook
The traditional Gateway Workbook, Profdc.xls, in the earlier versions of DC-SIM is now being replaced by the KBC Profimatics Simulation Gateway. This Gateway is used to open all Sim Suite 3.0 versions of SIM models. It contains most of the Visual Basic code used to initialize and support the DC-SIM Excel interface. You can now access the DCSIM data workbooks in two ways. 1. Start/Programs/KBC Profimatics/SIM Suite 3.0/DC-SIM. This would open the KBC Profimatics Simulation Gateway. Select DC-SIM from the dropdown menu, then select Proceed to open the data model workbook. Select the data model workbook in Windows Explorer.
2.
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Model Workbook and Model Workbook Template

The Model Workbook file is where you enter model input data, executing the model in Calibration, Predict or Optimization Modes, or viewing the results. An example Workbook file is included. A Model Workbook Template is loaded on your PC at installation time, and is named DCSIMV2006Master.xls. The default location is the Program Files\KBC Profimatics\Sim Suite 3.0\Profsim\Dcdata\ directory. The template file is the base format for all DC-SIM Excel files. It is write-protected. The templates file is write-protected and should not be altered or overwritten. If this happens, DC-SIM must be reinstalled. The DC-SM Workbook is created by taking the template file and using it for a specific coker unit, and then saving the new file. Never delete or insert rows or columns into the worksheets. All the worksheets have hidden columns and rows that may be corrupted if columns or rows are inserted or deleted. In addition, the interface code in some cases relies on data being in specific locations which could also be corrupted. The result would be unreliable model runs. Be careful when copying or moving data around the worksheets. It is safer and more convenient to use the Copy function provided with the interface. For manual copying we recommend using the Paste Special Values function, to avoid unintended propagation of formulas and formats.
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Getting Started
Once DC-SIM has been installed, start the program. The following entry window opens.
Available Models
Select DC-SIM from the dropdown box.
Proceed Button
Use Proceed to open a dialog box where you select a Model Workbook to be opened by Excel.
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Cancel Button
Selecting Cancel stops the loading process and closes the Prodc.xls workbook.
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Customizing the Workbook

With the standardization of the KBC Simulation Gateway, DC-SIM users are now limited in customization of the working environment. This is done with the DC-SIM Tool Menu/DC-SIM Options. Selecting this item lets you choose whether or not the results Load Confirmation Dialogs popup window should be present after each DC-SIM model run.
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Model Workbook
An example problem and a template file are provided with the installation of DC-SIM. You may also have a DC-SIM Workbook for your unit created by KBC. These workbooks consist of the following worksheets: Design Calibration Input Calibration Result Predict Input Predict Result Opt Input Opt Result Comparison Summary Charts Charts 2
Grouping Feature
Many of the sheets in the workbook contain a large number of rows. To make these long files manageable, the DC-SIM worksheets make extensive use of the Grouping feature provided with Excel.
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Grouping allows sections of worksheet rows and columns to be combined and hidden from view. The plus and minus signs on the left of the worksheets are used to unhide (+) or hide (-) the rows. At the top of the column of + and - are the grouping levels. Clicking on Level 1 hides all the rows. Clicking on Level 2 or Level 3 reveals all the rows in that level. Additionally, individual model cases are grouped in sets of ten. The worksheets using this feature must be unprotected to use the hide/unhide capabilities. They must also have the row and column headings enabled (choose Tools Options and select the View tab), to see the master grouping levels at the upper left-hand corner of the sheet. For more information, refer to the Excel documentation.
Comments
The DC-SIM worksheets provided also use Excel comments to give you valuable information. Comments appear as red triangles on the upper right of an individual cell. To view the text of the comment, put the cursor over the red triangle. When you move your cursor away from the red triangle, the comment box disappears.
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DC-SIM Menu
When starting a modeling session, a new menu is created called DC-SIM. It is attached to the standard Excel menu bar.
Some of the menu functions are also made available by clicking buttons on the worksheet. Each menu item for the DC-SIM is described below.
DC-SIM Options Item

The Options show the selections for customizing the DC-SIM general functions. Currently, you can choose whether or not the program advises you when a model run is completed and ready to be loaded onto the Results worksheet.
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Navigation Item
The Navigation function lets you navigate among all the worksheets. This could be used instead of directly selecting the Excel Worksheet Tabs. The Navigation secondary menu lists all the available worksheets in the Model Workbook.
Run Item
The Run function lets you run any of the model modes. It has the same function as the Run Button provided on each of the Input worksheets. The Run secondary menu lists the three model modes: Calibration, Predict and Optimize.
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Copy Case Data Item

The Copy Case Data copies certain values from on sheet to another or from one column to another. Its function has the same functionality as the Copy button on Input and Results sheets. (Refer to Calibration Input Worksheet on page 4-18 for more details).
Clear Case Data Item

The Clear Case Data function clears certain cells. It has the same function as the Clear Button on Input sheets. (Refer to Calibration Input Worksheet on page 4-18 for more details). The Clear option can also be used to perform the clear function on Result worksheets.
Text Files Item

The Text Files Data function displays a dialog box that gives you access to all the output files produced by DC-SIM. The reports are stored in the default directory and are opened, by default, with Microsofts WordPad, or a text editor you specify (see the section on Case Manager Settings).
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The advantage of opening the reports with this menu item is that the reports are automatically formatted with page breaks, etc., and for printing in Portrait orientation instead of Landscape. Print Zoom lets you control the size of the report pages printed on each page from Excel. Opening with WordPad is a bit faster and may be better when you only intend to browse rather than print.
Available Results Item

The Available Results function is specific to the Charts sheets and has the same function as the Available Results button. (Refer to Charts on page 4-33 for more details).
Import Case Data Item

The Import Case Data function brings information from test files in .DAT format into Excel. It has the same function as the Import button on the Calibration Input and Predict Input sheets. (Refer to Calibration Input Worksheet on page 4-18 for more details).
Export Case Data Item

The Export Case Data function creates a DAT text file under the userspecified name that includes all required input data needed to recreate the current worksheet when that DAT file is imported into another workbook. Only the information from the Calibration Input and Predict Input worksheets that have the Run Case selection specified are included on this DAT file. The information from the Optimizer Input worksheet is also included in this exported DAT file.
4 - 14 Using the Spreadsheet Interface KBC Proprietary DC-SIM User Guide
Transfer Workbook Data

