Aspen HYSYS Refining
Unit Operations Guide
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Version Number: 7.0 Copyright (c) 1981-2008 by Aspen Technology, Inc. All rights reserved. Aspen HYSYS, Aspen HYSYS Refining, Aspen RefSYS, Aspen Flare System Analyzer, Aspen Energy Analyzer, Aspen HYSYS Refining CatCracker, Aspen HYSYS Pipeline Hydraulics, and the aspen leaf logo are trademarks or registered trademarks of Aspen Technology, Inc., Burlington, MA. This manual is intended as a guide to using AspenTech’s software. This documentation contains AspenTech proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the software and the application of the results obtained. Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803-5501 USA Phone: (781) 221-6400 Website http://www.aspentech.com
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Aspen HYSYS Petroleum Refining Overview 1-1
1 Aspen HYSYS Petroleum Refining Overview 1.1 Introduction to RefSYS Options ..................................................... 2 1.2 Common Property Views ................................................................ 5 1.2.1 1.2.2 1.2.3 1.2.4
Aspen HYSYS Petroleum Refining Object Palette ........................... 7 Worksheet Tab ......................................................................... 6 Notes Page/Tab ........................................................................ 7 User Variables Page/Tab .......................................................... 10
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Introduction to Aspen HYSYS Petroleum Refining
1.1 Introduction to Aspen
HYSYS Petroleum Refining
Aspen HYSYS Petroleum Refining (formerly known as “RefSYS”) is based on the flowsheet capabilities of HYSYS (use of partial information, bi-directional of information, and so forth). Existing HYSYS simulation cases can be leveraged in Aspen HYSYS Petroleum Refining adding petroleum assays information and specific refinery unit operations. In order to run Aspen HYSYS Petroleum Refining features, you have to install both Aspen HYSYS Petroleum Refining and Aspen Properties, and have the Aspen HYSYS Petroleum Refining license. For more information on the petroleum assays, refer to Chapter 2 Petroleum Assay.
The key concept of Aspen HYSYS Petroleum Refining is the petroleum assay. A petroleum assay is a vector that stores physical properties and assay properties for a specific component list. Physical properties include all properties used in a typical HYSYS simulation case. Assay properties comprise refinery related properties as cloud point, octane numbers, flash point, freeze point, sulphur content, PONA distribution, GC data and etc. A component list typically consists of library components (for instance, methane to n-pentane) and pseudocomponents (hypothetical components). Aspen HYSYS Petroleum Refining is based on a flexible structure so that no pre-defined list of pseudo-components is required. Moreover, existing lists of pseudo-components created by the HYSYS Oil Environment can be used in Aspen HYSYS Petroleum Refining. Each component stores a value of a physical and assay property. The assay properties are usually imported from an assay management system, as for instance, CrudeManager from Spiral Software Ltd. At the Simulation Environment, each stream may have its own petroleum assay, that is, the physical and assay properties of components on one stream may differ from other streams. Bulk values for assay properties are calculated using specific lumping 1-2
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Aspen HYSYS Petroleum Refining Overview 1-
rules. When process streams are mixed together on any HYSYS or Aspen HYSYS Petroleum Refining operation, a new petroleum assay is created and special blending rules are employed to recalculate the physical and assay properties. This unique architecture allows the simulation of refinery-wide flowsheets using one single component list - resulting in optimal speed performance on calculations. Moreover, the propagation of those properties allows the integration of reactor models, since the required properties are available at the feed stream to the reactor unit. The various components that comprise HYSYS/Aspen HYSYS Petroleum Refining provide an extremely powerful approach to refinery simulation modeling. At a fundamental level, the comprehensive selection of operations and property methods allows you to model a wide range of processes with confidence. Perhaps even more important is how the HYSYS/Aspen HYSYS Petroleum Refining approach to modeling maximizes your return on simulation time through increased process understanding. The key to this is the Event Driven operation. By using a ‘degrees of freedom’ approach, calculations in HYSYS/Aspen HYSYS Petroleum Refining are performed automatically. Aspen HYSYS Petroleum Refining performs calculations as soon as unit operations and property packages have enough required information. Any results, including passing partial information when a complete calculation cannot be performed, is propagated bidirectionally throughout the flowsheet. What this means is that you can start your simulation in any location using the available information to its greatest advantage. Since results are available immediately - as calculations are performed - you gain the greatest understanding of each individual aspect of your process. The multi-flowsheet architecture of HYSYS/Aspen HYSYS Petroleum Refining is vital to this overall modelling approach. Although HYSYS/Aspen HYSYS Petroleum Refining has been designed to allow the use of multiple property packages and the creation of pre-built templates, the greatest advantage of using multiple flowsheets is that they provide an extremely effective way to organize large processes. By breaking flowsheets into 1-3
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Introduction to Aspen HYSYS Petroleum Refining
smaller components, you can easily isolate any aspect for detailed analysis. Each of these sub-processes is part of the overall simulation, automatically calculating like any other operation. The design of the HYSYS/Aspen HYSYS Petroleum Refining interface is consistent, if not integral, with this approach to modelling. Access to information is the most important aspect of successful modelling, with accuracy and capabilities accepted as fundamental requirements. Not only can you access whatever information you need when you need it, but the same information can be displayed simultaneously in a variety of locations. Just as there is no standardized way to build a model, there is no unique way to look at results. HYSYS/Aspen HYSYS Petroleum Refining uses a variety of methods to display process information - individual property views, the PFD, Workbook, Databook, graphical Performance Profiles, and Tabular Summaries. Not only are all of these display types simultaneously available, but through the object-oriented design, every piece of displayed information is automatically updated whenever conditions change. The inherent flexibility of HYSYS/Aspen HYSYS Petroleum Refining allows for the use of third party design options and custom-built unit operations. These can be linked to Aspen HYSYS Petroleum Refining through OLE Extensibility. Aspen HYSYS Petroleum Refining also offers an assortment of utilities which can be attached to process streams and unit operations. These tools interact with the process and provide additional information. All standard HYSYS unit operations are explained in the HYSYS Operations Guide and Aspen HYSYS Petroleum Refining unit operations are explained in this guide. The unit operations can be used to assemble flowsheets. By connecting the proper unit operations and streams, you can model a wide variety of refinery processes. Included in the available operations are those which are governed by thermodynamics and mass/energy balances, such as Heat Exchangers, Separators, and Compressors, and the 1-4
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Aspen HYSYS Petroleum Refining Overview 1-
logical operations like the Adjust, Set, and Recycle. A number of operations are also included specifically for dynamic modelling, such as the Controller, Transfer Function Block, and Selector. The Spreadsheet is a powerful tool, which provides a link to nearly any flowsheet variable, allowing you to model “special” effects not otherwise available in HYSYS/Aspen HYSYS Petroleum Refining.
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Common Property Views
In modelling operations, HYSYS/Aspen HYSYS Petroleum Refining uses a Degrees of Freedom approach, which increases the flexibility with which solutions are obtained. For most operations, you are not constrained to provide information in a specific order, or even to provide a specific set of information. As you provide information to the operation, HYSYS/Aspen HYSYS Petroleum Refining calculates any unknowns that can be determined based on what you have entered. For instance, consider the Pump operation. If you provide a fully-defined inlet stream to the pump, HYSYS/Aspen HYSYS Petroleum Refining immediately passes the composition and flow to the outlet. If you then provide a percent efficiency and pressure rise, the outlet and energy streams is fully defined. If, on the other hand, the flowrate of the inlet stream is undefined, HYSYS/Aspen HYSYS Petroleum Refining cannot calculate any outlet conditions until you provide three parameters, such as the efficiency, pressure rise, and work. In the case of the Pump operation, there are three degrees of freedom, thus, three parameters are required to fully define the outlet stream. All information concerning a unit operation can be found on the tabs and pages of its property view. Each tab in the property view contains pages which pertain to a certain aspect of the operation, such as its stream connections or physical parameters (for example, pressure drop and energy input).
1.2 Common Property Views Each operation in HYSYS contains some common information and options. These information and options are grouped into common tabs and pages. The following sections describe the common tabs and pages in HYSYS operation property view.
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Aspen HYSYS Petroleum Refining Overview 1-
1.2.1 Aspen HYSYS Petroleum Refining Object Palette The Aspen HYSYS Petroleum Refining object palette enables you to add Aspen HYSYS Petroleum Refining operations to the main PFD. The Aspen HYSYS Petroleum Refining operations are:
Refer to FCC Operation Guide for more information on FCC Reactor.
• • • • • • • •
Assay Manipulator Catalytic Reformer FCC Reactor Hydrocracker Petroleum Column Petroleum Feeder Petroleum Yield Shift Reactor Product Blender
To access the Aspen HYSYS Petroleum Refining object palette do one of the following: • •
Refining object palette
In the main case (Simulation) environment, press F6. In the main case (Simulation) environment, select Flowsheet | RefSYS Operations command from the menu bar.
1.2.2 Worksheet Tab The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the air cooler. The Conditions and Composition pages contain selected information from the corresponding pages of the Worksheet tab for the stream property view. The Properties page displays the property correlations of the inlet and outlet streams of the unit operations. The following is a list of the property correlations: • Vapour / Phase Fraction
• Vap. Frac. (molar basis)
• Temperature
• Vap. Frac. (mass basis)
• Pressure
• Vap. Frac. (volume basis)
• Actual Vol. Flow
• Molar Volume
• Mass Enthalpy
• Act. Gas Flow
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Common Property Views
• Mass Entropy
• Act. Liq. Flow
• Molecular Weight
• Std. Liq. Flow
• Molar Density
• Std. Gas Flow
• Mass Density
• Watson K
• Std. Ideal Liquid Mass Density
• Kinematic Viscosity
• Liquid Mass Density
• Cp/Cv
• Molar Heat Capacity
• Lower Heating Value
• Mass Heat Capacity
• Mass Lower Heating Value
• Thermal Conductivity
• Liquid Fraction
• Viscosity
• Partial Pressure of CO2
• Surface Tension
• Avg. Liq. Density
• Specific Heat
• Heat of Vap.
• Z Factor
• Mass Heat of Vap.
The Heat of Vapourisation for a stream in HYSYS is defined as the heat required to go from saturated liquid to saturated vapour.
The PF Specs page contains a summary of the stream property view Dynamics tab. The PF Specs page is relevant to dynamics cases only.
1.2.3 Notes Page/Tab The Notes page/tab provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general. Figure 1.1
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Adding Notes To add a comment or information in the Notes page/tab: 1. Go to the Notes page/tab. 2. Use the options in the text editor toolbar to manipulate the appearance of the notes. The following table lists and describes the options available in the text editor toolbar. Object
Icon
Description
Font Type
Use the drop-down list to select the text type for the note.
Font Size
Use the drop-down list to select the text size for the note.
Font Colour
Click this icon to select the text colour for the note.
Bold
Click this icon to bold the text for the note.
Italics
Click this icon to italize the text for the note.
Underline
Click this icon to underline the text for the note.
Align Left
Click this icon to left justify the text for the note.
Centre
Click this icon to center justify the text for the note.
Align Right
Click this icon to right justify the text for the note.
Bullets
Click this icon to apply bullets to the text for the note.
Insert Object
Click this icon to insert an object (for example an image) in the note.
3. Click in the large text field and type your comments. The date and time when you last modified the information in the text field will appear below your comments. The information you enter in the Notes tab or page of any operations can also be viewed from the Notes Manager property view.
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Common Property Views
Notes Manager The Notes Manager lets you search for and manage notes for a case. To access the Notes Manager do one of the following: • •
Select Notes Manager command from the Flowsheet menu. Press the CTRL G hot key.
Figure 1.2 Click the Plus icon to expand the tree browser.
View/Add/Edit Notes To view, add, or edit notes for an object, select the object in the List of Objects group. Existing object notes appear in the Note group. • •
To add a note, type the text in the Note group. A time and date stamp appears automatically. To format note text, use the text tools in the Note group toolbar. You can also insert graphics and other objects.
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Aspen HYSYS Petroleum Refining Overview 1-
• •
Click the Clear button to delete the entire note for the selected object. Click the View button to open the property view for the selected object.
Search Notes The Notes Manager allows you to search notes in three ways: • •
•
Select the View Objects with Notes Only checkbox (in the List of Objects group) to filter the list to show only objects that have notes. Select the Search notes containing the string checkbox, then type a search string. Only objects with notes containing that string appear in the object list. You can change the search option to be case sensitive by selecting the Search is Case Sensitive checkbox. The case sensitive search option is only available if you are searching by string. Select the Search notes modified since checkbox, then type a date.Only objects with notes modified after this date will appear in the object list.
1.2.4 User Variables Page/Tab The User Variables page or tab enables you to create and implement variables in the HYSYS simulation case. Figure 1.3
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Common Property Views
The following table outlines options in the user variables toolbar: Object
Icon
Function
Current Variable Filter drop-down list
Enables you to filter the list of variables in the table based on the following types: • All • Real • Enumeration • Text • Code Only • Message
Create a New User Variable icon
Enables you to create a new user variable and access the Create a New User Variable property view.
Edit the Selected User Variable icon
Enables you to edit the configuration of an existing user variable in the table. You can also open the edit property view of a user variable by double-clicking on its name in the table.
Delete the Selected User Variable icon
Enables you to delete the select user variable in the table. HYSYS requires confirmation before proceeding with the deletion. If a password has been assigned to the User Variable, the password is requested before proceeding with the deletion.
Sort Alphabetically icon
Enables you to sort the user variable list in ascending alphabetical order.
Sort by Execution Order icon
Enables you to sort the user variable list according to the order by which they are executed by HYSYS. Sorting by execution order is important if your user variables have order dependencies in their macro code. Normally, you should try and avoid these types of dependencies.
Move Selected Variable Up In Execution Order icon
Enables you to move the selected user variable up in execution order.
Move Selected Variable Down In Execution Order icon
Enables you to move the selected user variable down in the execution order.
Show/Hide Variable Enabling Checkbox icon
Enables you to toggle between displaying or hiding the Variable Enabling checkboxes associated with each user variable. By default, the checkboxes are not displayed.
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Aspen HYSYS Petroleum Refining Overview 1-
Add a User Variable To add a user variable: 1. Access the User Variables page or tab in the object property view. 2. Click the Create a New User Variable icon. The Create New User Variable property view appears. Create a New User Variable icon
3. In the Name field, type in the user variable name. 4. Fill in the rest of the user variable parameters as indicated by the figure below. Figure 1.4
For more information on the user variables, refer to Chapter 5 - User Variables from HYSYS Customization Guide.
Select the data type, dimension, and unit type using these dropdown list. These tabs contain more options for configuring the user variable. Code field Allows you to add password security to the user variable.
You can define your own filters on the Filters tab of the user variable editing property view.
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Common Property Views
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Petroleum Assay
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2 Petroleum Assay
2.1 Introduction................................................................................... 2 2.1.1 Centroid Point.......................................................................... 4 2.2 Petroleum Assay Manager Property View....................................... 5 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7
Adding Petroleum Assays .......................................................... 7 Viewing Petroleum Assays ......................................................... 7 Copying Petroleum Assays......................................................... 8 Deleting Petroleum Assays......................................................... 8 Importing Petroleum Assays ...................................................... 9 Exporting Petroleum Assays..................................................... 15 Creating User-Defined Blending Rules ....................................... 17
2.3 The Petroleum Assay Property View ............................................ 20 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6
Information Tab ..................................................................... 22 GC Data Tab .......................................................................... 35 Analysis Tab .......................................................................... 42 Estimation Tab ....................................................................... 43 Plots Tab ............................................................................... 45 Notes Tab.............................................................................. 45
2.4 Aspen HYSYS Petroleum Refining Unit Tags................................. 46
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Introduction
2.1 Introduction In refinery, the typical crude oil stream consist of the following characteristic: •
A continues mixture of many naturally occurring hydrocarbons with boiling points ranging from -160°C (Methane) to more than 1500°C.
•
Heavy fractions that are not mixtures of discretely identifiable components. These heavy fractions are often lumped together and identified as the plus-fraction starting from C7+ to C12+.
A proper description of the physical properties of the plusfractions is essential for reliable phase behaviour calculations and compositional modelling studies. Aspen HYSYS Petroleum Refining contains a data base that you can use to store and calculate the physical and petroleum properties of the crude oil stream. This data base is called a petroleum assay. A petroleum assay is a vector that stores physical properties and assay properties for a specific component list. Physical properties include all properties used in a typical HYSYS simulation case. Assay properties comprise refinery related properties as cloud point, octane numbers, flash point, freeze point, sulphur content, PONA distribution, GC data and etc. A component list typically consists of library components (for instance, methane to n-pentane) and pseudo-components (hypothetical components). Aspen HYSYS Petroleum Refining is based on a flexible structure so that no pre-defined list of pseudo-components is required. Moreover, existing lists of pseudo-components created by the HYSYS Oil Environment can be used in Aspen HYSYS Petroleum Refining. Each component stores a value of a physical and assay property.
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Petroleum Assay
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The assay properties are usually imported from an assay management system, as for instance, CrudeManager Aspen HYSYS Petroleum Refining Link from Spiral Software Ltd. At the Simulation Environment, each stream may have its own petroleum assay, that is, the physical and assay properties of components on one stream may differ from other streams. Bulk values for assay properties are calculated using specific lumping rules. When process streams are mixed together on any HYSYS or Aspen HYSYS Petroleum Refining operation, a new petroleum assay is created and special blending rules are employed to recalculate the physical and assay properties. If you do not have the Aspen HYSYS Petroleum Refining license, you cannot create or import a petroleum assay using the options in the Petroleum Assay Manager property view.
You can create a petroleum assay using the options in the Petroleum Assay Manager property view or the Oil Manager tab. The differences between the petroleum assays created in Petroleum Assay Manager and Oil Manager are listed in the following table: Oil Manager
Petroleum Assay Manager
Each petroleum assay have its own component list.
One component list is shared among multiple assays.
Property values are not calculated based on blending rule, because each assay has its own component list.
Contains blending rule equation for more accurate calculation.
Enables you to modify a few petroleum properties.
Enables you to modify more petroleum properties.
Simplified option to characterize a petroleum assay.
Advanced option to characterize a petroleum assay.
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Introduction
2.1.1 Centroid Point In Aspen HYSYS Petroleum Refining, the centroid boiling point of the cuts, represented by hypocomponents initial boiling points (IBPs) and final boiling points (FBPs), and their yields are calculated by: 1. Plotting the boiling point curves of the cuts in the crude oil stream versus their yields. 2. Each cut is identified by an initial and final boiling point temperature. 3. The centroid point is the boiling point temperature associated with the mid percent-yield of the corresponding cut. The mid percent-yield is the half-way % volume point between the % volume of the initial and final boiling point. Refer to the figure below: Figure 2.1
Temperature
FBPn
Centroidn IBPn Vol 1
Vol 2 Vol 1 = Vol 2
% Volume
The final boiling point temperature is assigned as the hypocomponent’s boiling point temperature. The centroid boiling point is used to estimate the physical properties of the component.
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Petroleum Assay
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4. Step #2 and #3 are repeated to generate the boiling point temperatures for all of the hypocomponents. 5. For library components, the centroid boiling temperature is set to their normal boiling point.
2.2 Petroleum Assay Manager Property View If you do not have the Aspen HYSYS Petroleum Refining license, the HYSYS simulation case will have no access to any petroleum assay.
The Petroleum Assay Manager property view enables you to create, manipulate, import, and export the petroleum assay. Figure 2.2
To access the Petroleum Assay Manager property view: 1. Enter the Basis environment of the simulation case. 2. In the menu bar, select Basis | Basis Manager to open the Simulation Basis Manager property view.
