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    Crude and Refinery Calculations

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    Anonymous 6s9Aw9
    This document outlines the key assumptions and simplifications made in a simplified refinery model. It describes the main processing units - including an atmospheric distillation unit, hydrotreater, catalytic cracker, and coker. It then provides the equations and calculations used to model yields from each unit, such as yields of gasoline, distillates, gases, and coke. The goal is to provide a generalized first-generation model for estimating refinery yields, while acknowledging it ignores some advanced processes and makes broad assumptions for simplicity.

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    Crude and Refinery Calculations

    Uploaded by

    Anonymous 6s9Aw9
    187 views5 pages
    This document outlines the key assumptions and simplifications made in a simplified refinery model. It describes the main processing units - including an atmospheric distillation unit, hydrotreater, catalytic cracker, and coker. It then provides the equations and calculations used to model yields from each unit, such as yields of gasoline, distillates, gases, and coke. The goal is to provide a generalized first-generation model for estimating refinery yields, while acknowledging it ignores some advanced processes and makes broad assumptions for simplicity.

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    Crude and Refinery Calculations

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    This document outlines the key assumptions and simplifications made in a simplified refinery model. It describes the main processing units - including an atmospheric distillation unit, hydrotreater, catalytic cracker, and coker. It then provides the equations and calculations used to model yields from each unit, such as yields of gasoline, distillates, gases, and coke. The goal is to provide a generalized first-generation model for estimating refinery yields, while acknowledging it ignores some advanced processes and makes broad assumptions for simplicity.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    187 views5 pages

    Crude and Refinery Calculations

    Uploaded by

    Anonymous 6s9Aw9
    This document outlines the key assumptions and simplifications made in a simplified refinery model. It describes the main processing units - including an atmospheric distillation unit, hydrotreater, catalytic cracker, and coker. It then provides the equations and calculations used to model yields from each unit, such as yields of gasoline, distillates, gases, and coke. The goal is to provide a generalized first-generation model for estimating refinery yields, while acknowledging it ignores some advanced processes and makes broad assumptions for simplicity.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 5

    HT

    Reformer

    Straigh Run: Kerosene, Diesel

    ADU

    Cat.
    Cracker

    HT

    VDU

    Coker

    Above is my simplified version of a refinery that illustrates the barebones version that Im using for the trial calculations. There are
    formulas and equations for more complex refinery set-ups, but this
    seemed the easiest to generalize. Specific cases can be put through
    the more rigorous numbers if necessary.
    Outline of some simplifications/assumptions that are occurring in this
    assessment:
    1. Gasoline blending is not taking into consideration. Because of
    this paraffins, aromatics and naphthenes from the reforming
    process are not separated into different percentages. Rather,
    they are all considered gasoline. Additionally, RON is assumed to
    be 94 for all calculations (this is on the high side and will give an
    estimate on the low side of gasoline output).
    2. Numerous advanced processes are being ignored, most noteably,
    alkylation and catalytic hydrocracking. The consequence of
    ignoring alkylation puts the gasoline production estimate on the
    low side. Catalytic hydrocracking can produce both gasoline and
    distillates (jet fuel, diesel). There are formulas to determine the
    percentage of output, but requires additional linear logic to
    decide what portion of the initial feed goes to the hydrocracker.
    This information was not included in the initial set-up. It has the
    potential to be considered later. The calculations are more
    complicated because the hydrocracker has the capability of

    3.
    4.
    5.

    6.

    being set up to provide more gasoline, diesel or jet fuel based on


    the needs of the refinery.
    The calculations are done on broad specifications. Exact refinery
    production calculations are considered as proprietary
    information.
    Distillates are isolated as a single category, but contain both
    diesel and jet fuel. There is no exact amount to separate the
    two. Diesel comprises the majority.
    Another important assumption is that the streams can only flow
    in a straight line. For example, once fractions are sent to the
    vacuum distillation unit, they can only be sent to the coker or
    produce what they will from the vacuum distillation unit (VDU).
    This is going to give low estimates, as certain fractions of VDU
    can be sent to catalytic crackers and reformers as well, but this
    starts to get outside the scope of the simple programing we
    wanted.
    Corrections for sulfur content are also being ignored. This would
    cause a slight over-estimate in product, especially for samples
    that are high in sulfur content. This calculation can be done on a
    case by case basis, but was too complicated for this simple first
    generation model.

    Step 1: Initial Distillation: CDU output.


    1. CDU unit (initial distillation): Important fractions to be
    considered for calculation data:
    a) 190-380 F: Naptha fraction proceeds to a hydrotreater
    to remove sulfur and other impurities and onto the
    catalytic reformer to produce gasoline.
    b) 380-580 F: These cuts are assumed to be used as
    straight run, with minimal purification in a hydrotreater,
    but can be taken as a percentage of the initial input.
    c) 580-650 F: This gas oil fraction goes through the
    hydrotreater, on to the catalytic cracker. The catalytic
    cracker is assumed to operate at 75% efficiency to
    produce gases, gasoline, gasoil (distillates?) and coke.
    d) 650-1050 F: This fraction comprises light, medium and
    heavy gas oils. The lighter hydrocarbons in this fraction
    can be used in marine diesel, while 800+ heads to the
    vacuum distillation unit (VDU) is isolated via the vacuum
    distillation unit and produces vacuum gas oil (light,
    medium and heavy) along with vacuum residue. The
    residue heads to the coker.
    e) 1050+ F: This is the residue fraction and after the VDU,
    it will head to the coker, where it will produce gasoline,
    distillate, gases and coke.

