Europe User Conference: MOL multi unit optimization of FCC and VGOHTR reactor models in petro-sim
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This document summarizes simulation work done to optimize the connection between an FCC unit and a VGO HTR unit at a MOL Group refinery. The simulation investigated increasing the VGO HTR unit's conversion from 28% to 43% and evaluated the impact on FCC yields. Calculations showed increasing VGO HTR conversion would lower the specific gravity of the FCC feedstock, increasing FCC conversion by an estimated 1.27% and providing $697,000 per month in additional financial benefits through improved yields. Further testing was recommended to validate the models and hydrogen consumption assumptions.
Europe User Conference: MOL multi unit optimization of FCC and VGOHTR reactor models in petro-sim
- 1. 18-19.06.2018_London Head of Process Simulation/simulation process engineer Klára Kubovicsné Stocz /Laura Szabó MULTI-UNIT OPTIMISATION OF FCC AND VGOHTR REACTOR MODELS IN PETRO-SIM™
- 2. AGENDA 1. Introduction of MOL and Danube Refinery 2. Simulation activities at DR 3. VGO HTR and FCC connection 4. Investigations and calculations a. Background and aim b. Measured data and calculation steps c. Financial Results 5. Summary
- 3. IS AN INTEGRATED, INTERNATIONAL OIL AND GAS COMPANY IS HEADQUARTERED IN BUDAPEST, HUNGARY HAS A TRACK RECORD OF OVER 100 YEARS IN THE INDUSTRY HAS LEAD POSITIONS IN OUR HOME MARKETS WITHIN CENTRAL EASTERN EUROPE CORE ACTIVITIES • CcSEBITDACONTRIBUTIONOFTHEMAINSEGMENTSIN2016(USDMN) ALL FINANCIAL DATA FROM 2016 UPSTREAM 675 DOWNSTREAM 1453 GAS MIDSTREAM 194
- 4. Tisza Capacity: 0.0 Mtpa Zala Capacity: 0.0 Mtpa Refineries with no dist. cap. MOL GROUP REFINERIES THE PRODUCTS INCLUDE, AMONG OTHERS, GASOLINE, DIESEL, HEATING OIL, AVIATION FUEL, LUBRICANTS, BITUMEN, SULPHUR AND LIQUEFIED PETROLEUM GAS PRODUCE AND SELL PETROCHEMICALS WORLDWIDE AND HOLD A LEADING POSITION IN THE PETROCHEMICAL SECTOR IN THE CENTRAL EASTERN EUROPE REGION Refineries Bratislava Capacity: 6.1 Mtpa Danube Capacity: 8.1 Mtpa Sisak Capacity: 2.2 Mtpa Rijeka Capacity: 4.5 Mtpa Mantua Product logistics hub Tiszaújváros Bratislava Petrochemical plants
- 5. SIMULATION ACTIVITIES Complete unit models Column models Furnace models Detailed HTX models Reactor models: Reformer VGO HTR FCC DCU NHT Crude processing evaluation Column operation checking HTX monitoring, cleaning strategies HTX –heat integration New project support Operation support Scheduling support
- 6. SCHEME OF DR VS SIMULATION MODELS 44 units Different technologies Atm. and vac distillation Reforming Isomerisation Aromatic extraction Fluid catalytic cracking Desulphurisation Hydrotreating Delayed coking Sulphur recovery Hydrogen plant Lube oil and wax production
- 7. VGO HTR AND FCC CONNECTION VGOHTRUnit • VGO HTR unit Max. Capacity 180 kt/month Feed properties: • Sulphur content 1,9-2,35 wt% Reactors: • R101/1-2: HDS catalyst in 3 beds • R101/3-4: HDS catalyst in first bed, HCK catalyst in second bed Targets: • Gasoil Sulphur content 30-60 ppm • Conversion 23-30 wt% Raffinate product: • S content usually 50-200 ppm (max. 400 ppm) Off gas LPG Naphtha Distillate Raffinate (FCC feed) H2 Make-up Vacuum Gasoil FCCunit Gas products C3s Naphtha Light Cycle oil (LCO) Clarified Oil Product (MCB) C4s Heavy Cycle oil (HCO) Coke Feed Treat gas (H2) Effluent R101/1 R101/2 R101/3 R101/4 • FCC unit Max. Capacity 118,5 kt/month Feed properties: • S content 50-200 ppm (can be 400 ppm) Reactor: • Reactor riser – regenerator system Targets: • Max C3 mixture yield Petro-SIM™ model
- 9. • VGO HTR unit revamp • Replacement of the catalyst • Opportunity to increase gasoil yield via raising VGO conversion (from 28 wt% to max 43wt% vs. feed) • Raffinate product better quality results in better FCC yields (more hydrogenated feed to FCC). STUDIES AND CALCULATIONS ASSUMPTION AIM • Define the impact of yield increase at VGO HTR on Raffinate product properties • Evaluation of impact of HTR enhancement on FCC conversion • (investigating separately FCC and VGO HTR then the two unit together) • Find the optimal operating parameter set • Filter out the feed variance effect