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Petroleum Assay Manager Property
3. Click the Extend Simulation Basis Manager button. To create a petroleum assay, you must specify a list of components and configure a fluid package. If you are importing a petroleum assay from a file, you do not have to specify components or a fluid package.
The following table lists and describes the objects in the Petroleum Assay Manager property view: Object
Description
Petroleum Assays list
Displays the petroleum assays available in the simulation case.
View button
Opens the Petroleum Assay property view of the selected petroleum assay.
Add button
Creates a blank petroleum assay, where you can enter your own petroleum assay properties.
Delete button
Deletes the selected petroleum assay from the simulation case.
Copy button
Creates a copy of the selected petroleum assay.
Import button
Imports a petroleum assay from an external file. You can import petroleum assay from three types of files: HYSYS (*.pet), Comma Separated Value File (*.csv), and XML File (*.xml).
Export button
Exports the selected petroleum assay to an external file. You can export the petroleum assay into four types of files: Spiral CrudeManager, HYSYS, Comma Separated Value File, and XML File.
Property Blending Methods table
Displays the blending rules/equations used to calculation the petroleum properties of the selected petroleum assay. You can change the equations used to calculate the petroleum properties by selecting a different blending rule in the drop-down list.
Petroleum radio button
Filters the information in the Property Blending Methods table to display only HYSYS default petroleum properties.
User radio button
Filters the information in the Property Blending Methods table to display only HYSYS non-default/ user created petroleum properties.
View Macro button
Enables you to access the Blending Macros property view and create user define blending rules. This button is only available if a petroleum property contains a user define blending macro.
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Petroleum Assay
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2.2.1 Adding Petroleum Assays To add a petroleum assay: 1. Open the Simulation Basis Manager property view. Click the Home View icon to open the Simulation Basis Manager property view. Home View icon
2. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 3. Click the Add button. The Petroleum Assay property view appears.
2.2.2 Viewing Petroleum Assays To view a petroleum assay: 1. Open the Simulation Basis Manager property view. Press CTRL B to open the Simulation Basis Manager property view. 2. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 3. Select the petroleum assay you want to view from the list in the Petroleum Assays group. 4. Click the View button. The Petroleum Assay property view appears.
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Petroleum Assay Manager Property
2.2.3 Copying Petroleum Assays To copy a petroleum assay: 1. Open the Simulation Basis Manager property view. Select Basis | Basis Manager from the menu bar to open the Simulation Basis Manager property view. 2. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 3. Select the petroleum assay you want to copy from the list in the Petroleum Assays group. 4. Click the Copy button. The Petroleum Assay property view of the copied assay appears. The copied petroleum assay has a default name of Petroleum Assay - n, where n is an integer value.
2.2.4 Deleting Petroleum Assays To delete a petroleum assay: 1. Open the Simulation Basis Manager property view. Click the Home View icon to open the Simulation Basis Manager property view. Home View icon
2. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 3. Select the petroleum assay you want to delete from the list in the Petroleum Assays group. 4. Click the Delete button. Aspen HYSYS Petroleum Refining removes the selected petroleum assay from the list. Aspen HYSYS Petroleum Refining will not ask for confirmation when deleting assays.
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Petroleum Assay
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2.2.5 Importing Petroleum Assays You may import petroleum assays in HYSYS, XML, .CSV, or PIMS formats. You can also import an H/CAMS CAL-II assay by editing the CAL-II output file as described in the Section - Converting an H/CAMS assay to PIMS format, and importing the data as a PIMS assay. For any selected format, the procedure below imports a component list, petroleum assay properties, and/or property package information, so a complete fluid package is created: 1. Press CTRL B to open the Simulation Basis Manager. 2. Click Extend Simulation Basis Manager. The Petroleum Assay Manager opens. 3. Click Import. The Assay Import property view opens. Figure 2.3
4. Select the type of assay you want to import by clicking on the appropriate radio button. Refer to Appendix A.6 PET Files for more information on PET files.
•
HYSYS imports a PET (HYSYS petroleum assay) file. The PET file contains the component list, physical properties, petroleum properties, fluid packages, reactions, and component maps associated to the petroleum assay. User Property names from HYSYS must be edited to use an alias in order for the imported properties to be passed to the proper Aspen HYSYS Petroleum Refining calculations. See Appendix - HYSYS User Property Aliases for Aspen HYSYS Petroleum Refining for a list of the aliases.
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Petroleum Assay Manager Property
•
Comma Separated Value File imports a CSV (Comma Separated Value) file. The CSV file is a simple structured data file. The file contains a table of components, and the component’s molecular weight, normal boiling point, specific gravity, and petroleum properties.
Refer to Appendix A.5 Petroleum Assay XML Files for more information on XML files.
•
XML File imports an XML file. The XML file contains the name of the petroleum assay, description, created date, last modified date, a list of components available, and the molecular weight, normal boiling point, specific gravity, and petroleum properties of each component.
Refer to PIMS for more information on PIMS file.
•
Refer to Appendix A.4 Comma Separated Value Files for more information on CSV files.
PIMS Format imports a PIMS assay table file. The PIMS file contains all the necessary assay data, much like the CSV file. However the PIMS data variable string tag is different than Aspen HYSYS Petroleum Refining data variable string tag. So Aspen HYSYS Petroleum Refining needs to map its variables to PIMS variables. Aspen HYSYS Petroleum Refining imports the following information from the petroleum assay:
•
Components. If there is no list of components or the default component list is incomplete, Aspen HYSYS Petroleum Refining creates a new list of components based on the components in the imported petroleum assay.
•
Fluid Package. If the existing fluid package does not contain the same component list as the imported petroleum assay or there are no fluid package, Aspen HYSYS Petroleum Refining automatically creates a new fluid package with Peng-Robinson as the default property package and attaches a new component list based on the imported petroleum assay. (To change the property package of the new fluid package, open the Fluid Package property view and select a different property package.)
•
Physical Properties. Aspen HYSYS Petroleum Refining imports the following three critical physical properties: molecular weight, centroid boiling point, and specific gravity. The rest of the physical properties are calculated based on the three critical properties.
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•
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Petroleum Properties. Aspen HYSYS Petroleum Refining imports all petroleum properties.
If the petroleum assay data file contains petroleum properties outside Aspen HYSYS Petroleum Refining petroleum property list, Aspen HYSYS Petroleum Refining imports the data from the non-default petroleum properties and designates the non-default petroleum properties as UserProp-n, where n is an integer value. If the petroleum assay data file has no values for a petroleum property, the system leaves the petroleum property blank.
5. Click the Continue button. A file browser opens. 6. Locate and select the assay file you want to open and click the Open button. If you are importing a PIMS Assay, follow the additional steps described in Section - PIMS Assay Import Additional Steps.
PIMS Assay Import Additional Steps If you are importing PIMS assay, there are more steps to follow after completing the procedure above, Importing a Petroleum Assay:
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Petroleum Assay Manager Property
1. After selecting the PIMS file, the Import PIMS Data property view appears: Figure 2.4
All the data shown initially in the table of the Import PIMS Data property view are default values not related to the csv file previously selected. To map the PIMS variable data to the Aspen HYSYS Petroleum Refining variable data, you must browse to and select the PIMS String Table.
2. In the Import PIMS Data property view, click Import Data String. Refer to Section 2.4 Aspen HYSYS Petroleum Refining Unit Tags for more
3. Select the PIMS String Table file (*.sdb extension) to map the PIMS variable tag with an Aspen HYSYS Petroleum Refining variable tag and click Open. (The default name and location for the data string file is: \[install location]\paks\PIMSAssay.sdb) The PIMS String Table file (*.sdb) consists of 3 sections: •
The Property Tag section, where the text used to for the PIMS petroleum property variables is mapped to the text of the Aspen HYSYS Petroleum Refining property description. Below is a sample of the PIMS tag (left) and associated Aspen HYSYS Petroleum Refining tag (right): - ISPG = "Standard Liquid Density" 2-12
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IFVT = "Boiling Temperature" VBAL = "Volume Fraction" IMWT = "Molecular Weight" IACD = "Acidity"
•
The Component Tag section, where the text used to represent PIMS components is mapped to the text of the Aspen HYSYS Petroleum Refining components: Below is a sample of the PIMS tag (left) and associated Aspen HYSYS Petroleum Refining tag (right): - NC1 = "Methane" - NC2 = "Ethane" - NC3 = "Propane" - IC4 = "I-Butane" - NC4 = "N-Butane" - IC5 = "I-Pentane"
•
The Unit Tag section. The Unit Tag section is optional. It maps PIMS unit abbreviations to Aspen HYSYS Petroleum Refining units if the PIMS Assay was stored using unit syntax other than that which Aspen HYSYS Petroleum Refining recognizes. You can add this section by appending a line for each “foreign” unit in the following format: UNIT_{PIMS property tag} = "{unit name}" for example: UNIT_IFVT = "C" means the PIMS property tag "IFVT" has units in C (Celcius). Refer to Section 2.4 - Aspen HYSYS Petroleum Refining Unit Tags for a table of Aspen HYSYS Petroleum Refining unit symbols.
4. Click the Import PIMS Data button. Aspen HYSYS Petroleum Refining reads in all the data from the assay table using the mapping instructions from the string table, and populates the list in the Import PIMS Data property view.
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Petroleum Assay Manager Property
Converting an H/CAMS assay to PIMS format There is no direct import for H/CAMS data. However, you can use CAL/LINK or PIMS to generate a PIMS assay file, and then import the PIMS file into Aspen HYSYS Petroleum Refining. If you do not license either program, you can develop a PIMS or .csv format file in a manual editor. You must make some minor edits to the PIMS file output from Cal-II, and create an .sdb mapping file for the PIMS to Aspen HYSYS Petroleum Refining import. Here is the workflow for creating and converting the Cal-II output file: In Cal-II 1. Create slate of components. 2. Identify properties of interest. 3. Generate the PIMS file from Cal-II In a text editor: Open the Cal-II PIMS file. Using an SPG line as an example, the Cal-II line format looks like this: SPGR01;Specific Gravity;0,7405 1. Remove any lines with the property value of “na”. 2. Use search and replace to change all of the commas ( , ) to dots, and all of the semicolons (;) to commas: SPGR01,Specific Gravity,0.7405 3. Make sure each property name begins with the correct PIMS tag. If there is no PIMS tag, add a PIMS tag. If there is a PIMS tag, but it is different from that recognized by Aspen HYSYS Petroleum Refining, then replace the PIMS tag with an Aspen HYSYS Petroleum Refining PIMS tag. Current valid PIMS tags are listed in the file [install dir]\paks\PIMSAssay.sdb. Usually the valid PIMS tag is the existing string with a leading “I” added, for example: 2-14
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ISPGR01;Specific Gravity;0,7405 Notable exceptions are CutTemperature with a PIMS tag of “IFVTR”, Mass Fraction with a PIMS tag of “WBAL” and Volume Fraction with a PIMS tag of “VBAL.” 4. Save the file with a .csv extension, and close. Now you must prepare the .sdb file to import along with the PIMS file. 1. Open the [install dir]\paks\PIMSAssay.sdb “string table” file. See Section - PIMS Assay Import Additional Steps above for a description of the sections of this file. 2. Save the file to a new name. 3. Check the following factors: If you have a user assigned tag not present in the .sdb file, enter it with a text description in the first section. Make sure every Component name has a description. If there is no description, the component will not be passed in the import process. At minimum, the value must be ‘’ ‘’ Optionally, append unit-correcting strings to the end of the file if the assay was stored using unit strings other than those Aspen HYSYS Petroleum Refining recognizes. See Section - PIMS Assay Import Additional Steps and Section 2.4 - Aspen HYSYS Petroleum Refining Unit Tags for more information 4. Save the file with an .sdb extension and close. You can now import the .csv file as a PIMS assay in the normal way. See Section 2.2.5 - Importing Petroleum Assays.
2.2.6 Exporting Petroleum Assays To export a petroleum assay: 1. Open the Simulation Basis Manager property view. Select Basis | Basis Manager from the menu bar to open the Simulation Basis Manager property view. 2-15
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Petroleum Assay Manager Property
2. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 3. Select the petroleum assay you want to export from the list in the Petroleum Assays group. 4. Click the Export button. The Assay Export property view appears. Figure 2.5
5. Select the file type for the exported assay by clicking on the appropriate radio button. Refer to Appendix A.7 Spiral Files for more information on the Spiral file.
•
Spiral Crude Manager radio button allows you to export the assay as a Spiral file. The Spiral file contains the name of the petroleum assay, description, created date, last modified date, a list of components available, and the molecular weight, normal boiling point, specific gravity, and petroleum properties of each component.
Refer to Appendix A.6 PET Files for more information on PET files.
•
HYSYS radio button allows you to export the assay as a PET (HYSYS petroleum assay) file. The PET file contains the component list, physical properties, petroleum properties, fluid packages, reactions, and component maps associated to the petroleum assay.
Refer to Appendix A.4 Comma Separated Value Files for more information on CSV files.
•
Comma Separated Value File radio button allows you to export the assay as a CSV file. The CSV file is a simple structured data file. The file contains a table of components, and the component’s molecular weight, normal boiling point, specific gravity, and petroleum properties.
Refer to Appendix A.5 Petroleum Assay XML Files for more information on XML files.
•
XML File radio button allows you to export the assay as a *.xml file. The XML file contains the name of the petroleum assay, description, created date, last modified date, a list of components available, and the molecular weight, normal boiling point, specific gravity, and petroleum properties of each component.
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With the exception of the PET file, the following information are exported to the petroleum assay files:
•
Petroleum assay name
•
Petroleum assay description
•
Petroleum assay creation and last modified dates
•
Component list
•
Component molecular weight
•
Component normal boiling point
•
Component specific gravity
•
Component petroleum properties.
The petroleum assay physical properties are not exported.
6. Click the Continue button. The File Selection for Exporting Petroleum Assay property view appears. 7. Select a location for the assay file using the Save in dropdown list, and type the name of the exported assay file in the File name field. 8. Click the Save button.
2.2.7 Creating User-Defined Blending Rules For more information, refer to Section 11.14 Macro Language Editor in the HYSYS User Guide.
Aspen HYSYS Petroleum Refining lets you create your own calculation blending method for the petroleum properties. The new blending rule method is created in the Macro Language Editor property view. To create a new blending rule method for a petroleum property: 1. Enter the Simulation Basis Environment. 2. Open the Simulation Basis Manager property view.
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Petroleum Assay Manager Property
3. Click the Extend Simulation Basis Manager button. The Petroleum Assay Manager property view appears. 4. In the Property Blending Methods group, select the Petroleum radio button. 5. In the Petroleum Property table, scroll up and down until you find the petroleum property you want to manipulate. Figure 2.6
6. Under the Blending Rule column, select the cell beside the petroleum property. 7. Click the down arrow select User Macro.
to access the drop-down list, and
Figure 2.7
8. Click the View Macro button that appears. Figure 2.8
The Blending Macros property view appears.
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9. Double click the selected property to custom define a blending rule. Figure 2.9 Double click to custom define the blending rule
Click to delete the user defined rule.
The Edit Existing Code of property view appears. For more information on the options in Editing Existing Code of property view, refer to Section 5.4 - User Variable Property View in the HYSYS Customerization Guide.
10. In the Editing Existing Code of property view, click the Show/Hide Variable Details icon options in the view.
to access more
Figure 2.10
Use the options in the Editing Existing Code of property view to configure the new petroleum property blending rule. 2-19
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The Petroleum Assay Property View
11. Click the OK button to accept the new petroleum assay blending rule.
2.3 The Petroleum Assay Property View The Petroleum Assay property view allows you to specify and manipulate the properties of the petroleum assay. Figure 2.11
The property view contains six tabs and a status bar: •
The Information tab contains all the options necessary to create a petroleum assay.
•
The GC Data tab allows you to manipulate the GC data of the petroleum assay.
•
The Analysis tab enables you to view the types of calculation errors that occur in the petroleum assay.
•
The Estimation tab enables you to import certain petroleum assay property values based on assumptions and equations.
•
The Plots tab displays the petroleum properties of the petroleum assay in graph format.
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•
The Notes tab allows you to specify information regarding the simulation case.
•
The status bar indicates the status of the petroleum assay.
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The Petroleum Assay Property View
2.3.1 Information Tab The Information tab allows you to specify the name, associated fluid package, description, properties, and composition of the petroleum assay. Figure 2.12
The following table lists and describes the objects available in the Information tab: Object
Description
Name field
Allows you to specify the name of the petroleum assay. The name you supply also appears in the title bar of the Petroleum Assay property view.
Associated Fluid Pkg drop-down list
Allows you to select the fluid package associated with the petroleum assay.
Created field
Displays the date and time when the petroleum assay was created.
Modified field
Displays the date and time when the petroleum assay was last modified.
Description field
Allows you to supply information about the petroleum assay.
Edit Properties button
Allows you to access the Editing Properties property view, where you can manipulate the petroleum property values.
Edit Composition button
Allows you to access the Petroleum Assay Composition property view, where you can enter the composition of the petroleum assay.
Edit Bulk Properties button
Enables you to access the Edit Bulk Properties Property View.
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For more information on FCC, refer to FCC Operation Guide.
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Object
Description
Reactor Type column
Displays the Aspen HYSYS Petroleum Refining reactor: FCC. The FCC reactor handles petroleum assay differently than the standard HYSYS reactors.
Is Ready? column
Displays whether the petroleum assay has been configured to handle the associate reactors. • Yes means the petroleum assay can be use for material streams flowing through the reactor. • No means the petroleum assay cannot be use for material streams flowing through the reactor.
Make Ready? column
Allows you to configure/prepare the petroleum assay to handle the associate reactor, before entering the simulation environment. Select the appropriate checkbox to prepare the petroleum assay.
To obtain the CrudeManager Aspen HYSYS Petroleum Refining Link, contact your local AspenTech
Crude Manager button
Refer to Importing HYSYS Assays and Importing a PIMS Assay Table sections for more information.
Hysys Oil Environment button
Allows you to access the CrudeManager Link and edit the petroleum assay using the assay management system from Spiral Software Ltd. In CrudeManager Link there are two different methods to characterizing a petroleum assay: • Lite. The method uses simple and smooth cuts to calculate the petroleum properties based on the user provided experimental data. • Advanced. This method uses statistical and prediction calculation models to calculate the petroleum properties based on the user provided experimental data. CrudeManager Link carries an HPI standard data base. Enables you to easily import old HYSYS assays and PIMS assay table into an Aspen HYSYS Petroleum Refining petroleum assay.
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The Petroleum Assay Property View
Edit Bulk Properties Property View The Edit Bulk Properties property view enables you to specify properties that apply to the entire petroleum assay, not properties that just applies to individual components. Figure 2.13
The current bulk properties available for specification are: •
Initial boiling point temperature
•
Final boiling point temperature
Editing Properties Property View The Editing Properties for Petroleum Assay property view, allows you to modify the property values of the petroleum assay. Figure 2.14
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The Editing Properties property view is split into two panes. •
The pane on the left allows you to filter and select which properties you want to manipulate.
•
The pane on the right provides options for you to enter the new property values.
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The Petroleum Assay Property View
The Sort By group in the left pane, allows you to filter the list of properties, in the tree browser below the group, based on the selected radio button: Click the Plus ( ) and Minus ( ) icons to expand and collapse the branches in the tree browser.
•
Property Name. Displays all the properties available (in Aspen HYSYS Petroleum Refining) in alphabetical order.
•
Group. Sorts and categorizes the properties based on their characteristic (for example, Thermodynamic, Property Package, Physical, User specified, Petroleum, and so forth).
•
Type. Sorts the properties based on the value type they provide (for example, single point value or multiple curve/ plot values).
•
Modify Status. Splits the properties between those that have been already modified by you, and those that still have their default values.