This function can be used only when you are in the template DCSIMV2006Master.xls workbook. This tool translates the Design, Calib Input and Predict input worksheets from any old version DC-SIM workbook into the current workbook format.
Import from Petro-Sim

This function is not operative in the stand-alone DC-SIM. It is enabled only when the Petro-Sim flowsheet software is also present.
Export Calibration to Petro-Sim

This function is not operative in the stand-alone DC-SIM. It is enabled only when the Petro-Sim flowsheet software is also present.
Links
This function is not operative in the stand-alone DC-SIM. It is enabled only within the appropriate flowsheet environment.
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Design Worksheet
The Design worksheet is used to configure unit specific information needed by the model. The schematic is used to set up the unit and model data that applies to all worksheets: Coker unit data included on the diagram consists of: Coker Configuration (recycle vs. once through) Quench Configuration HGO Tower Draw Stage Feed Injection Points Velocity Gas Oil Feed Option Liquid Products Stream Options Also included are selections controlling information in the model worksheet: Model Title Engineering Units Mol. Wt. Method Note that these setup data are global to the Model Workbook. Each workbook is specific for a given process unit configuration. If a different configuration is required, set up a new Model Workbook.
Below the schematic, you can input unit specific stream names. These stream labels are used throughout the workbook. Further down on the Design worksheet are the required additional unit data inputs representing the unit static coke drum dimensional data.
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Calibration Input Worksheet

The Calibration Input worksheet is used to enter test run data and run the calibration cases. Each column represents one case. The worksheet can handle up to 60 calibration cases.
Run Button
Run executes the model in Calibration mode. The calibration cases processed are those that have a non-blank character in the Run Case row (Row 3). At the start of model execution, a DOS box opens to display processing information. This box automatically closes after model execution has been completed. A message box prompts you to start loading the model results. While the DOS box is open, the model run can be aborted by terminating the operation in any valid manner (i.e., Ctrl-Break). The drop-down box located to the right of the Run button lets you select whether to clear the whole Calibration Result worksheet (Reset All Results) or only the columns corresponding to the cases solved (Spot Load Results), after selecting the Run button.
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Import Button
You can import text-based input files into the Model Workbook for files that have been stored in the correct text format. The text file extension must be *.DAT and is typically created by the Export function. Import initially opens a file input dialog box that lets you select the textinput file that is to be loaded. The selected text-input file is opened with Excel and a dialog box is displayed showing the Calibration cases (identified with 0) or Predict cases (identified with non-zero number) in text-input file that could be loaded.
To load a single case, select the case to be loaded and its destination case number (i.e., column). Once the Load is initiated, the interface prompts you to confirm:
This is a reiteration of the selection you made and needs to be confirmed by you.
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You must confirm the overwriting of the Design and Stream Titles data. The other option is to use Load All to import all the cases in the .DAT file. There is an option at the bottom of the Import Case Data window for you to Convert the data into a different set of units of measurement. In the first step, the selected input data, calibration and/or predict input cases, are converted to the new units of measurement. Next you can opt to keep the existing display of units of measurement on the worksheets by not loading the design data after the input data.
Copy Button
Copy lets you copy existing case data to other case columns in either the Calibration or Predict Input worksheets. This lets you transfer data to other case columns for the purpose of: Adjusting existing calibration or predict case data or altering tuning constants. Creating cross predicts i.e., creating a predict run using a calibration data set. Predicting using a specific calibration factor set. Predicting using an average calibration factor set. Calibration Input Worksheet data copy options include: 0 Calibration Inputs to Calibration Inputs 1 Calibration Inputs to Predict Inputs
2 Calibration Factors to Predict Factors 3 Average Calibration Factors to Predict
Predict Input Worksheet data copy options include: 0 Calibration Inputs to Predict Inputs 1 Calibration Factors to Predict Factors 2 Average Calibration Factors to Predict 3 Predict Case to Predict Case
If you select Case at Cursor Position, do not select a case number. The case where the cursor is positioned is selected for copying.
Clear Button
The Clear function lets you clear data from any number of columns.
CAUTION: Be certain of what you are clearing. You cannot recover the data if you inadvertently clear the wrong column.
DC-SIM User Guide KBC Proprietary Using the Spreadsheet Interface 4 - 21
Predict Input Worksheet

The Predict Input worksheet is the main worksheet used to run Predict cases and is also used to enter data for Optimization cases. Each column represents one case. The worksheet can handle up to 60 Predict cases.
The Predict case can be run in either a Primed or Cold predict mode. A Primed case is run stacked behind a Calibration case, which is run to initialize the model. The Cold Predict mode runs just the Predict case, but requires a complete set of input data and Calibration Factors. The Setup button above the Copy button lets you select either Primed Predict or Cold Predict. In a Primed case, or any case beyond the first case in either mode, any blank entries will cause the model to use the value supplied in the previous selected case. The drop-down menu located to the right of the Setup button lets you select one of the calibration cases as the Primed case. The selected Calibration case data is displayed in column J of the worksheet. The drop-down menu located under the Factors selection options lets you select whether to clear the entire Predict Result worksheet (Reset All Results) or only the columns corresponding to the cases just run before loading the new results (Spot Load Results).
Run Button
The Run function executes the model in Predict mode. The Predict cases processed are those that have a non-blank character in the Run Case row.
Setup Button
The Setup function lets you select various modes of running the model in the Predict mode.
Primed Predict can be run with these sets of calibration factors: 1. 2. 3. Base calibration factors generated during the calibration run just before running the predict case(s). Set of Average calibration factors from all the calibration cases present on the Calibration Results worksheet. Set of Selected Average calibration factors calculated only from the calibration cases selected for averaging on the Calibration Results worksheet.
When running Cold Predict, the Base calibration factors are the calibration factors present in the first Cold Predict case on the Predict Input worksheet. The Average and Selected Average options are the same as that used for Primed Predict. When using Average or Selected Average options in Cold Predict, it is not necessary to copy the calibration factors into the first Cold Predict case.
Copy Button
The Copy function lets you copy existing case data to other case columns in the Calibration Input worksheet or the Predict Input worksheet. The function is identical to that described in the Calibration Input Worksheet section.
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Import Button
The Import function lets you import previously saved calibration and predict case data from a *.DAT file. The function is identical to that described in the Calibration Input Worksheet section.
Clear Button
The Clear function lets you clear data from any number of columns. The function is identical to that described in the Calibration Input Worksheet section.
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Optimizer Input Worksheet