    Further calculations will be performed on the coker, catalytic cracker


    and reformer (although the reformer calculations will only be necessary
    if gasoline blending is considered).
    Calculations for CDU:
    TBP-true boiling point (correction for the simpler technique used to
    determine atmospheric distillation values in the lab): There are a
    couple methods of calculation
    TBP (R)= {(2.2ln(100/(100-LV%)))^2.7 +1}490
    TBP=a(ASSAYBP)^b (%=% of sample distilled) reported as T% (i.e.
    T10= TBP at 10%)
    %
    a
    B
    0
    0.9167
    1.0019
    10
    0.5277
    1.0900
    30
    0.7429
    1.0425
    50
    0.8920
    1.0176
    70
    0.8705
    1.0226
    90
    0.9490
    1.0110
    95
    0.8000
    1.0355
    Additional values that may be of importance for subsequent
    calculations:
    VABP=volume average boiling point=(T10+T30+T50+T70+T90)/5
    MeABP=mean average boiling point=VABP-
    =-0.94402-0.00865(VABP-32)^0.667+2.99791(SL)^0.335 SL=(T90T10)/(90-10)
    Watson Characterization Factor (K): Unit used to distinguish a crude
    feed, used in multiple further calculations: K=(Tb)^1/3/SG or
    K=(MeABP)^1/3/SG
    API= -0.0004(LV%)^3 +0.05(LV%)^2-2.4(LV%)+800use mid. point
    volume for each fraction. Can also calculate the
    LV%=percent of accumulated liquid volume (this is total based on what
    boiling point the fractions are collected at. The higher boiling point
    fractions will have higher numbers.
    IBP=initial boiling point
    EBP=end boiling point
    SG=specific gravity (usually provided in the assay, API=(141.5/SG)131.5)
    M=average molecular weight of the fraction=42.965[exp(2.097X10^4Tb-7.78712SG+2.08476X10^-3TbSG]Tb^1.26007SG^4.98308
    Wt%S can be determined if not given in the assay, but requires 3 other
    calculations.
    Tb=(((IBP+EBP)/2)-32)/1.8 (Can add 273 to get the temperature in
    Kelvin if necessarywhich it is to calculate K value)

    Cut Volume %: This can be determined from the initial percentages in


    the crude assay: %vol at EBP-%vol and IBP.
    Cut Volume=% in decimal form(BPD feed)this gives a BPD value. If
    the product is a straight run product, this value can be used as the
    output value of that fraction.
    Calculations: Naptha Hydrotreater and Catalytic Reformer
    BPD: This value will have been calculated in the CDU phase.
    SCFB (standard cubic feet per barrel)
    Sf=%wt of sulfur for fractioncan be calculated, but hopefully is given.
    From the hydrotreater, need to calculate the paraffin (P), napthene (N)
    and aromatic (A)volumes to get a C5+ vol% which is the amount of
    gasoline produced.
    Subscript p=product, subscript f=feed, Kf=Watson characterization
    factor of the feed
    Vol%P=12.8Kf^2-259.5Kf+1330
    Vol%N=-78.5Kf^2+1776.6Kf-9993.7
    Vol%A=38.4Kf^2-894.3Kf+5219.4
    Hydrotreater:
    SCFB H2 =191Sf-30.7
    APIp=0.01(SCFB H2) +0.036(APIf)-2.69
    APIp=APIf+ APIp
    C5+ vol%=142.7914-0.77033 X RON +0.219122 X (N+2A)F The RON
    number is based on the blend of gasoline desired. For the purpose of
    this set up, assume that RON=94. This number will be a percentage
    that will be multiplied by the BPD feed to give the BPD of gasoline
    produced by this process.
    Calculations: Middle Distillate Hydrotreater and Catalytic
    Cracker:
    Hydrotreater:
    SCFB H2 =110.8Sf+10.2(100)-659 (assumes 100% severity of
    hydrotreater)
    APIp=0.00297(SCFB H2) -0.11205(APIf)+5.5419
    APIp=APIf+ APIp
    Catalytic Cracker: Assumption 75% conversion (CONV)
    Coke wt%=0.05356XCONV-0.18598XAPI+5.966975
    Light cycle oil (distillates) LV%=0.0047XCONV^20.8564XCONV+53.576
    Gases wt%=0.0552XCONV+0.597
    Gasoline LV%=0.7754XCONV-0.7778

    Calculations: Coker
    CCR-Conradson carbon residue: This is a physical property of the
    crude, should be provided in the assay data. If it isnt, give a range
    between 10-25%
    Gas(C4-)wt%=7.8+0.144X(wt%CCR)
    Naptha wt%=11.29+0.343X(wt%CCR)
    Coke wt%=1.6 X(wt%CCR)
    Gas Oil wt%=100-wt% of other three
    Gas oil and naptha can be broken down further if necessary, but wont
    do that in first generation example.

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