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Petroleum Assay Composition Property View The Petroleum Assay Composition property view, allows you to modify the mole fraction of the components in the petroleum assay. Figure 2.15
The following table lists and describes the objects in the Petroleum Assay Composition property view: Object
Description
Component table
Allows you to specify the mole fraction of the components in the petroleum assay.
Normalize button
Allows you to normalize the total composition value to 1.
Cancel button
Exits the Petroleum Assay Composition property view without saving any of the changes.
Accept button
Exits the Petroleum Assay Composition property view and save the changes.
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The Petroleum Assay Property View
Importing HYSYS Assays An Aspen HYSYS Petroleum Refining petroleum assay contains an option that enables you to re-use assay information from old HYSYS cases and place them into an Aspen HYSYS Petroleum Refining petroleum assay. There are two ways of importing the assay information: •
You can import the assay into a petroleum assay while keeping the original component list from the old HYSYS case.
•
You can import the assay information from the old HYSYS case and apply the information to a new component list.
You cannot re-use/import the blending information from an old HYSYS assay into an Aspen HYSYS Petroleum Refining petroleum assay. The blend/cut information is always recalculated during the import process (using the predefined component list).
The imported HYSYS assay information does not contain any petroleum property information. So after you have imported the HYSYS assay into a petroleum assay, you can supply the petroleum property data using the Crude Manager or Edit Properties option in the Information Tab of the Petroleum Assay property view.
Keeping the Original Component List To import the HYSYS assay information into an Aspen HYSYS Petroleum Refining petroleum assay, while keeping the existing component list from the old case: 1. Open a HYSYS case with existing HYSYS assay. 2. Enter the Simulation Basis Environment.
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3. Open the Simulation Basis Manager property view, by selecting Basis | Basis Manager command in the menu bar. Figure 2.16
4. Click the Extend Simulation Basis Manager button. 5. In the Petroleum Assay Manager property view, click the Add button. 6. In the Petroleum Assay property view, select the fluid package (associated to the HYSYS Oil Characterization assay) in the Associated Fluid Pkg drop-down list. Figure 2.17
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The Petroleum Assay Property View
7. Click the HYSYS Oil Environment button. Figure 2.18
8. In the Available Assays property view, open the Select Assay drop-down list and select the assay you want to import to Aspen HYSYS Petroleum Refining. 9. Click the OK button.
Using a New Component List To import the HYSYS assays information into an Aspen HYSYS Petroleum Refining petroleum assay with a new component list: 1. Open a HYSYS case with existing HYSYS assay. 2. Enter the Simulation Basis Environment. 3. Open the Simulation Basis Manager property view, by selecting Basis | Basis Manager command in the menu bar. 4. Do one of the following: •
Import a component list and create a new fluid package to be associated to the imported component list.
•
Create a new component list from scratch and create a new fluid package to be associated to the new component list.
•
Import a fluid package containing the new component list.
5. In the Simulation Basis Manager property view, click the Oil Manager tab.
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6. Open the drop-down list in the Associated Fluid Package field and select the copied fluid package. Figure 2.19
7. Click the Extend Simulation Basis Manager button. 8. In the Petroleum Assay Manager property view, click the Add button. 9. In the Petroleum Assay property view, select the copied fluid package in the Associated Fluid Pkg drop-down list. Figure 2.20
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The Petroleum Assay Property View
10. Click the HYSYS Oil Environment button. 11. In the Available Assays property view, open the Select Assay drop-down list and select the assay you want to import into Aspen HYSYS Petroleum Refining. Figure 2.21
12. Click the OK button.
Importing a PIMS Assay Table There are two methods of importing PIMS assay table: •
Importing the entire information (assay properties and component list) from the PIMS assay table. Refer to Section 2.2.5 - Importing Petroleum Assays for more information.
•
Importing only the assay properties information from the PIMS assay table (See below).
Import Only PIMS Assay Properties To import only the assay properties from the PIMS assay table: 1. Open an existing simulation case or start a new case. If you are starting a new case, enter the component list and select a property package for the fluid package. 2. Click the Extend Simulation Basis Manager button. 3. On the Aspen HYSYS Petroleum Refining Petroleum Assay Manager property view, click Add button.
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4. In the new Petroleum Assay property view, select the fluid package in the Associated Fluid Pkg drop-down list. Figure 2.22
5. Click the HYSYS Oil Environment button. Figure 2.23
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The Petroleum Assay Property View
6. In the Petroleum Assay property view, click Import PIMS Assay to Oil Environment button. Figure 2.24
7. In the file browser, locate and select the PIMS assay table file (.csv format, by default under the [install dir]\paks directory.) Click Open. The Import PIMS Data property view appears: Figure 2.25
All the data shown initially will be default values and not related to the csv file previously selected.
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8. In the Import PIMS Data property view, click the Import Data String button to access the File Selection for Importing a PIMS String Table property view. Refer to Section 2.4 Aspen HYSYS Petroleum Refining Unit Tags for more
9. In the File Selection for Importing a PIMS String Table property view, select the PIMS String Table file (*.sdb extension) to map the PIMS variable tag with an Aspen HYSYS Petroleum Refining variable tag and click Open. Aspen HYSYS Petroleum Refining will read in all the data from the assay table using the mapping instructions from the string table and populate the list in the Import PIMS Data property view. 10. Click the Import PIMS Data button.
2.3.2 GC Data Tab The GC (gas chromatography) Data tab allows you to manipulate the GC data values of the petroleum assay. Figure 2.26
There are two types of GC data: •
Wide cut GC data is the value based on a lump/group of components within the cut. You can only specify wide cut GC data values in the GC Data Tab.
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The Petroleum Assay Property View
•
Narrow cut GC data is the value based on individual components within the cut. HYSYS calculates the narrow cut GC data. You cannot specify values for narrow cut data.
The following table lists and describes the objects in the GC Data tab: Object
Description
GC Data Characterization group
Contains the PONA tree that list the wide cut GC data available (in Aspen HYSYS Petroleum Refining) for manipulation. To select a GC data for manipulation: 1. In the GC Data Characterization group, expand the PONA tree browser by clicking the Plus icon . 2. Expand the branches until you find the GC data you want to manipulate. 3. Select the checkbox beside the GC data you want to manipulate
.
<< Remove All button
Enables you to remove all the GC data parameters in the GC Data table.
GC Data Characterization table
Allows you to enter the new values for the selected wide cut data at the specified cut point. • The specified cut point is the wide cut data’s true boiling point (TBP) or final boiling point temperature. • The first row only contains the ICP (Initial Cut Point) data, you must leave the rest of the cells in the first row
or have a value of 0. • The percentage values are based on the entire crude and not on the cut. When defining GC component data, if you supply values at a component group level, you cannot define any information in the sub level of the group, and vice versa.
Even Distribution radio button
Distributes the specified values evenly for the narrow cuts within the wide cut GC data. In this option, the calculation is faster and the mass balance is fulfilled. However, the generated values are less realistic.
Normal Distribution radio button
Distributes the specified values in a normal distribution format for the narrow cuts within the wide cut GC data.
Characterize button
Applies the new GC data values to the petroleum assay.
In this option, the generated values are more realistic. However, the calculation is slower and the mass balance is not fulfilled automatically. You need to manually achieve the mass balance by adjusting the settings in the Edit Property Distribution Parameters Property View.
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Object
Description
GC Data radio button
Allows you to view and enter individual GC data values in the GC Data Characterization table.
Mat Balance radio button
Allows you to view the sums up all the specified by-wt and by-vol GC data values (Wt Pct Entered and Vol Pct Entered) in the GC Data Characterization table. The sum values indicate the amount available for the Crude by Wt and by Vol (Total Crude Wt Pct and Total Crude Vol Pct). For example, if you over specified by entering more than is available, you can click the Normalize button to change the specified amount to the available amount and have all the GC data changed accordingly.
Advance Settings button
Opens the Edit Property Distribution Parameters Property View.
View Results button
Opens the Characterized GC Data Results Property View, which displays the calculated GC data values based on the modification.
The sum of the percentage values in each wide cut GC data column cannot surpass 100. An error message appears if your GC components are not in MW order, but this error does not stop the calculation.
PONA Tree Diagram When defining GC component data, there are several different levels which you can supply the values. There is the group component level, where you supply a general value applicable to a group of components, for example Aromatics for C8. There is the sub group component level, where you supply a specific value for each component in the group component, for example Aromatics for C8 m-Xylene. The general number of component groups and sub groups are shown in the PONA tree diagram (see Figure 2.27). If you supply values at a component group level, you cannot define any information in the sub group level, and vice versa. For example, if you define N C6, you cannot define N C6 cycC5 or N C6 cyc-C6. If you define a component data at sub level you cannot define N C6.
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The Petroleum Assay Property View
Abbreviations of the Wide Cut GC Data The following table lists the abbreviations and full name of the wide cut GC data in the GC Data tab: Abbreviations
Full Name
Abbreviations
Full Name
A
Aromatics
On
Normal Olefins
N
Naphthenes
ON
Naphthenic Olefins
O
Olefins
Pi
Iso Paraffins
P
Paraffins
Pn
Normal Paraffins
Oi
Iso Olefins
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Figure 2.27
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The Petroleum Assay Property View
Edit Property Distribution Parameters Property View The Edit Property Distribution Parameters property view allows you to manipulate the maximum boiling point temperature and standard deviation of the selected GC data property. Figure 2.28
The Reset to Defaults button allows you to restore the values in the table back to the default setting.
Properties such as A C6 Benzene, which represents pure components, will have a very small standard deviation of the order of 0.5 or lower. Properties such as Pi C8, which has a wider boiling point distribution will have a higher standard deviation.
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Characterized GC Data Results Property View This property view displays the calculated narrow cut GC data values based on the modifications made on the GC Data tab. Figure 2.29
From Figure 2.26, the Even Distribution radio button was selected. So when the modified GC data was characterized, the specified value is evenly distributed for the narrow cut GC data.
The Viewing Options group contains the following options that manipulates the information displayed in the table: •
By Weight radio button displays the GC data information associated to the component's weight.
•
By Volume radio button displays the GC data information associated to the component's volume.
•
User Selected Props radio button displays just the GC data that you have manipulated.
•
All Props radio button displays all the GC data.
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The Petroleum Assay Property View
2.3.3 Analysis Tab The Analysis tab displays the errors encountered when constructing the petroleum assay. Figure 2.30
Object
Description
Warning Level column
Displays the error level that indicates the seriousness of the associate errors: • Low indicates the error will only affect the associate property under the Warning Source column. • High indicates the error will affect the associate property under the Warning Source column and reactors that require the property value to perform calculation. • Critical indicates the error will affect the associate property under the Warning Source column and reactors that require the property value to perform calculation.
Warning Source column
Displays which petroleum assay property or parameter is affected or caused the error.
Warning column
Displays the cause of the error and what operations will be affected by the error.
Resolve PONA button
Enables you to normalize the GC data values, so that the sum of the GC data values equal 100%.
Analyze button
Enables you to activate the analysis option in the Analysis tab and view any errors in the active petroleum assay.
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2.3.4 Estimation Tab The Estimation tab allows you to import some petroleum assay property values based on assumptions and equations. The options in this tab is particularly useful if you do not have the raw data and want to generate some estimate values. Figure 2.31
A pre-selected estimation method is used for each property, although various known estimation methods might exist.
•
The Assay Properties Estimation list displays the list of properties for which estimation is currently implemented.
•
The Estimation Methods button enables you to access the Estimation Methods property view.
Figure 2.32
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The Petroleum Assay Property View
In the Estimation Methods property view, you can select different estimation method (using the appropriate dropdown list) for the properties in the Assay Properties Estimation list. •
The first column in the Assay Properties Estimation table displays the list of components in the petroleum assay.
•
The Values column displays the current component values of the selected petroleum property. These values are specified by you in the Information tab or imported from the petroleum assay properties files (*.csv, *.pet, *.xml, and Spiral).
•
The Estimated column displays the component values of the selected petroleum property if they were to be estimated. The Aniline Point, MON (Clear), Refractive Index, and Sulfur Content are estimated using methods from the following documents: 1"Use
of the Refractive Index in the Estimation of Thermophysical Properties of Hydrocarbons and Petroleum Mixtures", Mohammad R. Riazi and Yousef A. Roomi, Chemical Engineering Department, Kuwait University, Ind. Eng. Chem. Res. 2001, Vol. 40, No.8.
2“Estimation
of Sulfur Content of Petroleum Products and Crude Oils”, Mohammad R. Riazi, Nasrin Nasimi, and Yousef A. Roomi, Chemical Engineering Department, Kuwait University, Ind. Eng. Chem. Res. 1999, Vol 38, No.11.
•
The Accept button allows you to discard the current component values and replace them with the estimated values.
If the estimated value is , HYSYS was unable to calculate an estimate value. If you tried to accept the estimated value one of two events occur:
•
If the current value is also , HYSYS leaves the selected petroleum property value as unknown.
•
If the current value is not , HYSYS leaves the selected petroleum property value as the current value.
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2.3.5 Plots Tab The Plots tab displays the petroleum property values in graph format. Figure 2.33
2.3.6 Notes Tab The Notes tab provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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Aspen HYSYS Petroleum Refining
2.4 Aspen HYSYS Petroleum Refining Unit Tags Tags are case sensitive. You must use the correct name for Aspen HYSYS Petroleum Refining to recognize the unit tags in the PIMS assay file.
In a PIMS assay file, there are commands to designate units to the variable values. In the command, you must use the correct unit tag name recognized by Aspen HYSYS Petroleum Refining. The following table is the Aspen HYSYS Petroleum Refining unit tag along with the description of what units the tag represent: Tag Name = Unit
Tag Name = Unit
Tag Name = Unit
kPa = kilo pascals
psia = pounds per square inch absolute
bar = bar
MPa = mega pascals psi = pound per square inch
N/m2 = newton per square meter
lbf/ft2 = pounds-force per square foot
kg/cm2 = kilogram per square centimeter
torr = millimeter of mercury
atm = technical atmosphere
mmHg = millimeter of mercury
at = physical atmosphere
cmH2O(4C) = centimeter of water at 4 degrees Celsius
inHg(32F) = inch of mercury at 32 degrees Fahrenheit
MJ/h = mega joule per hour
inH2O(60F) = inch of water at 60 degrees Fahrenheit
inHg(60F) = inch of mercury at 60 degrees Fahrenheit
kW = kilo watt
kcal/h = kilo calories per hour
Btu/h = british thermal unit per hour
cal/h = calories per hour
MMBtu/hr = millions of british thermal unit per hour
hp = horse power
Mkcal/h = mega kilo calories per hour
kgmole/m3 = kilogram mole per cubic meter
C = Celsius
gmole/L = gram mole per litre
lbmole/ft3 = pound mole per cubic foot
K = Kelvin
g/cm3 = gram per cubic centimeter
lb/ft3 = pound per cubic foot
MW = mega watt
mbar = millibar
kJ/min = kilo joule per minute kJ/s = kilo joule per second
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Tag Name = Unit
Tag Name = Unit
Tag Name = Unit
F = Fahrenheit
API = american petroleum institute
SG_60/60api = standard gravity
cP = centipoise
dyne/cm = dyne per centimeter
R = Rankine
mP = millipoise microP = micropoise
dyn/cm = dyne per centimeter
cSt = centistokes
Pa-s = pascal second
lbf/ft = pound force per foot
kgmole/min = kilogram mole per minute
lbmole/hr = pound mole per hour
gmole/h = gram mole per hour
lbmole/h = pound mole per hour
MMSCFH = million standard cubic feet per minute
g/s = gram per second
tonne/d = metric tonne per day
kg/d = kilogram per day
tonne/h = metric tonne per hour
MMSCFD = million standard cubic feet per day lb/hr = pound per hour klb/day = kilo pound per day
tn(short)/h = short ton per hour
m3/h = cubic meter per hour
L/d = litre per day
barrel/day = barrel per day
kbpd = thousand barrels per day
USGPM = US gallons per minute
ft3/day = cubic fee per day
in = inch
miles = mile
m = meter
ft = feet
km/h = kilometer per hour
ft/s = feet per second
MPH = miles per hour
seconds = second
weeks = week
months = month
years = year
days = day
hours = hour
minutes = minute
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Aspen HYSYS Petroleum Refining
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Assay Manipulator
3-1
3 Assay Manipulator
3.1 Introduction................................................................................... 2 3.2 Assay Manipulator Property View .................................................. 3 3.2.1 Design Tab .............................................................................. 4 3.2.2 Assay Tab................................................................................ 6 3.2.3 Worksheet Tab ....................................................................... 10
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Introduction
3.1 Introduction The Assay Manipulator allows you to change the petroleum assay properties of a material stream, without the need to supply any theoretical equations or calculations to obtain the property values. The common reasons to change the petroleum assay property values are: • • • •
HYSYS does not have an operation that simulates a piece of equipment, in the actual plant, which changes the petroleum assay properties. There are no petroleum assay data that mimic the actual petroleum assay curves. The output petroleum properties of a HYSYS operation does not imitate the output petroleum properties from an actual plant operation. There is a need to conduct a sensitivity analysis on the simulation plant to see if a slight change in petroleum properties will affect the quality of the products.
Assay Manipulator supplies two ways to modify the petroleum assay properties: • •
Change properties. In this option, you can modify values of an individual petroleum property (for example, sulfur content of a hypothetical component). Shift properties. In this option, you can specify a target bulk value of a petroleum property in the stream (for example, the RON of a stream), and the assay manipulator automatically adjusts the values of all the individual petroleum properties to meet the new bulk value.
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Assay Manipulator
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3.2 Assay Manipulator Property View There are two methods to add an Assay Manipulator to your simulation: 1. From the Flowsheet menu, select Add Operation [or press F12]. The UnitOps property view appears. 2. Click the Aspen HYSYS Petroleum Refining Ops radio button. 3. From the list of available unit operations, select Manipulator. 4. Click the Add button. OR 1. Press F6 to access the Aspen HYSYS Petroleum Refining object palette. 2. Double-click the Assay Manipulator icon. Assay Manipulator icon
The Assay Manipulator property view appears. Figure 3.1
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Assay Manipulator Property View
There are three common objects at the bottom of the Manipulator property view, the following table describes these objects: Object
Description
Delete button
Allows you to delete the operation.
Status bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Ignored checkbox
Allows you to ignore the operation during calculations. When the checkbox is selected, HYSYS completely disregards the operation (and cannot calculate the outlet stream) until you clear the checkbox.
3.2.1 Design Tab The Design tab contains four pages: • • • •
Connections Parameters User Variables Notes
Connections Page On the Connections page, you can specify the feed and product streams attached to the Assay Manipulator. You can change the name of the operation in the Name field. Figure 3.2
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Parameters Page On the Parameters page, the following information appears: Object
Description
Transfer Temperature checkbox
When selected, the temperatures of the feed stream and the product stream are equal.
Transfer Pressure checkbox
When selected, the pressures of the feed stream and the product stream are equal.
Transfer Flow Rate checkbox
When selected, the flow rates of the feed stream and the product stream are equal.
Figure 3.3
User Variables Page For more information on implementing the User Variables, refer to Section 1.2.4 - User Variables Page/Tab.
The User Variables page allows you to create and implement variables in the HYSYS simulation case.
For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
Notes Page
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Assay Manipulator Property View
3.2.2 Assay Tab The Assay tab allows you to specify the changes in petroleum properties. The options available in this tab are grouped into the following pages: • • • •
Options Change Props Shift Props Composition
Options Page In the Options page, you can select the petroleum property you want to modify and select the type of modification method using the drop-down lists in the table. Figure 3.4
The table in the Properties/Options group contains the following: Column
Description
Property
You can select the petroleum property you want to manipulate using the drop-down list in the cells under this column.
Options
You can select the method of modification using the dropdown list in the cells under this column. There are two methods to choose from: Change Props and Shift Props.