The Optimizer Input worksheet is used to configure an optimization run which consists of perturbing a series of independent variables to maximize an objective function. The Optimization run is based on what is selected in the Predict Input sheet, plus additional information on the optimization sheet. The available independent and dependent variables are presented on the worksheet.
For each selected independent variable, provide the minimum value, maximum value, and move limit. Select one dependant variable to be maximized or minimized.
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For each selected dependent variable, (i.e., constraint) you must add a minimum or maximum value. The Optimizer can handle up to nine independent variables and nine dependent variables including the objective function. The selected variables and ranges are included in the DAT file when Export Case Data is performed.
Run Button
The Run function executes the model in Optimizer mode. Note that the cases processed before the start of the Optimizer include the Calibration case used to prime the Predict case and all the Predict cases with the Run Case status ON up to and including the Primed Predict case. To save time, you may want to create a Cold Predict case specific to the optimization and turn off all other Predict cases.
Setup Button
The Setup function displays a dialog box where you can change the Optimizer tolerances or configure the Optimizer reporting options. To switch the Optimizer to the Minimize Objective Function mode, check Minimization Option.
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To use the Optimizer as the LP Vector Generation Tool, check the Vector Generation Tool option.
VGen: LP Vector Generation Tool

On the Optimizer Input worksheet, there is also a utility tool useful for generating vectors for LP models. This tool uses the perturbation information specified on the Optimizer Input worksheet to impose step changes to the model and reports the results in a customized table. Specify this customized table using the same procedure as that described for CaseGen on the Comparison Worksheet section. Refer to CaseGen on page 4-30 for more information. The step changes are identified using the same set up procedure for selecting the independent variables and the perturbation step sizes on the Optimizer Input worksheet.
To run the VGen, check the Vector Generation Tool option in the Settings, then click the Run button.
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Result Worksheets
There are corresponding Result worksheets for each of the model modes.
For consistency, all Result worksheets present the same data in the same format. On the Calibration Result worksheet, the calibration factors can be averaged and the standard deviations calculated. You select the Calibration cases to be included in this averaging by entering non-blank characters in cells on row 4 to the right of the title, Select Calibration Factors for Average.
The averaged Calibration factors and standard deviations are located in columns BG through BI at the right end of the calibration factor section. To use the Average Calibration Factors in Predict cases, use the Setup button on the Predict Input worksheet to choose whether to use Average All or Average (Selected).
The Result worksheets for the Predict and Optimize modes are the same as the Calibration Result except: The Predict and Optimize Result worksheets do not have the calibration factor averaging section. The Predict Result worksheet contains indices and text material used by the Optimizer Input and various dialog boxes. The Optimizer Result worksheet does not contain output for calibration factors since they are the same for all optimization passes.
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Comparison Worksheet
The Comparison worksheet lets you compare two cases from any of the three Result worksheets. The absolute delta and percent delta for the case data are calculated automatically and displayed in columns G and H respectively. Empty cells means the two cases have exactly the same value for that variable.
CaseGen
A utility tool is available on the Comparison worksheet to create customized comparison table. Select the results to be included in the customized table by entering a number in the index column (column M) on the right side of the worksheet. Using sequence such as 5, 10, 15, lets you insert additional selections at a later time. The table is created using the numerical sequence in this column. (Hint: Select the section heading when the label in column A does not identify the stream. For example, if the label only states Mass Rate make sure the stream label is also selected.) The results can be presented either as absolute values or delta from the base case. The display mode is selected in cell on Row 16 with 0=delta and 1=absolute. The base case is the first case selected in column E. All the results cases on the chosen Result worksheet, starting with the case selected in column F, are included in the customized table. Once the table selections have been made, click the CaseGen button on the upper right corner to create the table and save the table to a separate file name.
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Summary Worksheet
The Summary worksheet displays summary data for a specified case result for quickly reviewing and printing case highlights. Select the case to be displayed using the list box and spinner as shown on the Comparison worksheet.
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Charts
There are two Charts worksheets. Charts is designed to look at one variable at a time across a number of cases. Charts-2 looks within a single case at a number of variables in profile.
Charts Worksheet
Use Charts worksheet to plot up to ten sets of X-Y charts of data selected from any of the three Result worksheets. For each set, specify one X variable and up to seventeen Y variables. The range of cases to be plotted is from a selected result sheet across a consecutive series of cases identified in the cells labeled First and Last.
Setup Button
Setup lets you select which Results worksheet and group of cases are to be plotted. The Available button opens a list of cases present on all three Results worksheets. The numbers displayed are the values in the profit cell for all cases in the three Results worksheets. Those with values indicate that case data exists for that case and are available for plotting.
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Update Button
Use Update to reset the plots after any change has occurred to the configuration.
Select Button
Select lists all the possible variables available for plotting from the Result worksheets. It also lets you select the specific variables and load them into either the X variable slot or one of the seventeen Y variables in Charts 1 through 17.
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Series /X Variable
Use Series /X Variable to toggle back and forth between X-Y mode and line mode (where the Y data is displayed case by case). When you work with X variables from Results page, Series is offered as the other choice for X-axis. When the charts are shown with the case sequence as the Xaxis, X-Variable is offered as the other choice.
Save
The X and Y variable indices for each set of 17 charts can be saved with a descriptive title. Ten sets of X, Y indices can be saved for the workbook.
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Load
Load brings back the desired set of X, Y indices for display on the Charts worksheet. Set 11 to 16 are predefined index sets. At present only set 11 is predefined using CFR as X axis.
Charts - 2 Worksheet
The Charts 2 worksheet displays the profiles shown below.
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Worksheet Comments and Model Help

The on-line help available with the interface is in the form of Excel comments and a help file available from the DC-SIM menu. To access Comments attached to individual cells, place the mouse pointer over the cell. A red triangle in the upper right hand corner of the cell indicates a comment. Refer to the Excel documentation for more information.
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Saving Files and DC-SIM Exit