- 10. • Measured data is filtered • The feed of the unit is always changing in the real life – aromatic content, S content, SPG, ABP etc. • At the model calculations the feed properties were not varied STUDIES AND CALCULATIONS MEASURED DATA AND CALCULATION 420 425 430 435 440 445 450 455 18,00 23,00 28,00 33,00 38,00 43,00 ABT(°C) VGO HTR conversion (wt%) Measured parameters ABP Volume average Boiling Temp 0,884 0,886 0,888 0,89 0,892 0,894 0,896 0,898 18,00 23,00 28,00 33,00 38,00 43,00 SPG VGO HTR conversion (wt%) Measured and Calc. parameters Bottom Spec Grav. (Measured) Bottom Spec. Grav (Model calc) • 1st study: compare measured and calculated parameters at VGO HTR by using calibrated model as base case Yellow : unit /measured parameters Blue: model/calculated parameters
- 11. Pure comparison of VGO HTR conversion to FCC yields is not entirely correct, because • Yields rather depend on FCC Unit`s parameters than VGO HTR conversion level. • Other issues in real life: • Ratio of direct and stored feed into FCC • FCC parameters, particularly Rx outlet temperature (ROT) • Operating mode, e.g. ZSM addition, ZSM-5 concentration in catalyst inventory, LLCO mode, HCO cut, etc. All in all, real life data indicated above do not help too much to define right correlation because of ever changing FCC conditions. STUDIES AND CALCULATIONS MEASURED DATA AND CALCULATION STEPS • 2nd study: real plant data about FCC feed quality vs. FCC yields 0% 10% 20% 30% 40% 50% 60% Fuel gas C3 mix C4 Gasoline LCO HCO Residue Coke Yields(wt%) FCC yields at Low Riser Temperature Low VGO HTR conversion Medium VGO HTR conversion High VGO HTR conversion 0% 10% 20% 30% 40% 50% 60% Fuel gas C3 mix C4 Gasoline LCO HCO Residue Coke Yields(wt%) FCC yields at Medium Riser Temperature Low VGO HTR conversion Medium VGO HTR conversion High VGO HTR conversion
- 12. -0,12% 1,01% 1,52% 1,91% -1,08% -0,49% -2,68% -0,06% -4,0% -3,0% -2,0% -1,0% 0,0% 1,0% 2,0% 3,0% 4,0% Fuel gas C3 mix C4 Gasoline LCO HCO Residue Coke Yield deviation Effect of higher conversion (lower SPG) • FCC max. potential throughput may decrease in real life!! (Available raffinate decreases) • The operating conditions are similar in both cases. Simplifictaions made in the model: • only direct feed source (from VGO HTR). • Rx outlet temperature (ROT) same • no ZSM addition Model calculation STUDIES AND CALCULATIONS MEASURED DATA AND CALCULATION STEPS Given ranges based on measured data Conversion increase is 4,26% • Effect of SPG decrease at FCC feed • effect of decrease feed Mass Flow • 3,31 wt% increase in conversion because of decreasing SPG • 0,95 wt% because of LSHV decreasing • summa 4,26 wt% increase in FCC conversion ~ 1,2 M$/month (at maximum FCC capacity) Rule of thumb is: if the feed SG decreases by -0,01 g/l conversion increases by 2,5% (sometimes can go up to 3-4%). FCC conversion 79,06 83,32 FCC feed t/month 118500 107000 Conversion change means naphtha and lighter products yield changing together MODEL with real SPG CALCULATIONS VGO_HTR conv 21% 40% LS VGO SPG 0.8960 0.8860 VGO_HTR
- 13. • 3rd study: VGO HTR and FCC models were modelled together (max VGO HTR feed) The reason of studying the two unit together - Although decrease of SPG at FCC feed causes conversion increase at FCC unit but if VGO HTR is operated on higher conversion the FCC can not operate on maximum capacity profit increase is not obvious (FCC feed decreases ~10%) STUDIES AND CALCULATIONS MEASURED DATA AND CALCULATION STEPS • Model calculation – conversion and yields and SPG are calulated by the model VGO_HTR conversion range 25 wt% - 40 wt% VGO_HTR Raffinate SPG (25%) = 0,8911 VGO_HTR Raffinate SPG (40%) = 0,8888 Impact on FCC yields ---- > 1,27 wt% increase in FCC conversion
- 14. Results of Pessimistic estimation (Increasing FCC conv. by only 1,27 % - 0,3 wt% increase in conversion because of decreasing SPG and 0,98 wt% because of LSHV decrease) Higher conversion in HDS (40 wt%) 697 k$/month INVESTIGATIONS AND CALCULATIONS FINANCIAL RESULTS
- 15. • Operating VGO_HTR on higher conversion is more valuable • Further questions: • SPG Sensitivity is realistic? ---> Test Run (VGO_HTR+FCC together, at the same time with VGO_HTR Guarantee test run) • Further tasks: • Calculating with Hydrogen consumption and price at financial calculation • Validating VGO HTR reactor model calculation of VGO HTR conversion effect on Raffinate SPG – Testing HCK reactor model for MHCK unit • Result of this evaluation will take attention our DS 2022 program SUMMARY
- 16. 16 Thank you for your kind attention!