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You can only apply one type of modification method for each petroleum property.
Change Props Page The Change Props page allows you to specify the exact value changes to the selected petroleum property. Figure 3.5
The following table lists and describes the objects available on this page: Object
Description
Drop-down list
You can activate the selected the petroleum property for modification.
Table
Allows you to type the modified values for the selected petroleum property in the drop-down list. The table also displays the selected petroleum property values from the feed stream.
Plot
Displays both the original and manipulated petroleum property values.
The drop-down list will be blank if you had not selected Change Props method for any of the petroleum properties in the Options page.
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Assay Manipulator Property View
Shift Props Page The Shift Props page allows you to specify shift value of the selected petroleum property. Figure 3.6
The following table lists and describes the objects available on this page: Object
Description
Drop-down list
You can activate the selected the petroleum property for modification.
Reference Assay table
You can choose the base/reference point(s) for the selected petroleum property to be shifted by doing one of the following: • Select the Use Feed checkbox to use the feed stream’s property values as the base point(s). • Use the drop-down list in the Use Assay cell to select the assay you want to use as the base point(s). You cannot select a different assay as the base point(s) if you have selected the Use Feed checkbox.
Targets table
You can type in the amount of shift for the selected petroleum property by doing one of the following: • Type the amount of shift for the product stream in the Product cell. • Type the difference amount between the product stream and the feed stream in the Prod - Feed cell.
Calculated Values table
Displays the calculated values based on the information entered in the Reference and Targets tables.
Plot
Displays both the original and manipulated petroleum property values.
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The drop-down list will be blank if you had not selected Shift Props method for any of the petroleum properties in the Options page.
Composition Page The Composition page enables you to manipulate the product composition. Using this feature, you can change the distillation curve (TBP, D86, D1160, and D2887) of a process stream in your flowsheet. Figure 3.7
To activate and access the options in the Composition page, select the Manipulate Product Composition checkbox.
The following tables lists and describes the options available in the Composition page: Object
Description
Manipulate Product Composition checkbox
Enables you to toggle between activating or ignoring the modified variable for the product stream composition.
Plus Fraction radio button
Enables you to toggle between accessing or hiding the options to manipulate the temperature vs. percent yield data.
Light Ends radio button
Enables you to toggle between accessing or hiding the options to manipulate the mass or volume fraction of the light ends composition.
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Assay Manipulator Property View
Object
Description
Mass/Volume dropdown list
Enables you to select mass or volume for the percent yield or composition fraction.
Right drop-down list
Enables you to select between four different temperature data that affects the percent yield. The four options are: TBP, ASTM D86, D2887, and D1160. This drop-down list is only available for the Plus Fraction option.
Yield column
Enables you to specify the mass or volume percent yield associated to the specified temperature. This column is only available for the Plus Fraction option.
Right column
Enables you to specify the temperature of the selected option from the Left drop-down list. This column is only available for the Plus Fraction option.
Fraction column
Enables you to specify the mass or volume fraction of the light ends composition. This column is only available for the Light Ends option.
Plot
Displays the composition vs. NBP data of both feed and product streams.
3.2.3 Worksheet Tab Refer to Section 1.2.2 Worksheet Tab for more information.
The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the Assay Manipulator.
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Catalytic Reformer
4-1
4 Catalytic Reformer
4.1 Introduction................................................................................... 3 4.1.1 Theory.................................................................................... 6 4.2 Overall Operation Structure/Environment ................................... 16 4.2.1 Main Environment .................................................................. 17 4.2.2 Catalytic Reformer Environment ............................................... 21 4.2.3 Calibration Environment .......................................................... 23 4.3 Reformer Configuration Wizard.................................................... 24 4.3.1 Configuration Page ................................................................. 26 4.3.2 Geometry Page ...................................................................... 27 4.3.3 Calibration Factors Page .......................................................... 28 4.4 Catalytic Reformer Property View ................................................ 29 4.4.1 4.4.2 4.4.3 4.4.4
Design Tab ............................................................................ 30 Reactor Section Tab ................................................................ 33 Stabilizer Tower Tab................................................................ 44 Results Tab............................................................................ 47
4.5 Feed Type Library Property View ................................................. 56 4.6 Reactor Section Property View..................................................... 58 4.6.1 4.6.2 4.6.3 4.6.4
Design Tab ............................................................................ 59 Feed Data Tab........................................................................ 61 Operation Tab ........................................................................ 64 Results Tab............................................................................ 73
4.7 Feed Type Property View ............................................................. 80 4.8 Calibration Set Library Property View .......................................... 81 4.8.1 Factor Set Property View ......................................................... 82 4-1
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Catalytic Reformer
4.9 Calibration Property View .............................................................86 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6
Design Tab .............................................................................91 Feed Data Tab ........................................................................94 Operation Tab.........................................................................95 Measurement Tab..................................................................103 Calibration Control Tab...........................................................107 Analysis Tab .........................................................................109
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Catalytic Reformer
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4.1 Introduction The Reformer model in Aspen HYSYS Petroleum Refining is a state-of-the-art Catalytic Naphtha Reformer Unit simulation system that can be used for modeling a CCR or Semiregenerative reformer unit as a standalone unit operation or as part of a refinery-wide flowsheet. The Catalytic Reformer operation includes feed characterization system, reactor section, stabilizer and product mapper. The reactor section includes reactors, heaters, compressor, separator, and recontactor. The reactor model is based on rigorous kinetics. The feed characterization system and product mapper are designed to work together with the Aspen HYSYS Petroleum Refining assay system so the Reformer model can be simulated in a refinery-wide flowsheet. Figure 4.1
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Introduction
Feed Characterization System The Reformer within Aspen HYSYS Petroleum Refining has its own set of library and hypothetical components. The table below list the components for the Catalytic Reformer environment: Hydrogen
Cyclopentane
24-Mpentane
O8*
6N9*
Methane
22-Mbutane
2-Mhexane
n-Octane
IP10*
A12*
Ethane
23-Mbutane
3-Mhexane
5N8*
n-Decane
P13*
Ethylene
2-Mpentane
3-Epentane
E-Benzene
5N10*
N13*
Propane
3-Mpentane
n-Heptane
o-Xylene
A10*
A13*
Propene
n-Hexane
O7*
m-Xylene
6N10*
P14*
i-Butane
O6*
11Mcycpentan
p-Xylene
IP11*
N14* A14*
n-Butane
Mcyclopentan
Ecyclopentan
6N8*
n-C11
1-Butene
Benzene
Toluene
IP9*
5N11*
i-Pentane
Cyclohexane
Mcyclohexane
n-Nonane
A11*
n-Pentane
22-Mpentane
MBP8*
5N9*
6N11*
O5*
23-Mpentane
SBP8*
A9*
P12*
N12*
The hypothetical component names can be interpreted by identifying the prefix with the component type and the suffix with the carbon number. The prefix component types are: • • • • • • • • •
O: Olefin MBP: Multi-branch paraffin SBP: Single-branch paraffin 6N: 6-Carbon Ring Naphthenic IP: Isoparaffin (no distinction on number of branches) 5N: 5-Carbon Ring Naphthenic A: Aromatic P: Paraffinic (no distinction on isomer type) N: Naphthenic (no distinction on number of carbons in ring)
These components are either used directly in the kinetic reactor model or they are easily mapped into the components used within the kinetic reactor model. The transition between the Main Environment and the Catalytic Reformer Environment will handle the calculation of the composition of the Reformer components. In order to do this, however, you must specify the feed type. The feed type will specify the ratios of various isomers within the feed to the 4-4
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Catalytic Reformer
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Reformer. These ratios, along with the distillation and PONA data from the attached inlet stream will be used to calculate the Reformer component compositions. Feed Component Ratios • nP5 /Total C5 Ratio
• N7 N5/[N5+N6 Ring] Ratio
• Normal P6 / Total P6 Ratio
• Normal P8 / Total P8 Ratio
• MB P6 / Total P6 Ratio
• MB P8 / Total P8 Ratio
• MCP / [MCP+CH] Ratio
• N8 N5/[N5+N6 Ring] Ratio
• Normal P7 / Total P7 Ratio
• iP9 / Total P9 Ratio
• MB P7 / Total P7 Ratio
• N9 N5/[N5+N6 Ring] Ratio
• iP5 /Total C5 Ratio
• iP10 / Total P10 Ratio
• N10 N5/[N5+N6 Ring] Ratio
• N11 N5/[N5+N6 Ring] Ratio
• iP11 / Total P11 Ratio
In the Catalytic Reformer Environment, you have more options for calculating the composition of the feed. The you can calculate the composition based on a boiling range of an assay, based on the specified bulk properties, or based on the specified the kinetic lumps. •
• •
For the assay option, you select an assay to associate with the feed. The feed type is specified along with the initial and final boiling point to generate a composition of the feed. For the bulk properties option, you specify the feed type along with distillation data and total naphthenics and aromatics in the feed. For the kinetic lumps option, you specify the feed type along with the composition of the components that is desired. You may optionally input a value for N+2A or N+3A to adjust the composition. If no value is entered for either N+2A or N+3A, the composition entered will be used directly.
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Introduction
4.1.1 Theory Reaction Kinetics - Components The components used for the reaction pathways in the Reformer model are either present in the Reformer component list, or can be easily calculated by summing the appropriate components. Below is a list of the components used in the reaction network: • H2
• NP6
• O8
• P1
• 5N6
• 5N8
• IP11 • NP11
• P2
• A6
• A8
• 5N11
• O2
• 6N6
• 6N8
• A11
• P3
• MBP7
• IP9
• 6N11
• O3
• SBP7
• NP9
• P12
• P4
• NP7
• 5N9
• N12
• O4
• O7
• A9
• A12
• P5
• 5N7
• 6N9
• P13
• O5
• A7
• IP10
• N13
• 5N5
• 6N7
• NP10
• A13
• MBP6
• MBP8
• 5N10
• P14
• SBP6
• SBP8
• A10
• N14
• O6
• NP8
• 6N10
• A14
The component names can be interpreted by identifying the prefix with the component type and the suffix with the carbon number. The prefix component types are: • • • • • • • • • •
P: Paraffinic (no distinction on isomer type) O: Olefin 5N: 5-Carbon Ring Naphthenic MBP: Multi-branch paraffin SBP: Single-branch paraffin NP: Normal paraffin 6N: 6-Carbon Ring Naphthenic IP: Isoparaffin (no distinction on number of branches) A: Aromatic N: Naphthenic (no distinction on number of carbons in ring)
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Catalytic Reformer
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The components P4, P5, and A8 are further delumped after the reaction network. P4 and P5 are mapped into their corresponding normal and isoparaffin components. A8 is mapped into ethylbenzene, o-xylene, m-xylene, and p-xylene.
Reaction Kinetic - Paths Nine fundamental reaction types are used in reformer kinetics: Reaction Type Isomerization Ring Close/Open Ring Expansion Dehydrogenation Hydrogenolysis Hydrocracking Hydrodealkylation Polymerization
Example
NP6 ⇔ SBP6 NP6 ⇔ 5N6 5N6 ⇔ 6N6 6N6 ⇔ A6 + 3H2 6N7 + H2 ⇒ 6N6 + P1 P5 + H2 ⇒ P2 + P3 A7 + H2 ⇒ A6 + P1 A7 + P5 ⇒ A12 + H2
Condensation
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4-8
Introduction
The reaction paths used for C6 through C8 are shown in the diagram below: Figure 4.2
where: x: carbon number from 6 to 8 nP: normal paraffins SP: single-branch paraffins MP: multi-branch paraffins 5N: 5-carbon ring naphthenics 6N: 6-carbon ring naphthenics A: aromatics As the carbon number increases beyond 8, the complexity of the paths is reduced.
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Catalytic Reformer
4-9
Reaction Kinetic - Expressions The reaction kinetic expressions for the Reformer are power law rate expressions based on concentrations. Here the dehydrogenation reaction is used as an example to illustrate the reaction kinetic expressions used to model these reactions. CycloHexane ⇔ Benzene + 3 H2 3
Rate = Activity × k f × ( [ 6N6 ] – [ A6 ] × [ H2 ] ⁄ K eq ) × PF
x
(4.1)
where: Activity = product of catalyst activity, metal site activity, and dehydrogenation specific activity kf = Arrhenius form of the forward reaction rate multiplier [6N6], [A6], [H2] = concentration of cyclohexane, benzene, and hydrogen Keq = Arrhenius form of the rate equilibrium factor PFx = pressure factor, default x=0.02 for dehydrogenation
Deactivation of Reformer Catalyst Reformer catalyst is a bifunctional catalyst, and the catalyst activity definition used in modeling must include separate terms for the metals and acid functions. The activity of the catalyst in a reformer is a function of several factors, a few of these are: 1. Coke laydown on the catalyst 2. Water/Chloride environment 3. Temporary poisons such as sulfur 4. Permanent poisons such as lead, zinc, and copper 5. Catalyst surface area 6. Platinum crystal size 7. Sintering 8. Shift from gamma alumina to alpha alumina 9. Catalyst breakage
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Introduction
Items #5 through #9 are basically mechanical changes in the catalyst and occur primarily during catalyst regeneration. These mechanical changes in the catalyst, which effect activity, can only be accounted for through direct analysis of the catalyst or indirectly from measurement of plant operation. Fortunately, to predict reformer operation on an on-going basis, these changes can be lumped together in the deactivation model and thus do not create a problem in the reaction modeling. Permanent catalyst poisons such as those listed in item #4 are normally very gradual and can be handled with routine activity model updates, using the same lump mechanism used for items #5 through #9. When a significant quantity of permanent poison is deposited on the catalyst over a short period of time, the deactivation model will need to be updated from plant operating data. This is true provided the unit will remain in service. In most cases where a significant quantity of a permanent poison is deposited on the catalyst, the reformer is taken off line and the catalyst replaced. The changes in catalyst performance due to the factors listed in items #4 through #9 require that the Reformer model be updated after each catalyst regeneration of semi-regenerative units, and every 6 to 12 months for cyclic and continuous catalyst circulation units. Temporary sulfur poisoning will need to be addressed in the Reformer deactivation model. The difficult aspect of this will be determining how much of a change in catalyst activity is due to the temporary poison and how much is due to another mechanism. Once the quantity of sulfur is known, the prediction of activity recovery will be very straightforward. The effect of coke laydown on activity creates two areas of major concern. The first is the actual prediction of coke laydown, and the second is estimating the impact of coke deposition on catalyst activity. The following sections describe how these are handled in the Aspen HYSYS Petroleum Refining Reformer model.
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Catalytic Reformer
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Coke Make Model There are several theories on coke laydown, one or more of them may be correct. The general concept with the greatest acceptance is that coke is formed from the condensation of polycyclic hydrocarbons. A second generally accepted concept is that polycyclics are formed from an intermediate olefin created primarily during the cyclization (and to some degree during isomerization) of naphthenes from paraffins, and from aromatics. The diagram below is a schematic of the coke make mechanism. Figure 4.3
Because the reaction rate of C6 ringed naphthenes to aromatics is extremely high, it can be safely assumed that very little coke is made from C6 ringed naphthenes. Also, the extremely low concentrations of naphthenes (both C5 ringed and C6 ringed) in the second and subsequent reactors, make it nearly impossible to generate accurate rate data from experimental data. Correlations of laboratory measurements of coke make and paraffin of C5 ringed naphthene concentration are further confused by the fact that the paraffins and naphthenes are existing in equilibrium, and the concentrations of both species decrease dramatically through the reactor systems. This is particularly true of the C9 and heavier material where: •
the vast majority of the coke originates
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Introduction
•
both species approach zero concentration in the last reactor where the majority of the coke is formed.
Literature reports give the reaction rates of the paraffin/ naphthene intermediate olefin in terms of the paraffin (or paraffin and naphthene) concentration. For commercial catalytic reformer modeling purposes, it can be assumed that the coke make is a function primarily of the C5 ring naphthenes and aromatics. Coke make in the Reformer is modeled via the reaction of paraffins, C5 ringed naphthenes, and aromatics to coke via a first order reaction mechanism. All C5 ringed naphthenes share a common activation energy as do the aromatics and paraffins. The frequency factors vary by carbon number and species. Each reactor has a coke make activity, as well as a total coke make activity for all reactors. The reaction rate is in the general form:
k P = A S × A RXI × F Pi × e k N = A S × A RXI × F Ni × e k A = A S × A RXI × F Ai × e
–EP -----------R×T –EN -----------R×T
(4.2)
–EA -----------R×T
where: kP = rate factor of paraffins, carbon number i to coke kN = rate factor of C5 ringed naphthenes, carbon number i to coke kA = rate factor of Aromatic, carbon number i to coke AS = Coke Activity of the Reactor System ARXI = Coke Activity of the individual Reactor FNi, FAi = Frequency Factors for C5 ringed naphthenes and aromatics, carbon number i EN, EA = C5 ringed naphthenes and Aromatics activation energies
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The rate factors are then used in the reaction equations in the following general format: dC ------- = ( k P [ TotalP ] + k N [ Total5N ] + k A [ TotalA ] ) × PF × H2HCF dt
(4.3)
where: dC ------- = coke/time dt kP = Paraffin to coke rate factor [TOTALP] = concentration of total paraffins kN = C5 ringed naphthene to coke rate factor [TOTAL5N] = concentration of total C5 ringed naphthenes kA = Aromatics to coke rate factor [TOTALA] = concentration of total aromatics PF = factor to adjust for changes in pressure H2HCF = factor to adjust for changes in H2/HC ratio
Each feed has an associated coke make multiplier. Default values are 1.0. This allows you to put a linear weighting on feeds with higher or lower coking tendencies than the base feed stock. This term is a simple multiplier on the coke rate expressions.
Catalyst Activity Model Catalyst activity is divided into a metals activity and an acid activity. These activities affect the reaction mechanisms as shown in the following table: Reaction Type
Acid
Isomerization
X
Ring Closure/Open
X
Ring Expansion
X
Metal
Pressure Multiplier X
X
Dehydrogenation
X
Hydrogenolysis - Para
X
X
X
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Introduction
Reaction Type
Acid
Hydrogenolysis - Naph
Metal X
Hydrocracking
X
Hydrodealkylation
X
Polymerization
X
Pressure Multiplier X X
Also shown in the table above are the reaction mechanisms that are affected by pressure changes. The acid and metals activities are independent functions of carbon on catalyst (COC) expressed as percent of catalyst. The general form for both the acid and metals activity functions is: 2
Activity = Intercept + Poly1 × COC + Poly2 × COC + 3 4 Poly3 × COC + Poly4 × COC
(4.4)
System Pressure Control The pressure points through the system are all based upon a single specified pressure. For the Catalytic Reformer in Aspen HYSYS Petroleum Refining this is the product separator pressure. The Catalytic Reformer uses a modified Bernoulli equation to calculate the following pressure drops based upon the base case pressure drops and flowing conditions and the specified flowing conditions: • • • • •
Product Separator to last Reactor Outlet Last Reactor Outlet to Last Reactor Inlet Last Reactor Inlet Pressure to Reactor(i) Inlet Pressure Reactor(i) Inlet Pressure to Reactor(i+1) Inlet Pressure First Reactor Inlet Pressure to Compressor Discharge
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Reactor Temperature Control The reactor inlet temperatures are calculated based upon the delta inlet temperature entered for each reactor. In this model a base temperature is used as a reference temperature for biasing the individual reactor inlet temperatures. Reactor(i) Inlet Temperature = Base Temperature + Reactor(i) Temperature Bias
(4.5)
This allows any one of the following to be a constant and the severity target: • • • • •
Base Temperature WAIT WABT RON for C5+ or C6+ Aromatics Production
Stabilizer Configuration The stabilizer is a conventional rigorous tower simulation using the HYSYS Petroleum Tower model. A vapor and liquid draw are taken off the overhead receiver, and the reformate off the reboiler.