Completed model files should be saved with their own unique names in the default Dcdata directory or custom directory using the Excel Save As option. Maintain the template file DCSIMV2006Master.xls as an empty template from which to start new models. As the inventory of calibration cases grows it may be desirable to save them as *.DAT files as described in the Export Case Data procedure. The easiest way to save data in this format is to select the calibration and predict cases using the Run Case flag (row 3 of Calibration and Predict Input worksheets). Use Export Case Data option from the DC-SIM Tool menu and specify the .DAT file name to save to. To Exit the model, close and exit as you would any Excel session.
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Appendix A Calibration Factors

Initialization Factors ............................................................................................................. A-2 DCSIM V2006 Tuning Factors............................................................................................. A-3 DC-SIM V2006 Calibration Factors ..................................................................................... A-6
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Appendix A - Calibration Factors - A 1
Initialization Factors
Initialization Factors
H2S Calibration Distribution NH3 Calibration Distribution K Factor Shift Initializer H2SDR NH3DR DUKNI
Default
0.25 0.13 0.5
Range
>0 >0 >0
Type
fraction of feed S distributed to H2S fraction of feed N distributed to NH3 Initial shift of cracked pseudo K from uncracked pseudo. Help to get product volumes converge used in cracking rate in furnace Tighter tolerance will improve reproducibility
Furnace Residence Time Factor Converge Tolerance Initial Factor
TIMNI TOLFACI
0.5 0.01
>0 >0
A 2 - Appendix A - Calibration Factors
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DCSIM V2006 Tuning Factors

Tuning Factors
Drum Temperature Scaling Factor Furnace Pressure Offset DRTSF
Default
0.5
Range
0 -1
Type
multiplier multiplier to adjust the Drum T nominally the furnace to drum pressure drop, main effect of furnace outlet V/L equilibrium drum pressure tuning factor, affect both drum and furnace V/L equilibrium cracking rate factor to tune for liquid yields tuning factor for coke make from polymerization intercept of the sulfurAPI correlation. Changing the intercept shifted the curve. FOE barrel conversion. Default is 6
PRFA2
0.5
>0
offset
Drum Pressure Offset Cracking Rate Factor Polymerization Rate Factor Sulfur/Nitroge n Gravity Intercept
PRFA1
>0
offset
CRACK COKER
1 1
>0 >0
multiplier multiplier
SGI
90
Fuel Oil Equivalent Conversion Constant Furnace Duty Scaling Factor Furnace Cracking T Factor Kinetics Tuning Flag CFR factor on Coke Make
FOEFC
---
FFAC
>0
multiplier
used to adjust the enthalpy of the furnace outlet stream Used to shift the equivalent cracking T in the furnace 0 = V2003 Kinetics; 1 = Use V2001 Kinetics
FURCRK
0 1.32
multiplier
IN(16)
0 or 1
CCFRADJ
multiplier
multiplier to ratio of recycle ratio to calib tower bottom recycle ratio. Impacts coke make from cracked feed, use 0.0001 for 0 power factor to ratio calib drum T vs drum T. Multiplied to total coke make
Drum T factor on Coke
COKDTADJ
multiplier
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Appendix A - Calibration Factors 3
Tuning Factors
Drum P factor on Coke COKPADJ
Default
1
Range
Type
multiplier factor based on delta of drum P from calib drum P. Impact total coke make. Use 0.0001 for 0 power factor to ratio calib drum T vs drum T. Multiplied H2S level. power factor to ratio drum P vs calib drum P. Multiplied H2S level. More sensitive than T factor. power factor to ratio drum P vs calib drum P. Multiplied coke sulfur level. More sensitive than T factor. power factor to ratio calib drum T vs drum T. Multiplied coke sulfur level.
H2S Sulfur Temperature factor H2S Sulfur Pressure factor
SULFTH2S
multiplier
SULFPH2S
multiplier
Coke Sulfur Pressure factor
SULFPFAC
multiplier
Coke Sulfur Temperature factor
SULFTFAC
multiplier
Advanced Tuning Factors

Advanced Tuning Factors Drum P factor unCrack V/L PFAC1
Default
Range
Type
>0
multiplier
multiplier factor on the vapor/liquid equilibrium for drum uncracked pseudo components multiplier factor on the vapor/liquid equilibrium for drum cracked pseudo components multiplier to the cracking rate for uncracked pseudo components multiplier to the cracking rate for cracked pseudo components multiplier to the coking rate for uncracked pseudo components multiplier to the coking rate for cracked pseudo components
Drum P factor Crack V/L
PFAC2
>0
multiplier
Crack rate factor for UnCracked comp Coke rate factor for UnCracked comp Crack rate factor for Cracked comp Coke rate factor for Cracked comp
CRAFAC1
>0
multiplier
COKFAC1
>0
multiplier
CRAFAC2
>0
multiplier
COKFAC2
>0
multiplier
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Advanced Tuning Factors

factor on Kinetic K1 for T effect on Cracking factor on Kinetic Act Eng for T effect on Cracking factor on Kinetic K2 for T effect on Coking factor on Kinetic Act Eng for T effect on Coking CKTK
Default
Range
Type
>0
multiplier
multiplier to the K1 factor in Cracking Arhenius kinetics: K1* exp (-A1/T) multiplier to the A1, activation energy, in Cracking Arhenius kinetics: K1* exp (A1/T) multiplier to the K2 factor in Coking Arhenius kinetics: K2* exp (-A2/T) multiplier to the A2, activation energy, in Coking Arhenius kinetics: K2* exp (A2/T)
CKTA
>0
multiplier
COKTK
>0
multiplier
COKTA
>0
multiplier
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DC-SIM V2006 Calibration Factors