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Overall Operation Structure/
4.2 Overall Operation Structure/Environment In the HYSYS, the Catalytic Reformer operation appears as an object icon in the Main environment PFD. Figure 4.4
The Catalytic Reformer operation is actually a subflowsheet containing the required reactor and stabilizer tower (if applicable) that make up a catalytic reformer. Figure 4.5
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Catalytic Reformer
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In the Catalytic Reformer subflowsheet environment, you can access another sublevel environment called Calibration Environment. Figure 4.6
4.2.1 Main Environment In the Simulation/Main environment, the following features are available for the Catalytic Reformer: • • • • •
create a catalytic reformer template create or add a catalytic reformer access Catalytic Reformer property view access Catalytic Reformer environment/subflowsheet delete existing catalytic reformer
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Overall Operation Structure/
Create Catalytic Reformer Template HYSYS enables you to create templates of catalytic reformers, so you can import them in existing HYSYS process flowsheet diagram (PFD). To create a catalytic reformer template: 1. Select File | New | Catalytic Reformer Template in the menu bar. The Reformer Configuration Wizard property view appears. HYSYS automatically creates a catalytic reformer fluid package with predetermined component list for the Catalytic Reformer template.
2. In the first page of the Reformer Configuration Wizard property view, you can configure the reactor part of the Catalytic Reformer. 3. Click Next. 4. In the second page of the Reformer Configuration Wizard property view, you can specify the reactor and heater parameters. 5. Click Next. 6. In the third and final page of the Reformer Configuration Wizard property view, you can select or specify a set of calibration factors. 7. Click Done. Aspen HYSYS Petroleum Refining completes the Catalytic Reformer subflowsheet, based on the specified information from the Reformer Configuration Wizard, and opens the Catalytic Reformer subflowsheet environment. 8. In the Catalytic Reformer environment, you can: • • •
Access and modify the reactor by double-clicking the reactor object icon in the Catalytic Reformer PFD. Access and modify the stabilizer tower by double-clicking on the stabilizer tower object icon in the Catalytic Reformer PFD. Access the Calibration environment and calibrate the Reformer model.
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9. In the menu bar, select File | Save As or File | Save command to save the Catalytic Reformer template as a *.ref file.
Create/Add Catalytic Reformer To add a catalytic reformer into a PFD: 1. Open the appropriate simulation case. 2. Open the UnitOps property view. 3. In the Categories group, select the Refinery Ops radio button. 4. In the Available Unit Operations group, select Catalytic Reformer and click Add. The Reformer Template Option property view appears 5. In the Reformer Template Option property view, do one of the following: •
Click Read an Existing CAT Template to add a Catalytic Reformer operation based on an existing template. The Catalytic Reformer operation appears on the PFD. • Click Configure a New Reformer Unit to add a Catalytic Reformer operation and configure it from scratch. The Reformer Configuration Wizard property view appears, and you have to configure the basic structure of the Catalytic Reformer operation using the features available in the Reformer Configuration Wizard. After you have specified the minimum information required, the Catalytic Reformer operation appears on the PFD. 6. Open the Catalytic Reformer property view and make the necessary changes/specifications/connections for the simulation case.
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Overall Operation Structure/
Access Catalytic Reformer Property View To open the Catalytic Reformer property view, do one of the following: • • •
On the PFD property view, right-click the Catalytic Reformer operation icon and select View Properties command from the Object Inspect menu. On the Workbook property view, click the Unit Ops tab, select the Catalytic Reformer under the Name column, and click the View UnitOp button. On the Object Navigator property view, select UnitOps radio button in the Filter group, select the applicable flowsheet in the Flowsheet group, select the Catalytic Reformer operation in the Unit Operations group, and click the View button.
Access Catalytic Reformer Environment To access the Catalytic Reformer subflowsheet environment: 1. In the Main PFD, open the Catalytic Reformer property view. 2. In the Catalytic Reformer property view, click the Reformer Environment button.
Delete Catalytic Reformer Operation To delete an existing Catalytic Reformer operation, do one of the following: • • • •
On the PFD property view, select the Catalytic Reformer operation icon and press DELETE. On the PFD property view, right-click the Catalytic Reformer operation icon and select Delete command from the Object Inspect menu. On the Catalytic Reformer property view, click the Delete button. On the Workbook property view, click the Unit Ops tab, select the Catalytic Reformer under the Name column, and click the Delete UnitOp button.
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Catalytic Reformer
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4.2.2 Catalytic Reformer Environment In the Catalytic Reformer environment, the following features are available for the Catalytic Reformer: • • • • •
access the individual operation property views that make up the Catalytic Reformer operation access Reformer Configuration Wizard select calibration factor set access the Calibration Environment access Results property view
Access Operation Property View 1. In the Catalytic Reformer environment, open the PFD property view. 2. On the PFD, do one of the following: • •
Double-click on the operation’s icon. Right-click on the operation’s icon, and select View Properties command in the object inspect menu.
Access Reformer Configuration Wizard To access the Reformer Configuration Wizard, do one of the following: • •
In the Catalytic Reformer environment, select Reformer | Configuration Wizard command in the menu bar. Open the Reformer Reactor Section property view, click the Design tab, select the Configuration page, and click the Configuration Wizard button.
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Overall Operation Structure/
Select Calibration Factor Set To select the Calibration Factor Set for the Catalytic Reformer operation: 1. Select Reformer | Calibration Factor command from the menu bar. The Calibration Factor Set property view appears. Figure 4.7
2. Open the Select a calibration factor set to use for simulation drop-down list and select a calibration factor set. You can click the Library button to open the Calibration Set Library Property View to create, clone, and modify a calibration factor set.
Access Calibration Environment To access the Calibration environment: 1. In the Main environment, open the Catalytic Reformer property view. 2. Click the Reformer Environment button to access the Catalytic Reformer environment. 3. Select Reformer | Calibration command in the menu bar.
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4.2.3 Calibration Environment In the Calibration environment, you can calibrate the Catalytic Reformer operation without affecting the actual operation in the simulation environment. After calibrating the operation to the desired performance, you can export the new parameter/variable values to the Catalytic Reformer operation in the simulation environment and view the new results. The following features are available in the Calibration environment: •
Calibrate the Catalytic Reformer
Calibrate the Catalytic Reformer To calibrate the Catalytic Reformer: 1. In the Calibration environment, select Calibration | Calibration Workbook command from the menu bar to open the Calibration property view. 2. Open the Data Set drop-down list and select a data set to be used on the calibration run. The default data set is based on the current Catalytic Reformer configuration. The features/options available in the first three tabs are available for you to make modifications to the existing Catalytic Reformer, if you want/need to: • • •
In the Design tab, you can make any modifications to the configuration and geometry parameters of the reactor. In the Feed Data tab, you can make any modifications to the feed stream. In the Operation tab, you can make any modifications to the overall operation performance of the Catalytic Reformer.
You can make changes to the Catalytic Reformer configuration and save the modifications as a separate data set.
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Reformer Configuration Wizard
3. In the Operation tab, specify values for the variables that affect the reactor performance/results. 4. In the Measurement tab, specify the reactor, compressor, and product stream parameters. 5. In the Calibration Control tab, select and specify the parameter and objective function values that will be used in the calibration calculation/run. 6. Click the Run Calibration button. •
If you only have one data set, the Validation Wizard Property View appears. Validate the data set and click the OK button to continue with the calibration run. • If you have more than one data set, the Select Data Sets for Calibration Property View appears. On the Select Data Sets for Calibration property view, select and validate the data set you want, and click the Run Calibration button to continue with the calibration run. 7. After the calibration run has finish, click the Analysis tab to view the calibration calculation results.
4.3 Reformer Configuration Wizard The Reformer Configuration Wizard enables you to quickly set up the Catalytic Reformer operation. The Reformer Configuration Wizard is made up of three sequential pages. You enter information in a page, then move on to the next page in order. The following table list the common buttons available at the bottom of the Reformer Configuration Wizard property view: Button
Description
Next>
Enables you to move forward to the next page.
Enables you to move backward to the previous page.
Cancel
Enables you to exit the Reformer Configuration Wizard without saving any changes or creating a catalytic reformer operation.
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Button
Description
Close
Enables you to exit the Reformer Configuration Wizard and keep any specifications or changes made to the catalytic reformer operation.
Done
Enables you to exit the Reformer Configuration Wizard and finish configuring the catalytic reformer operation.
To access the Reformer Configuration Wizard: 1. In the HYSYS desktop menu bar, select FILE | New | Reformer command. HYSYS automatically completes the Simulation Basis environment specifications and then enters the Simulation environment. The Reformer Configuration Wizard property view appears. or 1. In the Main Environment, press the F12 to open the UnitOps property view. 2. In the Available Unit Operations group, select Catalytic Reformer and click Add. The Reformer Template Option property view appears. 3. Click the Configure a New Reformer Unit button. The Reformer Configuration Wizard property view appears. or 1. In the Catalytic Reformer Environment, select Reformer | Configuration Wizard command from the menu bar. The Reformer Configuration Wizard property view appears. or 1. In the Reactor Section Property View, click the Design tab and select the Configuration page. 2. Click the Configuration Wizard button. The Reformer Configuration Wizard property view appears. or 1. In the Calibration Environment, select Calibration | Calibration Workbook to open the Calibration property view. 2. Click the Design tab and select the Configuration page.
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Reformer Configuration Wizard
3. Click the Configuration Wizard button. The Reformer Configuration Wizard property view appears.
4.3.1 Configuration Page The Configuration page 1 of the Reformer Configuration Wizard property view, enables you to specify the basic configuration of the Catalytic Reformer. Figure 4.8
Object
Description
Catalyst Type group
Contains two radio buttons that enables you to select the catalyst in the reactor: • CCR • Semi-Regen
Reaction Section group
Contains two radio buttons that enables you to select how many beds in the reactor: • 3 Beds • 4 Beds
Include Hydrogen Recontactor checkbox
Enables you to toggle between including or excluding a recontactor in the catalytic reformer.
Include Stabilizer Tower checkbox
Enables you to toggle between including or excluding a stabilizer tower in the catalytic reformer.
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4.3.2 Geometry Page The Geometry page 2 of the Reformer Configuration Wizard property view, enables you to specify the geometry information for the reactors. Figure 4.9
Object
Description
Length row
Enables you to specify the length of each reactor bed.
Cat. Wt. row
Enables you to specify the catalyst weight of each reactor bed.
Void Fraction field
Enables you to specify the void fraction of the catalyst.
Catalyst Density field
Enables you to specify the density of the catalyst.
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Reformer Configuration Wizard
4.3.3 Calibration Factors Page The Calibration Factors page 3 of the Reformer Configuration Wizard property view, enables you to select or specify a calibration factor. Figure 4.10
Object
Description
Use an existing set of calibration factors drop-down list
Enables you to select an existing calibration factor set. The default selection is the default calibration factor set provided by HYSYS.
Library button
Enables you to access the Calibration Set Library Property View.
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4.4 Catalytic Reformer Property View The Catalytic Reformer property view contains features used to manipulate the overall Catalytic Reformer operation and enable you to enter the Catalytic Reformer environment. To access the Catalytic Reformer property view: 1. In the Main environment, open the PFD property view. 2. In the PFD property view, double-click on the Catalytic Reformer object icon. Figure 4.11
The following table lists and describes the common features in the Catalytic Reformer property view: Object
Description
Delete button
Enables you to delete the Catalytic Reformer operation.
Reformer Environment button
Enables you to enter the Catalytic Reformer Environment.
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Catalytic Reformer Property View
Object
Description
Status bar
Displays the status of the reactor section of the catalytic reformer operation.
Ignore checkbox
Enables HYSYS to ignore the Catalytic Reformer operation during the process flowsheet calculation.
4.4.1 Design Tab The Design tab contains features used to configure the overall structure of the Catalytic Reformer operation. The features are grouped into the following pages: • • •
Connections Calibration Factors Notes
Connections Page The Connections page enables you to rename the operation, and connect/disconnect streams flowing into and out of the Catalytic Reformer. Figure 4.12
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Depending on the configuration of the Catalytic Reformer, the image of the operation will vary.
Object
Description
Name field
Enables you to specify a name for the Catalytic Reformer operation.
Reformer Feeds table
Enables you to connect feed streams to the Catalytic Reformer, specify the internal feed stream names, and select the type for the feed streams.
Products table(s)
Enables you to connect product streams to the Catalytic Reformer and specify the internal feed stream name.
Feed Type Library button
Enables you to access the Feed Type Library Property View and modify the feed stream type and data.
Calibration Factors Page The Calibration Factors page enables you to create, edit, view, and apply a calibration factor set to the Catalytic Reformer. Figure 4.13
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Catalytic Reformer Property View
Object
Description
Calibration Factor Set drop-down list
Enables you to select and apply a calibration factor set to the Catalytic Reformer. Initially, Aspen HYSYS Petroleum Refining provides a default calibration factor set. The calibration factors in the default set are read only. If you want to manipulate the factor values, you have to create your own calibration factor set.
Calibration Factors Library button
Enables you to access the Calibration Set Library Property View. The Calibration Set Library property view enables you to create, import, clone, edit, export, and delete a calibration factor set.
Calibration Factors table
Displays the following calibration factors: • Isomerization Tuning Factors • Olefin Distribution Factor • Equilibrium Constant Tuning Factors • Light Ends Tuning Factors • Kinetic Pathways Tuning Factors • Dehydrogenation Tuning Factors • Ring Closure Tuning Factors • Cracking Tuning Factors • Paraffin Isomerization Tuning Factors • Ring Expansion Tuning Factors • General Coke Activities • DP Factors • Base Heat Flux • Pinning Coefficients • RON Activity Factors
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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4.4.2 Reactor Section Tab The Reactor Section tab contains features used to configure the reactor in the Catalytic Reformer operation. The features are grouped into the following pages: • • • • • • • •
Feeds Reactor Control Catalyst Recontactor Product Heater Solver Options Solver Console Advanced
Feeds Page The Feeds page enables you to modify the properties of the feed streams entering and exiting the Catalytic Reformer. Figure 4.14
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Catalytic Reformer Property View
Object
Description
Feed Conditions table
Enables you to modify the following properties of the feed stream(s) entering the Catalytic Reformer: • volume flow rate • mass flow rate • standard volume flow rate • temperature
Combined row
Displays the total value for each of the following columns: • Volume Flow • Mass Flow • Std Vol Flow
Reactor Control Page The Reactor Control page enables you to modify the variables that control the reactor in the Catalytic Reformer. Figure 4.15
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Object
Description
Reactor Temperature Specification table
Enables you to specify the following variables that control the reactor temperature: • WAIT (weight average inlet temperature) • WABT (weight average bed temperature) • Reactor Inlet Reference Temperature • Rx 1 Temperature Bias • Rx 1 Inlet Temperature • Rx 2 Temperature Bias • Rx 2 Inlet Temperature • Rx 3 Temperature Bias • Rx 3 Inlet Temperature • Rx 4 Temperature Bias • Rx 4 Inlet Temperature • C5+ RON • C6+ RON • Sum of Aromatics, Wt.% of Feed
Hydrogen Recycle table
Enables you to configure the Hydrogen recycle performance: • Recycle Compressor Flow • H2HC Ratio (mol/mol)
Product Separator table
Enables you to configure the product separator: • Product Separator Temperature • Product Separator Pressure
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Catalytic Reformer Property View
Catalyst Page The Catalyst page enables you to specify catalyst parameters for the reactor beds. The features available in the Catalyst page varies depending on which type of reactor you selected for the Catalytic Reformer: •
For the CCR reactor, you can specify the regenerator condition, and either specify the catalyst circulation rate or the coke on catalyst weight %.
Figure 4.16
Object
Description
CatCircRate field
Enables you to specify the catalyst circulation rate.
Coke on Catalyst (wt%) rows
Enables you to specify the Coke on Catalyst weight percentage for each reactor beds.
Coke Laydown Rate (kg/h) rows
Enables you to specify the Coke Laydown rate for each reactor beds.
Percent Pinning (%) rows
Enables you to specify the Pinning percent for each reactor beds.
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For the Semi-regen reactor, you can specify the start and end time for the reaction, the initial coke on catalyst, and the coke on catalyst equilibrium distribution factor.
Figure 4.17
Object
Description
Simulation End/Start Times table
Enables you to specify the start and end time for the simulation reaction.
COC at Start of Simulation table
Enables you to specify the initial coke on catalyst value for all the reactor beds.
Equilibrium Distribution Factors table
Enables you to specify the equilibrium distribution factor of the coke on catalyst for all the reactor beds.
Average COC table
Enables you to specify the average coke on catalyst value for all the reactor beds.
Rate of Coke Production table
Enables you to specify the coke laydown rate for all the reactor beds.
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Catalytic Reformer Property View
Recontactor Page The Recontactor page enables you to configure the booster compressors and recontactor drums. If the Catalytic Reformer does not have a recontactor, the Recontactor page appears blank. Figure 4.18
Object
Description
Outlet Pressure row
Enables you to specify the outlet pressure of the booster compressor for the following: • low pressure • high pressure
Inlet Stream DP row
Enables you to specify the inlet stream pressure difference of the recontactor drum for the following: • low pressure • high pressure
Product Temperature row
Enables you to specify the product stream temperature of the recontactor drum for the following: • low pressure • high pressure
Murphree Efficiency row
Enables you to specify the Murphree efficiency of the recontactor drum for the following: • low pressure • high pressure
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Product Heater Page The Product Heater Page enables you to specify the temperature or heat duty of the heater, and the outlet stream pressure or pressure difference of the heater. Figure 4.19
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Catalytic Reformer Property View
Solver Options Page The Solver Options page enables you to modify the calculation variables used to determine the reaction results of the reactor. Figure 4.20
Object
Description
Convergence Tolerance group
Contains the Residual field that enables you to specify the maximum residual value allowed for the convergence calculation.
Iteration Limits group
Contains two fields that enable you to control the iteration range for the OOMF Solver performance: • Maximum Iterations field enables you to specify the maximum number of iterations. • Minimum Iterations field enables you to specify the minimum number of iterations.
Creep Step Parameters group
Contains three fields that enable you to configure the creep function of the OOMF Solver: • On/Off Switch drop-down list. Enables you to select On (enable) or Off (disable) option for the creep feature. • Iterations field. Enables you to specify the number of iterations per creep step. • Step Size field. Enables you to specify the size of each creep step.
Completeness Checking group
Contains the Override Spec Group Completeness checkbox that enables you to toggle between: • HYSYS overriding its normal behaviour of requiring that spec groups be complete before solving. • HYSYS retaining its normal behaviour of requiring that spec groups be complete before solving.
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Object
Description
SQP Hessian Parameters group
Contains features used to manipulate the SQP Hessian parameters: • Initialization drop-down list. Enables you to select one of four options to initialize the Hessian value: Normal (default). Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and online problems that start very far from a solution. Aggressive. Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few Degrees of Freedom at solution. Ideal applications are well-posed online realtime optimization problems. Scaled. A combination of the Aggressive and Advanced modes. Recommended for highly constrained optimization problems with few Degrees of Freedom at solution and a nonlinear objective function. Advanced. Hessian initialized with 2nd order information. Recommended for problems with many Degrees of Freedom at solution and/or quadratic objective function. Ideal for data reconciliation problems, both online and offline. • Scaling factor field. Enables you to specify the scaling factor. • Updates stored field. Enables you to specify the number of updates stored during calculation (default value is 10).
Line Search Parameters group
Contains features used to configure the line search parameters: • Algorithm drop-down list. Enables you to select one of four methods for the line search algorithm: Normal (default). A proprietary line search designed to balance robustness with efficiency. Exact. A well-known exact penalty line search. It is too conservative for most practical problems. Residual. A proprietary line search designed to initially favour the convergence of residuals over the objective function improvement. Square. A line search designed to attempt to enforce bounds on cases with no Degrees of Freedom. It should be used only in cases where there are multiple solutions to a problem, and the desired solution lies within the bounds. • Step Control drop-down list. Enables you to select one of three options for the step size: Normal (default). The original method. Aggressive. A modified method that tends to take larger steps. Conservative. A modified method that tends to take smaller steps. • Step Control Iterations field. Enables you to specify the number of step iterations.
Variable Scaling Parameter group
Contains the On/Off Switch drop-down list that enables you to select one of the following options: • On. Activates the variable scaling parameter. • Off. Deactivates the variable scaling parameter.
Failure Recovery Action dropdown list
Enables you to select one of the following action in case of failure: • Do nothing. • Revert to the previous results before the solve (this is the default option). • Revert to the default input and results.
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Catalytic Reformer Property View
Solver Console Page The Solver Console page enables you to view the solver message generated by the reactor and run script commands. Figure 4.21
Object
Description
Simulation Engine Message and Script Commands field
Displays the messages and commands from the solver of the FCC reactor.
Enter Script Command field
Enables you to enter the text code for a command for the solver.
Clear Message button
Enables you to clear the messages in the Simulation Engine Message and Script Commands field.
Get Prev. Command button
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script Command field.
Get Next Command button
Enables you to retrieve the next command from the command history and place the text code in the Enter Script Command field.
Run Command button
Enables you to run the command code in the Enter Script Command field.
Clear Command button
Enables you to clear the command history.
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Advanced Page The Advanced page displays in detail the parameters that affect the performance of the Catalytic Reformer. The features in the Advanced page are intended for expert users who have detailed knowledge on the Catalytic Reformer. Figure 4.22
The following table lists and describes the variables available in the Advanced page: Parameter
Description
FOE Densities
The Fuel Oil Equivalent (FOE) density of the following components: H2, Methane, Ethane, and Ethylene.
Heater Efficiencies
The Heater efficiency variables enable you to specify the heat transfer efficiencies of the heater in each reactor.
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Catalytic Reformer Property View
Parameter
Description
General Kinetic Calibration Factors
The General Kinetic calibration factors enable you to adjust the activities for a specific reaction type (using the activity for the reaction type) or to adjust the reactions rates of all reactions simultaneously (using the Global Activity).
Activity Profile Constants
The Activity Profile Constants enable you to adjust the activity profile through a reactor. The only real valid reason for adjusting the Activity Distribution is to match measured internal reactor temperatures. Great care must be taken in this effort to insure that the exact locations of internal thermocouples are known. It is not recommended to tune to internal temperatures unless duplicate thermocouples are located in the beds at the same levels but in different quadrants of the reactor.
4.4.3 Stabilizer Tower Tab The Stabilizer Tower tab contains features used to manipulate the tower in the Catalytic Reformer. The features are grouped into the following pages: • •
Zone Pressures Specs
If the Catalytic Reformer does not contain a stabilizer tower, the above pages are blanked.
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Zone Pressures Page The Zone Pressures page enables you to specify the top pressure values for the fractionator zones and the bottom pressure of the fractionator. Figure 4.23
Specs Page Refer to Specs Page section from Chapter 6 Petroleum Column for more information.
The Specs page enables you to specify the values of the product output streams of the fractionator. These are the values that the Column algorithm tries to meet. There are two specs options to choose from: TBP Cut Point or Product Flow Fraction. Depending on which option you select in the Spec Option group, the features available in the Specs page varies.
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Catalytic Reformer Property View
•
TBP Cut Point option
Figure 4.24
•
Product Flow Fraction option
Figure 4.25
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4.4.4 Results Tab The Results tab displays the calculated simulation results of the Catalytic Reformer. The information are grouped in the following pages: • • • • • • • •
Summary Feed Blend Product Yields Product Properties Reactors Heaters Recontactor Product Streams
Summary Page The Summary page displays the calculated results of the Catalytic Reformer. Figure 4.26
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Catalytic Reformer Property View
Feed Blend Page The Feed Blend page displays the detailed characterization of each individual feed and blended feed streams entering the Catalytic Reformer. Figure 4.27
Properties • • • • • • •
mass flowrate volume flowrate standard volume flowrate moles flowrate molecular weight specific gravity API gravity
• • • • • • • •
components paraffins naphthenics aromatics D86 Initial point D86 cut points TBP Initial point TBP cut points
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Product Yields Page The Product Yields page displays the Net Reactor yields from the simulation. Figure 4.28
The Grouped Yield, Detailed Yield, and Fractionated radio buttons enables you to select how the information is displayed in the Product Yields page. •
Grouped Yields option displays the following properties:
Table
Properties
Grouped Yields
Displays the weight% and volume% values for the following properties: • • • • • • • • •
sum sum sum sum sum sum sum sum sum
of normal paraffins single-branched paraffins of multi-branch paraffins of all paraffins of Olefins of 5 ring Naphtha of 6 ring Naphtha of all Naphtha of all aromatics
• • • • • • • • • •
sum sum sum sum sum sum sum sum sum sum
of of of of of of of of of of
C4+ C5+ C6+ C8 aromatics C5 paraffins C6 paraffins C7 paraffins C8 paraffins C9 paraffins C10 paraffins
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Catalytic Reformer Property View
Table
Properties
Isomer Weight Ratios
Displays the isomer to normal weight ratios for the following components: • • • • • •
• C6+ • C6+ single-branch to multibranch • A8 para-xylene % • A8 meta-xylene % • A8 ortho-xylene % • A8 ethyl-benzene %
C4 C5 C6 C7 C8 C9
•
Detailed Yields option displays the following properties:
Table
Properties
Detailed Yields
Displays the weight% and volume% values for the following properties: • • • • • • • • • • • • • • • • • • • •
H2 P1 P2 OL2 P3 O3 IP4 NP4 O4 IP5 NP5 O5 5N5 MBP6 SBP6 NP6 O6 5N6 A6 6N6
• • • • • • • • • • • • • • • • • • • •
MBP7 SBP7 NP7 O7 5N7 A7 6N7 MBP8 SBP8 NP8 O8 5N8 ETHYLBENZENE O-XYLENE M-XYLENE P-XYLENE 6N8 IP9 NP9 5N9
• • • • • • • • • • • • • • • • • • • • •
A9 6N9 IP10 NP10 5N10 A10 6N10 IP11 NP11 5N11 A11 6N11 P12 N12 A12 P13 N13 A13 P14 N14 A14
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•
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Fractionated option displays the following properties:
Table
Properties
Vapor Streams
Displays the weight% and mole% (of net H2, Stab O/H vapor, and vent H2) for the following properties: • • • • • • • • • • • • • • • • • • • • •
Liquid Streams
MASS VOLUME H2 P1 P2 OL2 P3 O3 IP4 NP4 O4 IP5 NP5 O5 5N5 MBP6 SBP6 NP6 O6 5N6 A6
• • • • • • • • • • • • • • • • • • • • •
6N6 MBP7 SBP7 NP7 O7 5N7 A7 6N7 MBP8 SBP8 NP8 O8 5N8 ETHYLBEN O-XYLENE M-XYLENE P-XYLENE 6N8 IP9 NP9 5N9
• • • • • • • • • • • • • • • • • • • • •
A9 6N9 IP10 NP10 5N10 A10 6N10 IP11 NP11 5N11 A11 6N11 P12 N12 A12 P13 N13 A13 P14 N14 A14
Displays the mass, volume, and mole basis (of Stab O/H liquid and Stab btms) for the following properties: • • • • • • • • • • • • • • • • • • • • •
Flow Rate H2 P1 P2 OL2 P3 O3 IP4 NP4 O4 IP5 NP5 O5 5N5 MBP6 SBP6 NP6 O6 5N6 A6 6N6
• • • • • • • • • • • • • • • • • • • • •
MBP7 SBP7 NP7 O7 5N7 A7 6N7 MBP8 SBP8 NP8 O8 5N8 ETHYLBEN O-XYLENE M-XYLENE P-XYLENE 6N8 IP9 NP9 5N9 A9
• • • • • • • • • • • • • • • • • • • •
6N9 IP10 NP10 5N10 A10 6N10 IP11 NP11 5N11 A11 6N11 P12 N12 A12 P13 N13 A13 P14 N14 A14
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Catalytic Reformer Property View
If the Catalytic Reformer does not contain a stabilizer tower, the Fractionated option displays a blank page.
Product Properties Page The Product Properties page displays the properties of the net reactor yield from the simulation and the fractionated cuts if a fractionator is included. Figure 4.29
The Net Yield Properties group a table that displays the following properties: • • •
C5+ RON C6+ RON sum of aromatics, weight% of feed
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If a stabilizer tower is attached, the following tables appear: Table
Properties
Stabilizer Overhead Liquid
• molecular weight • API gravity
• specific gravity
Stabilizer Bottoms
• • • • • • • •
• • • • • • •
RON MON RVP specific gravity API gravity molecular weight Single-Branched Paraffins wt% Multi-Branched Paraffins wt%
Normal Paraffins wt% Total Paraffins wt% Total Olefins wt% 5C-Ring Naphthenics wt% 6C-Ring Naphthenics wt% Total Naphthenics wt% Total Aromatics wt%
Reactors Page The Reactors page displays the key simulation results of the reactors. Figure 4.30
The following calculated variable results are displayed for each reactor: • • •
Inlet Temperature Outlet Temperature Delta T. Temperature difference between the inlet stream and outlet stream. 4-53
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Catalytic Reformer Property View
• • • • • •
Inlet Pressure Outlet Pressure Delta P. Pressure difference between the inlet stream and outlet stream. Inlet Moles. Inlet stream flow rate in moles. Outlet Moles. Outlet stream flow rate in moles. Residence Time. The length of time the fluid stream remains within the reactor.
Heaters Page The Heaters page displays the calculated results of the heater properties after the reaction. Figure 4.31
Recontactor Page The Recontactor page displays calculated results of the recontactor. If the Catalytic Reformer does not contain a recontactor, then the Recontactor page appears blank.
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Figure 4.32
The following properties are displayed for the Booster Compressor and Recontactors at low and high pressures: •
•
For Booster Compressor: inlet stream moles flow rate, inlet stream temperature, inlet stream pressure, outlet stream temperature, outlet stream pressure, and gas power. For Recontactors: inlet vapour temperature, inlet vapour temperature, inlet vapour delta pressure, inlet liquid moles flow rate, inlet liquid temperature, inlet liquid pressure, inlet liquid delta pressure, heat loss, product temperature, product vapour fraction, Murphree efficiency, vapor mass, vapor moles, liquid temperature, liquid pressure, and liquid H2.
The following properties are displayed for the H2 Vent at low pressure: H2 to vent splitter, H2 to HP recontactor drum, fraction of H2 to HP recontactor drum, H2 Vent stream, and fraction of H2 to Vent H2.
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Feed Type Library Property View
Product Streams Page The Product Streams page displays the properties of the product stream exiting the Catalytic Reformer. Figure 4.33
4.5 Feed Type Library Property View The Feed Type Library property view enables you to import, export, delete, and configure the feed type data. You cannot delete the default feed type provided by Aspen HYSYS Petroleum Refining.
To access the Feed Type Library property view: 1. Open the Catalytic Reformer Property View. 2. Click the Design tab and select the Connections page. 3. Click the Feed Type Library button.
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The Feed Type Library property view appears. Figure 4.34
The following table lists and describes the options available in the Feed Type Library property view. Object
Description
Feed Types list
Displays the names of the feed type available in the Catalytic Reformer
Import button
Enables you to import feed types (from *.csv files) into the Catalytic Reformer.
Export button
Enables you to export a selected feed type, in the Feed Types list, to a *.csv file.
Delete button
Enables you to delete a selected feed type, in the Feed Types list, from the Catalytic Reformer.
Properties of Selected Feed Type table
Enables you to modify the property information of a selected feed type in the Feed Types list.
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Reactor Section Property View
4.6 Reactor Section Property View The Reactor Section property view enables you to configure and modify the reactor part of the catalytic reformer operation. To access the Reactor Section property view: 1. Enter the Catalytic Reformer subflowsheet environment. 2. Access the PFD by clicking the PFD icon. PFD icon
3. On the PFD property view, right-click the Reactor Section object icon. 4. Select View Properties command from the object inspect menu. The Reformer Reactor Section property view appears. Figure 4.35
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The following table lists and describes the common features in the Reactor Section property view: Object
Description
Delete button
Enables you to delete the reactor section.
Status bar
Displays the status of the reactor section of the catalytic reformer operation.
Ignore checkbox
Enables HYSYS to ignore the reactor section during the process flowsheet calculation.
4.6.1 Design Tab The Design tab contains the features used to configure the reactor section of the Catalytic Reformer operation. These features are grouped into the following pages: • • •
Configuration Geometry Notes
Configuration Page The Configuration page enables you to specify the reactor name, and displays the reactor type, number of reactor beds, and whether the reactor contains a recontactor. To modify the configuration, click the Configuration Wizard button to access the Reformer Configuration Wizard property view.
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Reactor Section Property View
Figure 4.36
Geometry Page The Geometry page enables you to specify detailed information/ structure of the reactor beds and heaters. Figure 4.37
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Object
Description
Length
Enables you to specify the length of the reactor bed.
Cat. Wt.
Enables you to specify the weight of the catalyst in the reactor bed.
Void Fraction
Enables you to specify the ratio/fraction between empty space in the reactor vs. space taken by the tubes.
Catalyst Density
Enables you to specify the density of the catalyst in the reactor beds.
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
4.6.2 Feed Data Tab The Feed Data tab contains features used to configure and modify the feed stream properties entering the Reformer Reactor Section. The features are grouped into the following pages: • •
Library Properties
You can also access the features in the Feed Data tab by clicking the Feed Type Library button in the Connections page of the Catalytic Reformer property view.
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Reactor Section Property View
Library Page The Library page enables you to create, copy, modify, import, export, and delete feed data types entering the reactor operation. Figure 4.38
Object
Description
Feed Types group
Displays the list of feed data types available for the reactor.
Import button
Enables you to import a feed data from a file. The feed data are saved in *.csv type files.
Export button
Enables you to export the selected feed data (from the Available Feed Types group) into a *.csv file. The exported feed data can be imported into a different applicable operation.
Delete button
Enables you to delete the selected feed data in the Available Feed Types group.
Properties of Selected Feed Type table
Enables you to modify the property information of a selected feed type in the Feed Types list.
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Properties Page The Properties page enables you to specify properties for virtual feeds. The virtual feeds are feeds not represented by internal or external streams in the subflowsheet and flowsheet respectively. Figure 4.39
Object
Description
Feeds group
Displays both real and virtual feed streams connected to the Catalytic Reformer.
Add button
Enables you to create a virtual feed stream. Aspen HYSYS Petroleum Refining automatically assigns a default name to the virtual feed stream and treats the virtual stream as an internal stream.
Delete button
Enables you to delete the selected feed stream from the Feeds group. If the selected feed stream is a real stream, then both the internal and external streams will be deleted.
Assay radio button
Enables you to specify assay properties of the selected feed type in the Feed Type list.
Bulk Properties radio button
Enables you to specify bulk properties of the selected feed type in the Feed Type list.
Kinetic Lumps radio button
Enables you to specify kinetic lumps properties of the selected feed type in the Feed Type list.
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Reactor Section Property View
Object
Description
Use GC Data checkbox
Enables you to use the GC data (from the selected feed stream) to derived the composition. This checkbox is only available if you select the Assay radio button and if the selected feed stream contains GC data.
Assay drop-down list
Enables you to select the assay associated to the selected feed type in the Feed Type list. This drop-down list is only available if you select the Assay radio button.
Feed Properties group
Contains a table that displays the list of properties available for you to view or modify of the selected feed stream. The variables available in this table varies depending on which radio button you select in the Selected Feed group.
4.6.3 Operation Tab The Operation tab contains features used to manipulate the operation parameters of the Catalytic Reformer operation. The features are grouped into the following pages: • • • • • • • •
Feeds Reactor Control Catalyst Recontactor Product Heater Solver Options Solver Console Advanced
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Feeds Page Refer to Feeds Page section for more information.
The Feeds page enables you to modify the physical properties of the feed streams entering and exiting the reactor section of the Catalytic Reformer operation. Figure 4.40
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Reactor Section Property View
Reactor Control Page Refer to Reactor Control Page section for more information.
The Reactor Control page enables you to modify the variables that control the reactor. Figure 4.41
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Catalyst Page Refer to Catalyst Page section for more information.
The Catalyst page enables you to modify the catalyst properties in the reactor. The options in the Catalyst page varies depending on which Catalytic Reformer configuration you selected. Figure 4.42
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Reactor Section Property View
Recontactor Page Refer to Recontactor Page section for more information.
The Recontactor page enables you to configure the recontactor in the reactor. If the Catalytic Reformer does not contain a recontactor, the Recontactor page will appear blank. Figure 4.43
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Product Heater Page The Product Heater page enables you to specify the outlet pressure, pressure difference, outlet temperature, and/or heater duty. Figure 4.44
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Reactor Section Property View
Solver Options Page Refer to Solver Options Page section for more information.
The Solver Options page enables you to modify the calculation variables used to determine the reaction results of the reactor. Figure 4.45
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Solver Console Page Refer to Solver Console Page section for more information.
The Solver Console page enables you to view the solver message generated by the reactor and run script commands. Figure 4.46
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Reactor Section Property View
Advanced Page Refer to Advanced Page section for more information.
The Advanced page enables you to view in detail the parameters that affect the performance of the Catalytic Reformer. The features in the Advanced page are intended for expert users who have detailed knowledge on the Catalytic Reformer. Figure 4.47
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4.6.4 Results Tab The Results tab enables you to view the calculated variable results of the Catalytic Reformer. The information are grouped into the following pages: • • • • • • • •
Summary Feed Blend Product Yields Product Properties Reactor Section Heaters Recontactor Product Streams
Summary Page The Summary page displays the calculated results of the Catalytic Reformer. Figure 4.48
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Reactor Section Property View
Feed Blend Page The Feed Blend page displays the calculated physical properties of the feed stream entering the reactor. Figure 4.49
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Product Yields Page The Product Yields page displays the calculated yield results of the product stream exiting the reactor. Figure 4.50
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Reactor Section Property View
Product Properties Page The Product Properties page displays the calculated physical properties of the product stream exiting the reactor. Figure 4.51
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Reactors Page For more information, refer to Reactors Page section.
The Reactors page displays the key simulation results of the riser and reactor. Figure 4.52
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Reactor Section Property View
Heaters Page The Heaters page displays the calculated results of the heater properties after the reaction. Figure 4.53
Recontactor Page The Recontactor page displays calculated results of the recontactor. If the Catalytic Reformer does not contain a recontactor, then the Recontactor page appears blank.
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Figure 4.54
Product Streams Page The Product Streams page displays the properties of the product stream exiting the Catalytic Reformer. Figure 4.55
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Feed Type Property View
4.7 Feed Type Property View The Feed Type property view enables you to modify the selected feed data. Figure 4.56
Object
Description
Name field
Enables you to specify the name of the feed data.
Description field
Enables you to provide an explanation/description of the feed data.
Created field
Displays the date and time when the feed data was created.
Modified field
Displays the date and time when the feed data was last modified.
Kinetic Lump Weight Percents table
Enables you to specify the value of the kinetic lumps ratio in the feed data.
Normalize button
Enables you to normalize the values in the Ratio Value column so the sum of the ratio equals 1.
Delete button
Enables you to delete the current feed type in the Feed Type property view.
To access the Feed Type property view, in the Reformer Reactor Section property view, click the Feed Data tab, select the Library page, and click the Add button.