Calibration Factors
C4- Hydrocarbon C4- Mol. Wt. Coking Rate
--XKUP(1) XKUP(2) XKUP(3)
Type
multiplier multiplier multiplier Gas Yield calibration factor, ratio of actual yield to predicted yield Gas MW factor, ratio of actual C4- MW to predicted MW factor based on ratio of actual coke/predicted coke yields from Concarbon in feed Fraction Feed Sulfur to H2S Fraction Feed Nitrogen to NH3 Offset Offset Offset Offset Offset Offset Offset Offset Offset multiplier multiplier multiplier multiplier Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Factor to adjust mol % distribution used to match predict yield to actual Shift to Sulfur to product 1 distribution factor, multiplier to total liquid sulfur Shift to Sulfur to product 2 distribution factor, multiplier to total liquid sulfur Shift to Sulfur to product 3 distribution factor, multiplier to total liquid sulfur Shift to Sulfur to product LCGO distribution factor, multiplier to total liquid sulfur Shift to Sulfur to product HCGO distribution factor, multiplier to total liquid sulfur Shift to Sulfur to product FZGO distribution factor, multiplier to total liquid sulfur
H2S NH3 Hydrogen (offset) Methane (offset) Ethane (offset) Ethylene (offset) Propane (offset) Propylene (offset) Isobutane (offset) Normal Butane (offset) Butylene (offset) Stream #1 Sulfur Distr Stream #2 Sulfur Distr Stream #3 Sulfur Distr Stream #4 Sulfur Distr Stream #5 Sulfur Distr Stream #6 Sulfur Distr
XKUP(4) XKUP(5) XKUP(6) XKUP(7) XKUP(8) XKUP(9) XKUP(10) XKUP(11) XKUP(12) XKUP(13) XKUP(14) XKUP(15) XKUP(16) XKUP(17) XKUP(18)
XKUP(19)
multiplier
XKUP6(1)
multiplier
KBC Proprietary
DC-SIM User Guide
Calibration Factors
Coke Sulfur Distr Stream #1 Nitrogen Distr Stream #2 Nitrogen Distr Stream #3 Nitrogen Distr Stream #4 Nitrogen Distr Stream #5 Nitrogen Distr Stream #6 Nitrogen Distr Coke Nitrogen Distr Stream #1 RON (offset) Stream #1 MON (offset) Stream #2 RON (offset) Stream #2 MON (offset) Stream #3 RON (offset) Stream #3 MON (offset) Stream #2 Aniline Pt(offset) Stream #3 Aniline Pt(offset) Stream #4 Aniline Pt(offset) Stream #5 Aniline Pt(offset) Stream #6 Aniline Pt(offset) Stream #1 Bromine Number Stream #2 Bromine Number Stream #3 Bromine Number Stream #4 Bromine Number
--XKUP(20) XKUP(21) XKUP(22) XKUP(23) XKUP(24) XKUP(25) XKUP6(2) XKUP(26) XKUP(27) XKUP(28) XKUP(29) XKUP(30) XKUP(29) XKUP(30) XKUP(31) XKUP(32) XKUP(33) XKUP(34) XKUP6(3) XKUP(35) XKUP(36) XKUP(37) XKUP(38)
Type
multiplier multiplier multiplier multiplier multiplier multiplier multiplier Sulfur factor for Concarbon coke contribution Shift to N2 to product 1 distribution factor, multiplier to total liquid N2 Shift to N2 to product 2 distribution factor, multiplier to total liquid N2 Shift to N2 to product 3 distribution factor, multiplier to total liquid N2 Shift to N2 to product LCGO distribution factor, multiplier to total liquid N2 Shift to N2 to product HCGO distribution factor, multiplier to total liquid N2 Shift to N2 to product FZGO distribution factor, multiplier to total liquid N2 N2 factor for Concarbon coke contribution Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Calibration RON Calibration MON Calibration RON Calibration MON Calibration RON Calibration MON Actual-Predicted. If no data, set to XKUP(32) Actual-Predicted. If no data, set to XKUP(33) Actual-Predicted Actual-Predicted Actual-Predicted Calibration Bromine Number Calibration Bromine Number Calibration Bromine Number Calibration Bromine Number
DC-SIM User Guide
KBC Proprietary
Calibration Factors
Stream #5 Bromine Number Stream #6 Bromine Number Stream #1 KFactor Shift Stream #2 KFactor Shift Stream #3 KFactor Shift Stream #4 KFactor Shift Stream #5 KFactor - UK2 Stream #6 KFactor - UK2 Cutpoint Shift Stream 1-2 Cutpoint Shift Stream 2-3 Cutpoint Shift Stream 3-4 Cutpoint Shift Stream 4-5 Cutpoint Shift Stream 5-6 Stream 1-2 TBP Cutpoint Stream 2-3 TBP Cutpoint Stream 3-4 TBP Cutpoint Stream 4-5 TBP Cutpoint Stream 5-Recycle Cutpoint Convergence Tolerance Factor Stream 1 D86 90% Cutpoint Stream 2 D86 90% Cutpoint
--XKUP(39) XKUP6(4) XKUP(40)
Type
Offset Offset Offset Calibration Bromine Number Calibration Bromine Number Shift to cracked pseudo K in product 1, based on convergence of predicted vs actual product volume Shift to cracked pseudo K in product 2, based on convergence of predicted vs actual product volume Shift to cracked pseudo K in product 3, based on convergence of predicted vs actual product volume Shift to cracked pseudo K in product 4, based on convergence of predicted vs actual product volume Cracked K factor, UK2 Offset Offset Offset Offset Offset Offset deg F deg F deg F deg F deg F Shift to cracked pseudo K in FZGO Shift to cutpoint in pseduos to converge product yields Shift to cutpoint in pseduos to converge product yields Shift to cutpoint in pseduos to converge product yields Shift to cutpoint in pseduos to converge product yields Shift to cutpoint in pseduos to converge product yields Cutpoint from actual b.p. curves Cutpoint from actual b.p. curves Cutpoint from actual b.p. curves Cutpoint from actual b.p. curves Cutpoint from actual b.p. curves Internal Calibration Iteration Convergence Factor deg F deg F D86 Cutpoint from actual b.p. curves D86 Cutpoint from actual b.p. curves
XKUP(41)
Offset
XKUP(42)
Offset
XKUP(43)
Offset
XKUP(44) XKUP6(5) XKUP(45) XKUP(46) XKUP(47) XKUP(48) XKUP6(6) XKUP(49) XKUP(50) XKUP(51) XKUP(52) XKUP(53) XKUPN(10) XKUPC(1) XKUPC(2)
KBC Proprietary
DC-SIM User Guide
Calibration Factors
Stream 3 D86 90% Cutpoint Stream 4 D86 90% Cutpoint Stream 5 D86 90% Cutpoint Stream 1 D86/TBP Cutpoint Shift Stream 2 D86/TBP Cutpoint Shift Stream 3 D86/TBP Cutpoint Shift Stream 4 D86/TBP Cutpoint Shift Stream 5 D86/TBP Cutpoint Shift Stream #1 T00 TBP Shift Stream #1 T10 TBP Shift Stream #1 T30 TBP Shift Stream #1 T50 TBP Shift Stream #1 T70 TBP Shift Stream #1 T90 TBP Shift Stream #1 T99 TBP Shift Stream #2 T00 TBP Shift Stream #2 T10 TBP Shift Stream #2 T30 TBP Shift Stream #2 T50 TBP Shift Stream #2 T70 TBP Shift Stream #2 T90 TBP Shift Stream #2 T99 TBP Shift Stream #3 T00 TBP Shift