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4.8 Calibration Set Library Property View The Calibration Set Library property view enables you to manage the calibration factor sets. There are several methods to access the Calibration Set Library property view: • • •
In the Reformer Configuration Wizard property view, go to the Calibration Factors (3 of 3) page and click the Library button. In the Catalytic Reformer Property View, select the Design tab, select the Calibration Factors page, and click the Calibration Factors Library button. In the Catalytic Reformer Environment, select Reformer | Calibration Factor command from the menu bar, and click the Library button in the Calibration Factor Set property view.
Figure 4.57
The following table lists and describes the options available in the Calibration Set Library property view: Object
Description
Available Calibration Factor Sets list
Displays all the factor sets available in the current calibration environment.
View/Edit button
Enables you to view or modify the data of the selected factor set in the Available Calibration Factor Sets list.
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Calibration Set Library Property
Object
Description
Add button
Enables you to add a new factor set and access the Factor Set Property View.
Delete button
Enables you to delete the selected factor set in the Available Calibration Factor Sets list.
Clone button
Enables you to create a copy/clone of the selected factor set in the Available Calibration Factor Sets list.
Import button
Enables you to import a calibration factor set data from a *.csv file.
Export button
Enables you to export/save the selected factor set (in the Available Calibration Factor Sets list) to a file *.csv.
HYSYS provides a default calibration factor set with values in the Calibration Set Library. The calibration factor values, in the Default calibration factor set, are read only. To modify the calibration factors, you need to make a clone of the Default Calibration Factor set, and modify the calibration factor values in the cloned set.
4.8.1 Factor Set Property View The Factor Set property view displays the variable values that make up the calibration factor set. You can also edit the variable values in the Factor Set property view. You cannot modify the variable values of the default calibration factor set provided by HYSYS.
To access the Factor Set property view: 1. Open the Calibration Set Library Property View. 2. Do one of the following: • • •
Click the Add button to create a new calibration factor set. Select the calibration factor set you want to view in the Available Calibration Factor Sets list and click the View/ Edit button. Select the calibration factor set you want to edit in the Available Calibration Factor Sets list and click the Clone button. 4-82
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The Factor Set property view appears. Figure 4.58
The options in the Factor Set property view is grouped into three pages: • • •
Reactor Advanced Stabilizer
All three pages in the Factor Set property view contains the following common options: Object
Description
Name field
Enables you to specify the name of the calibration factor set.
Description field
Enables you to provide a brief description on the calibration factor set.
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Calibration Set Library Property
Object
Description
Date Created field
Displays the date and time when the calibration factor set was created.
Date Modified field
Displays the date and time when the calibration factor set was last modified.
Reactor Page The Reactor page enables you to access the Reactor Factors group and specify variable values associated to the reactor. Figure 4.59
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Advanced Page The Advanced page enables you to access the Advanced Factors group and specify variable values associated to the advanced options. Figure 4.60
Stabilizer Page The Stabilizer page enables you to enables you to access the Fractionator Cuts group and specify variable values associated to the stabilizer tower. The Stabilizer page is blank if the Catalytic Reformer does not contain a stabilizer tower.
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Calibration Property View
Figure 4.61
4.9 Calibration Property View The Calibration property view enables you to calibrate the Catalytic Reformer. Figure 4.62
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The Calibration property view is only accessible in the Calibration Environment.
The following table lists and describes the common features in the Calibration property view: Object
Description
Run Calibration button
Enables you to select one or more data set for the calibration run and access the Validation Wizard feature. This button is unavailable until all required data is entered.
Data Set drop-down list
Enables you to select different data sets for entering the data or viewing the results for the calibration or the prediction run.
Manage Data Sets button
Enables you to access the Data Set Manager Property View to manage the data set.
Push Data to Simulation button
Enables you to export input data from the current data set in the calibration property view to the property view in the Catalytic Reformer environment. Any existing simulation data will be overwritten with the current calibration data.
Pull Data from Simulation button
Enables you to import input data from the property view in the Catalytic Reformer environment into the current data set in the Calibration property view. Any existing calibration data will be overwritten with the current simulation data.
Return to Simulation button
Enables you to exit the Calibration environment and return to the Catalytic Reformer environment.
Status bar
Displays the current status of the calibration/ prediction run.
Validation Wizard When you click the Run Calibration button, HYSYS lets you select the data set you want to use for the calibration run, and validate the selected data set before the calibration is actually run. The Run Calibration button in the Calibration property view is unavailable until all necessary calibration input is complete.
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Calibration Property View
Depending on how many data sets are available for the calibration run one of the following property views appears when you click the Run Calibration button: • •
Select Data Sets for Calibration property view Validation Wizard property view
Select Data Sets for Calibration Property View This property view displays status and names of data sets available with the calibration run. Figure 4.63
The Select Data Sets for Calibration property view appears only when there is more than one data set for the calibration run.
Object
Description
Include column
Contains a checkbox that enables you to include or exclude the data sets for the calibration run. When a clear checkbox is selected, the Validation Wizard property view appears.
Data Set Name column
Displays the name of the data sets available for the calibration run.
Status column
Displays the status of the associate data set.
Run Calibration button
Enables you to run the calibration using the selected data set in the Select Data Sets for Calibration group. This button is not active until you have selected and validated a data set.
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Object
Description
Stop button
Enables you to stop the calculation process during a calibration run. This button is only active during the calibration run calculation.
Close button
Enables you to close the Select Data Sets for Calibration property view without performing any calibration run.
Validation Wizard Property View This property view displays the mass flows and hydrogen flows of feed and product streams (derived from the input data). Figure 4.64
If there is only one data set for the calibration run, the Validation Wizard property view appears when you click the Run Calibration button.
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Calibration Property View
Object
Description
Feed group
Displays the following properties for the feed streams of the data set: • stream name • mass flowrate • total mass flowrate • feed hydrogen • total hydrogen
Mass and Hydrogen Balance group
Displays the mass and hydrogen closure before and after the product masses are adjusted.
Product group
Displays the following properties for the product streams of the data set: • stream name • measured mass flowrate • adjusted mass flowrate • measured hydrogen flow rate • adjusted hydrogen flow rate • total measured mass flowrate • total adjusted mass flowrate • total measured hydrogen flow rate • total adjusted hydrogen flow rate You can also assign or not assign bias to the product stream by clicking the appropriate checkbox in the Assign Bias column.
OK button
Enables you to close the Validation Wizard property view and accept the changes made in the property view.
Cancel button
Enables you to close the Validation Wizard property view without accepting any changes made in the property view.
The information displayed in the Validation Wizard property view enables you to analyse the measurement data before accepting the data set for the calibration run. If the total product mass rate is greater than the total feed mass rate by about 2-3%, you should review the flow rate and gravity information of the products. If you think the error is acceptable, you can decide how you would like to distribute the mass imbalance by assigning the bias to any of the product streams (except coke). Once the bias is assigned, the Validation Wizard adjusts the mass flow of the selected product stream(s) to match the feed total mass flow by re-normalization.
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Data Set Manager Property View The Data Set Manager property view enables you to add, modify, clone, delete, or rename the Catalytic Reformer data sets associated to the calibration run. Figure 4.65
Object
Description
Available Data Sets list
Displays all the data sets available in the associate calibration/prediction run.
Add button
Enables you to add a new data set to the calibration/prediction run.
Delete button
Enables you to delete the selected data set in the Available Data Sets list.
Clone button
Enables you to clone the selected data set in the Available Data Sets list.
Rename button
Enables you to rename the selected data set in the Available Data Sets list.
4.9.1 Design Tab The Design tab contains features used to configure the reactor in the Catalytic Reformer operation. The features are grouped into the following pages: • • •
Configuration Geometry Notes
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Calibration Property View
Configuration Page The Configuration page enables you to access the Reformer Configuration Wizard and modify reactor type, number of reactor beds, and whether the reactor contains a recontactor. Figure 4.66
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Geometry Page For more information, refer to Geometry Page section.
The Geometry page enables you to specify detailed information/ structure of the reactor beds and heaters. Figure 4.67
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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Calibration Property View
4.9.2 Feed Data Tab The Feed tab contains features used to configure and modify the feed stream properties entering the FCC Reactor Section. The features are grouped into the following pages: • •
Library Properties
Library Page For more information, refer to Library Page section.
The Library page enables you to create, copy, modify, import, export, and delete feed data types entering the reactor operation. Figure 4.68
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Properties Page For more information, refer to Properties Page section.
The Properties page enables you to specify properties for virtual feeds. The virtual feeds are feeds not represented by internal or external streams in the subflowsheet and flowsheet respectively. Figure 4.69
4.9.3 Operation Tab The Operation tab contains features used to manipulate the operation parameters of the Catalytic Reformer operation. The features are grouped into the following pages: • • • • • • • • •
Feeds Reactor Control Catalyst Recontactor Product Heater Stabilizer Solver Options Solver Console Advanced
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Calibration Property View
Feed Page Refer to Feeds Page section for more information.
The Feeds page enables you to modify the physical properties of the feed streams entering and exiting the reactor section of the Catalytic Reformer operation. Figure 4.70
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Reactor Control Page Refer to Reactor Control Page section for more information.
The Reactor Control page enables you to modify the variables that control the reactor. Figure 4.71
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Calibration Property View
Catalyst Page Refer to Catalyst Page section for more information.
The Catalyst page enables you to modify the catalyst properties in the reactor. Figure 4.72
Recontactor Page Refer to Recontactor Page section for more information.
The Recontactor page enables you to configure the recontactor in the reactor. If the Catalytic Reformer does not contain a recontactor, the Recontactor page will appear blank.
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Figure 4.73
Product Heater Page The Product Heater page enables you to modify the outlet pressure, pressure difference, outlet temperature, and/or heater duty. Figure 4.74
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Calibration Property View
Stabilizer Page The Stabilizer page enables you to modify the feed temperature, top vapour pressure, bottom pressure, and reboiler duty (if applicable). Figure 4.75
The Stabilizer page is blank if the Catalytic Reformer configuration does not include a stabilizer.
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Solver Options Page Refer to Solver Options Page section for more information.
The Solver Options page enables you to modify the calculation variables used to determine the reaction results of the reactor. Figure 4.76
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Calibration Property View
Solver Console Page Refer to Solver Console Page section for more information.
The Solver Console page enables you to view the solver message generated by the reactor and run script commands. Figure 4.77
Advanced Page The Advanced page enables you to view the detail parameters that affect the performance of the Catalytic Reformer. The information in the Advanced page are intended for expert users who have detailed knowledge on the Catalytic Reformer.
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Figure 4.78
4.9.4 Measurement Tab The Measurement tab contains features used to configure the operations, manipulate the product streams, and analyse the production measurement results. The features are grouped into the following pages: • • •
Operation Products Analysis
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Calibration Property View
Operation Page The Operation page enables you to modify the parameters of the reactor, compressor, and recycle stream. Figure 4.79
The following table lists and describes the options available in the Operation page: Object
Description
Inlet Pressure column
Enables you to modify the inlet pressure of the stream entering each reactor.
Pressure Drop column
Enables you to modify the pressure drop in each reactor.
Delta T
Enables you to modify the temperature difference in each reactor.
Discharge Pressure cell
Enables you to modify the pressure of the stream exiting the compressor.
Suction Pressure cell
Enables you to modify the suction pressure of the compressor.
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Object
Description
H2 Purity of Recycle cell
Enables you to modify the purity of hydrogen in the recycle stream.
Measured Octanes group
Enables you to modify the RON and MON values of the product stream for C5+ and C6+. If you do not have values for the measured octanes on a C5+ and C6+ basis, the model will estimate values from the reformate values entered in the Products page, Measurement tab. The estimated values are displayed on the Analysis page, Measurement tab.
Products Page The Products page enables you to modify the product stream parameters. Figure 4.80
The following table lists and describes the options available in the Products page: Object
Description
Gas Rate row
Enables you to modify the gas flow rate of the applicable product stream.
Liquid Rate row
Enables you to modify the liquid flow rate of the applicable product stream.
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Calibration Property View
Object
Description
Mass Rate row
Enables you to modify the mass flow rate of the applicable product stream.
RON row
Enables you to modify the RON (research octane number) value of the applicable product stream.
MON row
Enables you to modify the MON (motor octane number) value of the applicable product stream.
Composition row
Enables you to select the basis used to specify the composition of the product stream. There are three options: • percentage in moles • percentage in weight • percentage in volume
component rows
Enables you to modify the composition of the product streams.
Analysis Page The Analysis page enables you to view the analysis results of the product measurement data. Figure 4.81
The information is split into four groups: •
The Mass and Hydrogen Balances group displays the mass flow rate and hydrogen flow rate for the feed stream, product stream and closure.
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• •
•
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The Ring Generation group displays the flow rate for the number of carbons in the feed and reformate stream, and the percentage change between the two streams. The Light Ends Ratios group displays the molar flow rate of the light end components in the product stream, percentage value of the light ends in the product stream, and the Iso to Normal butane ratio. The Estimated Octanes group displays octanes estimated from the measured reformate on a C5+ and C6+ basis.
4.9.5 Calibration Control Tab The Calibration Control tab contains features used to control the calibration calculation. The features are grouped into the following pages: • •
Parameter Objective Function
Parameter Page The Parameter page enables you to modify the initial, lower bound, and upper bound parameter value, and select which parameters are used in calibrating the reactor model. Figure 4.82
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Calibration Property View
The following table lists and describes the options available in the Parameter page: Object
Description
First column
Displays the list of available calibration parameters for you to select and/or modify.
Included column
Enables you to toggle between considering or ignoring the calibration parameter by selecting or clearing the appropriate checkboxes.
Initial Value column
Enables you to modify the initial value of the calibration parameters.
Lower Bound column
Enables you to specify the lower bound value of the calibration parameters.
Upper Bound column
Enables you to specify the upper bound value of the calibration parameters.
HYSYS provides default factor set values for the initial values of the parameters (in the Initial Value column).
Objective Function Page The Objective Function page enables you to construct the objective function for the calibration. Figure 4.83
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The first column contains the list of available variables for the calibration objective function and the second column enables you to specify the sigma value for each variables.
4.9.6 Analysis Tab The Analysis tab displays the calculated results of the calibration. The calibration results are grouped into the following pages: • • • • • • • • • •
Calibration Factors Mass Balance Summary Feed Blend Product Yields Reactors Heater Recontactor Stabilizer Product Streams
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Calibration Property View
Calibration Factors Page Refer to Section 4.9.5 Calibration Control Tab for more information on the Parameter and Objective Function pages.
The Calibration Factors page enables you to save, export, and edit the current calibration factor set in the calibration run. Figure 4.84
The Calibration Factors page also contains two groups: •
•
The Parameter group displays the whether the variable was used as a reconciliation variable in the calibration, the initial and final values of the variable and the upper and lower bounds used for the reconciliation variables. The Objective Function group displays the sigma used for each term in the objective function, the measured value, the model value and the delta (model - measured) value.
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Save Calibration Factor Set To save the current calibration factors: 1. Click the Save for Simulation button. The Save for Simulation button is activated only when the calibration of the current set (as indicated in the Data Set drop-down list) is successfully completed.
The Save Calibration Factor Set property view appears. Figure 4.85
2. Enter a name of the calibration factor set in the Set Name field. To export the current calibration factor set values into the simulation environment, select the Use this set for current simulation checkbox. 3. Click OK.
Export Calibration Factor Set To export the calibration factor set into a file: 1. Click the Export button. The Export button is activated only when the calibration of the current set (as indicated in the Data Set drop-down list) is successfully completed.
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Calibration Property View
The File selection for exporting Factor Sets property view appears. Figure 4.86
2. Use the Save in drop-down list to select the location and folder for the exported calibration factor set file. 3. Enter the name of the calibration factor set file in the File name field. The calibration factor set data is saved as a *.csv file. 4. Click Save.
Modify Calibration Factor Set To modify the current calibration factor set: 1. Click the Calibration Factors Library button. The Calibration Set Library Property View appears. 2. In the Calibration Set Library property view, select the calibration factor set you want to modify. Aspen HYSYS Petroleum Refining automatically assigns the following name to the current calibration factor set “Set-n”, where n is an integer number.
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3. Click the Edit button to open the Factor Set Property View. The Calibration Set Library also enables you to add, delete, clone, import, and export calibration factor sets. 4. In the Factor Set property view, make the modifications and accept the modified values by closing the property view.
Mass Balance Page The Mass Balance page displays the calculated flow rate of the feed and product streams, and the mass and hydrogen balance. Figure 4.87
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Calibration Property View
Summary Page The Summary page displays the calculated values of the WAIT, yields and RON of the octane and reformate, recycle H2 properties, Hydrogen yield properties, and aromatic yield properties. Figure 4.88
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Feed Blend Page The Feed Blend page displays the calculated physical properties of the feed stream from the calibration run. Figure 4.89
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Calibration Property View
Product Yields Page The Product Yields page displays the calculated yield results of the product stream from the calibration run. Figure 4.90
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Reactors Page For more information, refer to Reactors Page section.
The Reactors page displays the key simulation results of the riser and reactor from the calibration run. Figure 4.91
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Calibration Property View
Heater Page The Heater page displays the calculated results of the heater parameters from the calibration run. Figure 4.92
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Recontactor Page For more information, refer to Recontactor Page section.
The Recontactor page displays calculated results of the recontactor from the calibration run. Figure 4.93
If the Catalytic Reformer does not contain a recontactor, then the Recontactor page appears blank.
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Calibration Property View
Stabilizer Page The Stabilizer page displays the calculated results of the stabilizer from the calibration run. Figure 4.94
If the Catalytic Reformer does not contain a stabilizer, then the Stabilizer page appears blank.
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Product Streams Page The Product Streams page displays the properties of the product stream from the calibration run. Figure 4.95
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Calibration Property View
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Hydrocracker
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5 Hydrocracker
5.1 Introduction................................................................................... 3 5.1.1 Feed Characterization System .................................................... 3 5.1.2 Reaction Kinetics...................................................................... 6 5.2 Overall Operation Structure/Environment ................................... 17 5.2.1 Main Environment .................................................................. 18 5.2.2 HCR Environment ................................................................... 21 5.3 HCR Configuration Wizard............................................................ 23 5.3.1 Configuration Page ................................................................. 24 5.3.2 Geometry Page ...................................................................... 26 5.3.3 Calibration Factors Page .......................................................... 27 5.4 HCR Property View....................................................................... 28 5.4.1 5.4.2 5.4.3 5.4.4
Design Tab ............................................................................ 29 Reactor Section Tab ................................................................ 31 Fractionator Tab ..................................................................... 39 Results Tab............................................................................ 41
5.5 Feed Type Library Property View ................................................. 46 5.6 HCR Reactor Section Property View ............................................. 48 5.6.1 5.6.2 5.6.3 5.6.4
Design Tab ............................................................................ 49 FeedData Tab......................................................................... 51 Operation Tab ........................................................................ 53 Results Tab............................................................................ 59
5.7 Calibration Set Library Property View .......................................... 63 5.7.1 Factor Set Property View ......................................................... 64
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Hydrocracker
5.8 Results Property View ..................................................................67 5.8.1 5.8.2 5.8.3 5.8.4 5.8.5 5.8.6
Feed Blend Page .....................................................................67 Product Yields Page .................................................................68 Product Properties Page ...........................................................69 Reactor Page ..........................................................................69 Hydrogen System Page ............................................................70 Hydrogen Balance Page ...........................................................70
5.9 Calibration Property View..............................................................71 5.9.1 Design Tab............................................................................76 5.9.2 Feed Data Tab.......................................................................79 5.9.3 Operation Tab..........................................................................87 5.9.4 Operation Measure Tab .............................................................95 5.9.5 Product Measure Tab ................................................................96 5.9.6 Calibration Control Tab............................................................101 5.9.7 Analysis Tab ..........................................................................102 5.10 References................................................................................113
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Hydrocracker
5-3
5.1 Introduction The Hydrocracker model in Aspen HYSYS Petroleum Refining is a state-of-the-art Hydrocracker Unit simulation system that can be used for modeling a single-stage, two-stage Unicracker, or two-stage Isocracker hydrocracker unit as a standalone unit operation or as part of a refinery-wide flowsheet. The Hydrocracker unit operation includes feed characterization system, reactor section, recycle gas loop(s), product separation, and product mapper. The reactor model is based on rigorous kinetics. The feed characterization system and product mapper are designed to work together with the Aspen HYSYS Petroleum Refining assay system so the Hydrocracker model can be simulated in a refinery-wide flowsheet.