--XKUPC(3) XKUPC(4) XKUPC(5) XKUPCS(1) XKUPCS(2) XKUPCS(3) XKUPCS(4) XKUPCS(5) XKUP(54) XKUP(55) XKUP(56) XKUP(57) XKUP(58) XKUP(59) XKUP(60) XKUP(61) XKUP(62) XKUP(63) XKUP(64) XKUP(65) XKUP(66) XKUP(67) XKUP(68)
Type
deg F deg F deg F Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset D86 Cutpoint from actual b.p. curves D86 Cutpoint from actual b.p. curves D86 Cutpoint from actual b.p. curves TBP CUTPOINT - D86 CUTPOINT TBP CUTPOINT - D86 CUTPOINT TBP CUTPOINT - D86 CUTPOINT TBP CUTPOINT - D86 CUTPOINT TBP CUTPOINT - D86 CUTPOINT Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints.
DC-SIM User Guide
KBC Proprietary
Calibration Factors
Stream #3 T10 TBP Shift Stream #3 T30 TBP Shift Stream #3 T50 TBP Shift Stream #3 T70 TBP Shift Stream #3 T90 TBP Shift Stream #3 T99 TBP Shift Stream #4 T00 TBP Shift Stream #4 T10 TBP Shift Stream #4 T30 TBP Shift Stream #4 T50 TBP Shift Stream #4 T70 TBP Shift Stream #4 T90 TBP Shift Stream #4 T99 TBP Shift Stream #5 T00 TBP Shift Stream #5 T10 TBP Shift Stream #5 T30 TBP Shift Stream #5 T50 TBP Shift Stream #5 T70 TBP Shift Stream #5 T90 TBP Shift Stream #5 T99 TBP Shift Stream #6 T00 TBP Shift Stream #6 T10 TBP Shift
--XKUP(69) XKUP(70) XKUP(71) XKUP(72) XKUP(73) XKUP(74) XKUP(75) XKUP(76) XKUP(77) XKUP(78) XKUP(79) XKUP(80) XKUP(81) XKUP(82) XKUP(83) XKUP(84) XKUP(85) XKUP(86) XKUP(87) XKUP(88) XKUP6(10)
Type
Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints. Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info)
XKUP6(11)
Offset
KBC Proprietary
DC-SIM User Guide
Calibration Factors
Stream #6 T30 TBP Shift Stream #6 T50 TBP Shift Stream #6 T70 TBP Shift Stream #6 T90 TBP Shift Stream #6 T99 TBP Shift Calib External Flow Control Quench Stream 4+ CCN and Metals Weight Reference Stream 5+ CCN and Metals Weight Reference Stream 6+ CCN and Metals Weight Reference Sulfur in Coke from Con Carbon Nitrogen in Coke from Con Carbon Coke Ash Coke VCM (offset) Coke HGI factor H2S Sulfur Temperature factor H2S Sulfur Pressure factor Coke Sulfur Temperature factor Coke Sulfur Pressure factor Stream 4 CCR Distr Stream 5 CCR Distr
--XKUP6(12)
Type
Offset Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info) Used with Calib Drum T to determine if too much Flow Control Quench predict input. multiplier Wt distribution in Gas Oil and Coke, used for ConCarbon and Metals prediction Wt distribution in Gas Oil and Coke, used for ConCarbon and Metals prediction Wt distribution in Gas Oil, FZGO, and Coke, used for ConCarbon and Metals prediction Sulfur in precipitated coke N2 in precipitated coke Offset Offset multiplier multiplier multiplier multiplier multiplier multiplier multiplier factor of coke ash to feed metal ratio wt% VCM correction factor ratio of calibration HGI input to calculated HGI H2S T response factor from Tuning Factor section H2S P response factor from Tuning Factor section Coke Sulfur T response factor from Tuning Factor section Coke Sulfur P response factor from Tuning Factor section used in CCR correlation used in CCR correlation
XKUP6(13)
Offset
XKUP6(14)
Offset
XKUP6(15)
Offset
XKUP6(16)
Offset
XKUP(89)
XKUP(90)
XKUP(91)
multiplier
XKUP6(9)
multiplier
XKUP(92) XKUP(93) XKUP(94) XKUP(95) XKUPN(5) XKUPN(8) XKUPN(9) XKUPN(6) XKUPN(7) XKUP(96) XKUP(97)
DC-SIM User Guide
KBC Proprietary
Calibration Factors
Stream 6 CCR Distr Stream 4 Metals Distr Stream 5 Metals Distr Stream 6 Metals Distr DISADJ DUK HTCK Flow Control Quench molar Enthalpy Offset Furnace Duty Factor Reference CFR Reference CFRD Reference CFRN Reference Velocity GO % of Furnace Feed Reference Quench Del T (DTQ) Furn to Drum Delta T Drum Delta Temperature Quenched Vapor to Frac Delta T T.C. Quench Oil vol Enthalpy Offset Drum Minus Frac Pressure Frac Minus WGS Suction Residence Time Base Volume Residence Time Basis HGO Draw Temp Cutpt Shift
--XKUP6(7) XKUP(98) XKUP(99) XKUP6(8) XKUP(100) XKUP(101) XKUP(102) XKUP(103)
Type
multiplier multiplier multiplier multiplier multiplier offset multiplier Offset used in CCR correlation used in Metal correlation used in Metal correlation used in Metal correlation Gas yield factor to converge liquid factor shift between feed K and recycle (cracked) K Heat of Cracking factor used to calculate Drum outlet temperature correction to Flow Control Quench enthalpy, btu/mole factor to adjust furnace duty during calibration Calibration CFR Calibration CFR using only distillates Calibration CFR (only tower bottom recycle, exclude distillate recycle) Calibration Velocity Gas Oil % of feed
XKUP(104) XKUP(105) XKUP(106) XKUP(107) XKUP(108)
multiplier
XKUP(109) XKUP(110) XKUP(111) XKUP(112) XKUP(113) XKUP(114) XKUP(115) XKUP(116) XKUP(117) XKUP(118)
deg F deg F deg F deg F Offset psi psi cuft multiplier deg F
Drum vapor delta T due to Quench Furnace outlet to Drum Inlet heat loss T Drum inlet T - Drum outlet T Heat loss of Quenched Drum Vapor to Frac inlet correction to Temperature Control Quench enthalpy, Btu/bbl delta P between Drum and Fractionator overhead delta P between Fractionator overhead and gas compressor suction P Furnace base flow rate used to adjust furnace residence time Furnace residence time factor for cracking kinetics Shift between HGO draw temperature and HGO cut point
KBC Proprietary
DC-SIM User Guide
Calibration Factors
Tower Temperature Adjustment Calibration FZGO Cut Point Stream 3 Cloud Update Stream 4 Cloud Update Stream 5 Cloud Update Stream 6 Cloud Update Stream 3 Pour Update Stream 4 Pour Update Stream 5 Pour Update Stream 6 Pour Update Calib External Temp Control Quench Calibration Drum Pressure Calibration Drum Out Temp Calibration Total Feed CCR Calibration Total Feed API Product API Adjust Factor for Slurry Oil Calibration Coke Yield Furnace Cracking T Tuning Factor Calib HGO T50 Calib HGO API FZGO Cracking Factor FZGO Tail Index TGO Bias
--XKUP(119)
Type
deg F Adjustment to tower temperature profile to match plant data Calibration FZGO cut point delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual delta between API predicted vs actual Used with Calib Ext Flow Control Quench to determine if too much Flow Control Quench predict input. psi deg F wt%
XKUP(120) XKUPN(3) XKUP(121) XKUP(122) XKUP(123) XKUPN(4) XKUP(124) XKUP(125) XKUP(126) XKUP(127)
deg F deg F deg F deg F deg F deg F deg F deg F deg F
XKUP(128) XKUP(129) XKUPN(11) XKUPN(12) XKUPN(13)
multiplier
Power factor to UK2 ratio used in Predict mode to adjust product API when slurry oil is in feed
XKUPN(14) XKUPN(15) XKUPN(16) XKUPN(17) XKUPN(18) XKUPN(19) XKUPN(20)
wt% multiplier Used to shift the equivalent cracking T in furnace
multiplier
Used to adjust FZGO range cracking Used to match plant data FZGO endpoint
Offset
Tower HGO temperature internal bias
DC-SIM User Guide
KBC Proprietary
Calibration Factors
Release Version Prod 2 Flash Point Update Prod 3 Flash Point Update LGO Flash Point Update HGO Flash Point Update FZGO Flash Point Update Release Build Prod 1 Olefins Update Prod 1 Naphthenes Update Prod 1 Aromatics Update Prod 2 Olefins Update Prod 2 Naphthenes Update Prod 2 Aromatics Update Prod 3 Olefins Update Prod 3 Naphthenes Update Prod 3 Aromatics Update Spare Spare Spare Spare Spare Spare Spare Spare Spare VDRUM - Volume
--XKUPN(21) XKUPN(22) XKUPN(23) XKUPN(24) XKUPN(25) XKUPN(26) XKUPN(27) XKUPN(28) XKUPN(29)
Type
Offset Offset Offset Offset Offset
Offset Offset
XKUPN(30) XKUPN(31) XKUPN(32)
Offset Offset Offset
XKUPN(33) XKUPN(34) XKUPN(35)
Offset Offset Offset
XKUPN(36) XKUPN(37) XKUPN(38) XKUPN(39) XKUPN(40) XKUPN(41) XKUPN(42) XKUPN(43) XKUPN(44) XKUPN(45) XKUP(130)
Offset
cuft
KBC Proprietary
DC-SIM User Guide
Calibration Factors
DDRUM Diameter HDVOL - Head Volume TLOUT - Top T/L Outage CELLS - Number of Cells MNOUT Minimum Outage
--XKUP(131) XKUP(132) XKUP(133) XKUP(134) XKUP(135)
Type
ft cuft ft
ft
DC-SIM User Guide
KBC Proprietary
KBC Proprietary
DC-SIM User Guide
Index
A
A Guide to Problem Solving 1:9 Adjustment of Coker Feed Back End Distillation 1:4 Aniline Point 2:28 Available Models 4:6 Available Results Button 4:34 Available Results Item 4:14
Constraints 2:30 Conventional Recycle Coker 2:17 Conversion of Old DC-SIM Workbook to Current Version Workbook 1:5 Copy Button 4:20, 4:24, 4:25 Copy Case Data Item 4:13 Customizing the Workbook 4:8
D
Data Flow 4:3 DC-SIM Calibration Guidelines 2:20 DC-SIM Menu 4:11 DC-SIM Model Installation 3:3 DC-SIM Options Item 4:11 DC-SIM V2006 Calibration Factors A:6 DCSIM V2006 Tuning Factors A:3 Definition of Combined Feed Ratio (CFR) 2:17 Delayed Coker Refinery Unit 1:7 Design Worksheet 4:16 Diesel Cloud Point, Pour Point and Flash Point 2:28 Drum Dimension Input Data 2:5
B
Bromine Number 2:28
E C
Calibration as a Once Through Unit 2:13 Calibration Case Checklist 2:12 Calibration Factors for PONA of Naphtha Range Product 1:5 Calibration Input Data 2:7 Calibration Input Worksheet 4:18 Calibration of Once Through Unit as a Conventional Recycle Unit 2:15 Cancel Button 4:7 CaseGen 4:31 Charts 4:34 Charts - 2 Worksheet 4:37 Charts Worksheet 4:34 Clear Button 4:21, 4:25 Clear Case Data Item 4:13 Coke Ash Content 2:29 Coke HGI 2:29 Coke Inventory 2:24 Coke Volatile Matter (VCM) 2:29 Comments 4:10 Comparison Worksheet 4:31 Configuration Guidelines 2:13
DC-SIM User Guide KBC Proprietary
Excel Interface Standardization 1:6 Export Calibration to Petro-Sim 4:15 Export Case Data Item 4:14
F
Feedback 1:9 Fractionator Configuration for Extra Low Recycle Operation 1:4
G
Gateway Workbook 4:4 Getting Started 4:6 Grouping Feature 4:9
H
Help and Error Messages 1:9 How DC-SIM Works 2:3 How the Calibration Case Works 2:11 How the Optimizer Works 2:30 How the Predict Case Works 2:26
Index - I 1
I
Import Button 4:19, 4:25 Import Case Data Item 4:14 Import from Petro-Sim 4:15 Initialization Factors A:2 Installation 3:3 Inter-conversion of Units of Measurement for Data File During IMPORT 1:5
L
Links 4:14, 4:15 Load 4:37
Predicting Viscosity and Flash Point Product Properties 1:4 Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit 2:15 Problems When Running the Application 3:11 Proceed Button 4:6 Product Cutpoints Target 2:24 Product Properties 2:28 Program Security 1:5, 3:3 PSV Steam Input to Fractionator 1:5
Q
Quench 2:22
M
Microsoft Excel 4:3 Microsoft References 3:2 Model Workbook 4:9 Model Workbook and Model Workbook Template 4:5
R
Reset Button 4:35 Result Worksheets 4:29 Run Button 4:18, 4:24, 4:27 Run Item 4:12 Run the Optimizer using the Run button on the worksheet. 2:30, 2:31
N
Naphtha PONA 2:29 Naphtha RON and MON 2:28 Navigation Item 4:11, 4:12 New Tuning Factor for Furnace Cracking Temperature 1:3 Nitrogen 2:28 Number and Decimal Regional Settings 3:4
S
Save 4:36 Saving Files and DC-SIM Exit 4:39 Security Settings and Macros 3:9 Select Button 4:35 Select the Optimizer Input Worksheet. 2:30 Select Variable Button 4:35 Series /X Variable 4:36 Setting up a Shortcut 3:8 Settings Button 4:27 Setup Button 4:24, 4:27, 4:34 Special Once Through Coker Configuration with No HCGO Net Product 1:5 Starting DC-SIM 3:8 Starting the Program 3:7 Starting with the Data Workbook 3:7 Sulfur 2:28 Summary Worksheet 4:33
O
Once Through Coker 2:17 Opening DC-SIM with the Start Bar 3:7 Optimizer Improvements 1:3 Optimizer Input Worksheet 4:26 Optimizer Log 2:30, 2:31 Optimizer Run Checklist 2:30 Other Properties 2:29 Overview 1:2
P
PC System Requirements 3:2 Predict Case Checklist 2:26 Predict Input Data 2:22 Predict Input Worksheet 4:23
T
Technical Help and Feedback 1:9
2 Index
KBC Proprietary
DC-SIM User Guide
Test Run Data for Model Calibration 2:4 Testing the Program Execution 3:10 Text Files Item 4:13 Transfer Workbook Data 4:15
U
Update Button 4:35
V
Velocity Gas Oil 2:17, 2:23 VGen LP Vector Generation Tool 4:28 Viscosity @ 50 C 2:29
W
What Is Installed 3:4 What's New in This Release 1:3 Worksheet Comments and Model Help 4:38
Z
Zero Natural Recycle Configuration Once Through 2:13
DC-SIM User Guide
KBC Proprietary
Index - I 3

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DC-SIM

KBC Advanced Technologies, LLC

Copyright KBC Advanced Technologies plc 2005. All rights reserved.

DC-SIM Data Requirements

Using the Spreadsheet Interface

Appendix A - Calibration Factors

DC-SIM User Guide

DC-SIM User Guide

Whats New in This Release

New Tuning Factor for Furnace Cracking Temperature

DC-SIM User Guide

Fractionator Configuration for Extra Low Recycle Operation

Predicting Viscosity and Flash Point Product Properties

Adjustment of Coker Feed Back End Distillation

DC-SIM User Guide

Special Once Through Coker Configuration with No HCGO Net Product

PSV Steam Input to Fractionator

Calibration Factors for PONA of Naphtha Range Product

Conversion of Old DC-SIM Workbook to Current Version Workbook

Inter-conversion of Units of Measurement for Data File During IMPORT

Excel Interface Standardization

DC-SIM User Guide

Delayed Coker Refinery Unit

DC-SIM User Guide

DC-SIM User Guide

Technical Help and Feedback

Help and Error Messages

DC-SIM User Guide

DC-SIM User Guide

DC-SIM Data Requirements

2 - 2 DC-SIM Data Requirements

DC-SIM User Guide

How DC-SIM Works

2 - 3 DC-SIM Data Requirements

DC-SIM User Guide

Test Run Data for Model Calibration

2 - 4 DC-SIM Data Requirements

DC-SIM User Guide

Drum Dimension Input Data

2 - 5 DC-SIM Data Requirements

2 - 6 DC-SIM Data Requirements

DC-SIM User Guide

Calibration Input Data

2 - 7 DC-SIM Data Requirements

DC-SIM User Guide

2 - 8 DC-SIM Data Requirements

DC-SIM User Guide

c = Required; c* = Conditional on presence of stream selection on design worksheet; blank = Optional

2 - 9 DC-SIM Data Requirements

DC-SIM User Guide

2 - 10 DC-SIM Data Requirements

DC-SIM User Guide

How the Calibration Case Works

2 - 11 DC-SIM Data Requirements

DC-SIM User Guide

Calibration Case Checklist

2 - 12 DC-SIM Data Requirements

DC-SIM User Guide

Calibration as a Once Through Unit

2 - 13 DC-SIM Data Requirements

DC-SIM User Guide

OR Both HGO and FZGO mixed together to be used as velocity gas

2 - 14 DC-SIM Data Requirements

Create XKUP (108) = 100VelGO/ (CFRFeeds 1-5)