5.1.1 Feed Characterization System For more information about the Hydrocracker subflowsheet, refer to Section 5.2.2 - HCR Environment.
The Hydrocracker within Aspen HYSYS Petroleum Refining has its own set of library and hypothetical components. The following is the component list for the Hydrocracker subflowsheet: Nitrogen
C9A*
MAN2HI*
HNNITA2*
IC9-2*
H2S
C10A*
HN1*
HA4*
NC10*
Hydrogen
LTHA*
HA1*
C47P*
NC11*
Ammonia
MBNITN*
MTHA2*
VN1*
NC12*
Methane
MBNITA*
HN2*
VA1*
NC14*
Ethane
MTHN*
HN3*
VN2*
NC16*
Propane
MTHA*
HN4*
VN3*
C10N-1*
C4*
MS12*
MA2NHI*
VN4*
C10N-2*
C5*
MNNITA*
HAN*
VAN*
C12N*
C6P*
MN3LO*
MANAHI*
VBNITA2N*
C14N*
C6N*
MANLO*
HA2*
VA2*
C16N*
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Introduction
C6A*
MA2LO*
HAN2*
VTHA2N*
C12A*
C7P*
MAN2LO*
C26P*
VAN2*
C14A*
C7N*
C18P*
HAN3*
VAN3*
C16A*
C7A*
MA2NLO*
HA2N*
VA2N*
IC10*
LTH*
MN1HI*
HANA*
VANA*
IC11*
LBNIT*
MA1HI*
HA2N2*
VA2N2*
IC12*
C8P*
MANALO*
HA3*
VA3*
IC14*
C8N*
MN2HI*
HTHAN*
VA4*
IC16*
LNNIT*
MN3HI*
HBNITAN*
VNNITA3*
12N2*
C8A*
MANHI*
HS28*
VTHA3*
14N2*
C9N*
MTHAN*
HTHA2*
NC9*
16N2*
LS8*
MA2HI*
HBNITA2*
IC9-1*
Below is a legend to help you decode the meaning of the above list: •
For components starting with C, the number beside the C indicates the carbon number of the component. These components end in P, N, or A indicating whether they are paraffins, naphthenes, or aromatics.
There are two isomers for C10N.
• • • • •
For components starting with NC, they are normal paraffins. The number beside the C indicates the number of carbon atoms. For components starting with IC, they are isoparaffins. The number beside the C indicates the number of carbon atoms. For components ending in N2, they are two ring naphthenic compounds. The prefix number indicates the number of carbon atoms. For components starting with L, they boil in the gasoline range. For components starting with M, they boil in the distillate range. For these components with LO ending, they boil toward the beginning of the distillate temperature range. For these components with HI ending, they boil toward
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the end of the distillate temperature range. • • • • • • • • • • • •
For components starting with H, they boil in the gas-oil range. For components starting with V, they boil in the vacuum resid range. A Th in the component indicates a thiophene ring. A BNit indicates a ring structure containing a basic nitrogen. An NNit indicates a ring structure containing a non-basic nitrogen. An N followed by a number indicates the number of naphthenic rings in a component. An A followed by a number indicates the number of aromatic rings in a component. An ANA indicates two aromatic rings separated by a naphthenic ring. An S in a compound indicates a sulfidic structure followed by a number indicating the number of carbon atoms. Medium (M) components ending with LO have 14 carbon atoms, medium components ending with HI have 18 carbon atoms. Heavy (H) components have 21 carbon atoms. Vacuum Resid (V) components have 47 carbon atoms.
These components are either used directly in the kinetic reactor model or mapped into the components used within the kinetic reactor model. Aspen HYSYS Petroleum Refining provides a transition command between the main flowsheet environment and the Hydrocracker subflowsheet environment to handle the calculation of the composition of the Hydrocracker components. In order to use the transition command, you must specify a feed type. The feed type will specify a base composition of components in the kinetic reactor model basis. This base fingerprint, along with the distillation, gravity, sulfur content, nitrogen and basic nitrogen content, and bromine number can be used to generate the composition of the kinetic lumps used by the model. In the Hydrocracker subflowsheet environment, you have more options for calculating the composition of the feed. For example, you can calculate the composition based on a boiling range of an assay by specifying bulk properties or by specifying the kinetic lumps. 5-5
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Introduction
•
•
•
For the assay option, you can select an assay to be associated with the feed. The feed type is specified along with the initial and final boiling point to generate a composition of the feed. For the bulk properties option, you can specify the feed type along with distillation data, gravity, sulfur content, nitrogen and basic nitrogen content, and bromine number. You can optionally input data for refractive index, viscosity, and Ca content. For the kinetic lumps option, you can specify the feed type along with the composition of the components that is desired. You can also enter a bromine number to generate the inlet composition of olefins in the feed.
5.1.2 Reaction Kinetics The reactor model in the Hydrocracker model in Aspen HYSYS Petroleum Refining is based on rigorous kinetics. There are 97 components in the reaction network and 177 reaction pathways. The components and reaction networks are consistent with typical Hydrocracking reactions.
Components The component slate chosen to represent the feed and the product streams of the Hydrocracker plant is comprised of 116 components covering the full range from hydrogen to hydrocarbons with 47 carbon atoms (B.P. 1300 C). In the reactor model, the 19 olefin components are assumed to be completely saturated in the first reactor bed. These olefins are saturated in an Aspen extended reaction block before the kinetic model for the first reactor bed. The Aspen extended reaction block calculates the enthalpy of reaction for the olefin saturation. This heat is distributed through the first reactor bed. This method reduces the number of components throughout the reactor section in order to improve the model performance. •
The Component Slate for the Hydrocracker Reactor Model table shows the corresponding components in the reactor model. The total number of components in the reactor model is 97.
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5-7
The Component Slate for Hydrocracker Model only in the feed table shows the corresponding olefin components in the feed but not in the reactor model.
The light ends will be defined using discrete components through C3. For C4 to C10 hydrocarbons, one pure component is used to represents several isomers. For example, the n-butane represents both n-butane and iso-butane. For higher boiling point components, only compounds with carbon number 14, 18, 26, and 47 are used to represent a wide range of boiling point components. The components also cover different classes of hydrocarbons that include one-ring naphthenics to 4-ring aromatics. The 13 sulfur components are separated into 8 groups: thiophenes, sulfides, benzothiophenes, tetrahydrobenzothiophenes, dibenzothiophenes, tetrahydrodibenzothiophenes, naphthabenzothiophenes, and tetrahydronaphthabenzothiophenes. The nitrogen compounds are represented by 10 components that include both basic and non-basic nitrogen compound.
Component Slate for the Hydrocracker Reactor Model Component
Formula
Abbreviation
Nitrogen
N2
N2
Ammonia
NH3
NH3
Hydrogen Sulfide
H2S
H2S
Hydrogen
H2
H2
Methane
CH4
C1
Ethane
C2H6
C2
Propane
C3H8
C3
N-Butane
C4H10_2
C4
N-pentane
C5H12_2
C5
2,3-dimethylbutane
C6H14_2
C6P
2,3-dimethylpentane
C7H16_5
C7P
2,3-dimethylhexane
C8H18_6
C8P
2,6-dimethylheptane
C9H20_4
C9P
Class
Paraffins CnH2n+2
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Introduction
Component
Formula
Abbreviation
2,5-dimethyloctane
C10H22-1
C10P
n-tetradecane
C14H30
C14P
n-octadecane
C18H38
C18P
Tetracosane
C26H54
C26P
C47 Paraffins
C47H96
C47P
Methylcyclopentane
C6H12-2
C6N
Methylcyclohexane
C7H14-6
C7N
Cyclohexane, 1,4dimethyl
C8H16-7
C8N
1-trans-3,5trimethylcyclohexane
C9H18-1
C9N
C14-1-ring-cycloheaxane
C14H28
MN1Lo
C18-1-ring-cycloheaxane
C18H36
MN1Hi
C21-1-ring-cycloheaxane
C21H42
HN1
C47-1-ring-cycloheaxane
C47H94
VN1
Trans-decaline (two Ring)
C10H18-2
C10N
C14-2-ring-cyclohexane
C14H26
MN2LO
C18-2-ring-cycloheaxane
C18H34
MN2HI
C21-2-ring-cycloheaxane
C21H40
HN2
C47-2-ring-cycloheaxane
C47H92
VN2
C14-3-ring-cyclohexane
C14H24
MN3Lo
C18-3-ring-cycloheaxane
C18H32
MN3Hi
C21-3-ring-cycloheaxane
C21H38
HN3
C47-3-ring-cycloheaxane
C47H92
VN3
C21-4-ring-cycloheaxane
C21H36
HN4
C47-4-ring-cycloheaxane
C47H88
VN4
Benzene
C6H6
C6A
Toluene
C7H8
C7A
Class
Naphthenes CnH2n
CnH2n-2
CnH2n-4
CnH2n-6
Aromatics
Para Xylene
C8H10_3
C8A
2-methyl-3ethylbenzene
C8H12-3
C9A
1,2,3,4,tetrahydronaphthalene
C10H12
C10A
n-octylbenzene
C14H22
MA1Lo
C18-1ring-Arom
C18H30
MA1Hi
C21-1ring-Arom
C21H36
HA1
C47-1ring-Arom
C47H88
VA1
C14tetrahydronaphthalene
C14H20
MANLo
CnH2n-6
CnH2n-8
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Component
Formula
Abbreviation
C18tetrahydronaphthalene
C18H28
MANHi
C21tetrahydronaphthalene
C21H34
HAN
C47tetrahydronaphthalene
C47H86
VAN
C14-naphthalene
C14H16
MA2Lo
C18-naphthalene
C18H24
MA2Hi
C21-naphthalene
C21H30
HA2
C47-naphthalene
C47H82
VA2
C14-1 ring-Arom-2-ring Naphthene
C14H18
MAN2Lo
C18-1 ring-Arom-2-ring Naphthene
C18H26
MAN2Hi
C21-1 ring-Arom-2-ring Naphthene
C21H32
HAN2
C47-1 ring-Arom-2-ring Naphthene
C47H32
VAN2
C14-2 ring-Arom-1-ring Naphthene
C14H14
MA2NLO
C18-2 ring-Arom-1-ring Naphthene
C18H22
MA2NHi
C21-2 ring-Arom-1-ring Naphthene
C21H28
HA2N
C47-2 ring-Arom-1-ring Naphthene
C47H80
VA2N
C21-3ring-Arom
C21H24
HA3
C47-3ring-Arom
C47H76
VA3
Fluorene, 9-methyl
C14H12
MANALo
C18H20
MANAHi
C21H26
HANA
C47H78
VANA
C21-4ring-Arom
C21H18
HA4
C47-4ring-Arom
C47H70
VA4
C21-1 ring-Arom-3-ring Naphthene
C21H30
HAN3
C47-1 ring-Arom-3-ring Naphthene
C47H82
VAN3
C21-2 ring-Arom-2-ring Naphthene
C21H24
HA2N2
C47-2 ring-Arom-2-ring Naphthene
C47H76
VA2N2
C4H4S
LTH
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Class
CnH2n-12
CnH2n-10
CnH2n-14
CnH2n-18 CnH2n-16
CnH2n-24 CnH2n-12
CnH2n-18
Sulfur Components Thiophene
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Introduction
Component
Formula
Abbreviation
C8-Cyclo-sulfide
C8H16S
LS8
C12-Cyclo-sulfide
C12H24S
MS12
C28-Cyclo-sulfide
C28H56S
HS28
Benzothiophene
C8H6S
LTHA
Benzothiophene, dimethyl-
C10H10S
MTHA
C10-tetarhydrobenzothiophene
C10H12S
MTHN
C14-trtrahydrodibenzothiophene
C14H16S
MTHAN
C21-trtrahydrodibenzothiophene
C21H30S
HthAN
C14- dibenzothiophene
C14H12S
MthA2
C21- dibenzothiophene
C21H26S
HthA2
C47-tetrahydronaphthabenzothiophene
C47H84S
VthA2N
C47naphthabenzothiophene
C47H72S2
VTHA3
Pyrrolidine (non-basic Nitrogen)
C4H9N
LBNit
Pyrrole (basic nitrogen)
C4H5N
LNNit
Quinoline, 1,2,3,4tetrahydro- (non-basic)
C9H11N
MBNITN
Quinoline (basic)
C9H7N
MBNITA
Class
Nitrogen Components
C9H9N
MNNitA
Phenanthridine, tetrahydro-
C21H33N
HBNitAN
Phenanthridine
C21H25N
MBNitA2
Carbazole, dimethyl-
C21H27N
MNNitA2
C35H55N
VBNitA2N
C47H73N
VNNitA3
Component Slate for Hydrocracker Model only in the feed Component
Cumene
Formula
Abbreviation
C6H12
C6-olef
C7H14
C7-olef
C8H16
C8_OLEF
C8H8
C8A_OLEF
C10H20
C10_OLEF
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Component
Formula
Abbreviation
C10H16
C10N_OLE
C10H10
C10A_OLE
C14H28
C14_OLEF
C14H26
MN1Lo_OL
C14H20
MA1Lo_OL
C18H36
C18_OLEF
C18H34
MN1Hi_OL
C18H28
MA1Hi_OL
C21H40
HN1_OLEF
C21H34
HA1_OLEF
C26H52
C26_OLEF
C47H94
C47_OLEF
C47H92
VN1_OLEF
C47H86
VA1_OLEF
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Reaction Paths The Hydrocracker model in Aspen HYSYS Petroleum Refining includes the following reaction types: • • • • • • •
Hydrodesulfurization (HDS) Hydrodenitrogenation (HDN) Saturation of aromatics (Hydrogenation) Ring opening Ring dealkylation Paraffin hydrocracking Saturation of olefins Saturation of olefin reaction calculations are done in a separate Aspen extended reaction block before the stream flows into bed 1. In the reactor bed 1, the heat of reaction calculated for the olefin saturation reactions is distributed through the bed.
The Hydrocracker reaction scheme has the following important characteristics: • • • • •
45 reversible aromatics saturation reactions 19 irreversible olefins saturation reactions Saturation and dealkylation of non-basic nitrogen lumps Dealkylation and HDN for basic nitrogen lumps Saturation and dealkylation for hindered sulfur lumps 5-11
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Introduction
•
Dealkylation and HDS for unhindered sulfur lumps
The figure below shows the importance of modeling aromatics saturation reversible. Figure 5.1 Hydrocracker Example for Aromatics Crossover
Above a certain temperature, equilibrium effects start to outweigh kinetic effects, and additional saturation becomes difficult. This temperature-dependent aromatics crossover causes the degradation of middle distillate properties - kerosene smoke point and diesel cetane - near the end of hydrocracker catalyst cycles.
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The figure below illustrates the importance of including both hindered and unhindered sulfur components in the reaction scheme. Figure 5.2 Reaction Pathway Illustration: Sulfur-Containing Components
As discussed in recent publications: • • •
aliphatic sulfur compounds are relatively easy to remove with hydroprocessing thiophenes, benzothiophenes, and dibenzopthiopenes are somewhat more difficult substituted benzo- and dibenzothiophenes are very hard to remove.
In the Direct Mechanism for the hydrodesulfurization of dibenzothiophene: • • • •
Dibenzothiophene adsorbs to the catalyst surface The catalyst abstracts sulfur Biphenyl desorbs from the catalyst surface Hydrogen removes sulfur from the catalyst as H2S
Alkyl substitution of dibenzothiophene at the 4-position, the 6position - or both - sterically hinders this pathway. Before these hindered molecules can be desulfurized, they must first be saturated (which converts a planar aromatic ring into a more flexible saturated ring) or dealkylated.
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5-14
Introduction
As shown in the previous figure, the reaction scheme for the Hydrocracker in Aspen HYSYS Petroleum Refining prohibits direct desulfurization of 4,6-alkyl dibenzothiophenes. The figure below reflects this feature of the models. Figure 5.3 Hydrocracker Example of H2 Consumption vs. Product Sulfur
As the extent of desulfurization increases, hydrogen consumption rises geometrically, in part because the model requires alternative HDS pathways for substituted dibenzothiophenes, and in part because at the higher required temperatures other saturation and cracking reactions are accelerated.
Reaction Kinetic Expression Rate equations are based on the Langmiur-Hinshelwood (adsorption-adsorption/reaction/ desorption) mechanism. H2S inhibits HDS reactions, and both NH3 and organic nitrogen inhibit acid-catalysed reactions. For each reaction type, an adsorption term is calculated as a multiplier for the rate expression. Each reaction type is first order with respect to the hydrocarbon and each reaction type has a unique order for hydrogen. There are also a set of activity factors that affect various reactions based on the type of reaction and the boiling point of the component.
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Hydrocracker
Activity Class
Description
SAT
Overall saturation activity
HSAT
Bottoms saturation activity
MSAT
Distillation saturation activity
LSAT
Naphtha saturation activity
HDS
Overall hydro-desulfurization activity
HHDS
Bottoms hydro-desulfurization activity
MHDS
Distillate hydro-desulfurization activity
LHDS
Naphtha hydro-desulfurization activity
HDN
Overall hydro-denitrogenation activity
HHDN
Bottoms hydro-denitrogenation activity
LHDN
Naphtha hydro-denitrogenation activity
PCR
Overall paraffin cracking activity
HPCR
Bottoms paraffin cracking activity
MPCR
Distillate paraffin cracking activity
LPCR
Naphtha paraffin cracking activity
RDA
Overall ring dealkylation activity
HRDA
Bottoms ring dealkylation activity
MRDA
Distillate ring dealkylation activity
LRDA
Naphtha ring dealkylation activity
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For example, the rate expression for hydro-denitrogenation of LNNIT would have the following form: n d------------------------[ LNNIT ]- = ACT × ADS NIT × k f × [ LNNIT ] × [ H 2 ] dt
(5.1)
where: [LNNIT] = Concentration of LNNIT ACT = Total activity for the reaction This is a product of each activity that affects the reaction. In this case, the activities affecting the reaction are the HDN and LHDN. ADSNIT = LHHW Adsorption term [H2] = Hydrogen concentration n = Power for H2 for denitrogenation reactions This value is unique for each reaction type.
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5-16
Introduction
Deactivation of Hydrocracker Catalyst The Hydrocracker model includes a deactivation model which allows the model to predict the number of days remaining in a catalyst cycle. The deactivation is a function of the severity, the amount of multi-ring aromatics in the feed, and the H2 partial pressure of the system. The user specifies the number of days in service and the weight average boiling point (WABP) for the end of the cycle.
System Pressure Control For the Hydrocracker in Aspen HYSYS Petroleum Refining, the user always specifies the High Pressure Separator pressure and the pressure for the recycle gas loop compressors. The pressures are calculated backwards from the High Pressure Separator based on specified pressure difference.
Reactor Temperature Control The Hydrocracker model in Aspen HYSYS Petroleum Refining allows the user to control the severity of the reactors in a variety of ways: • • • •
Specify the inlet temperature for each reactor bed. Specify the outlet temperature for each reactor bed. Specify the WABT (weight average bed temperature) for each reactor bed. Specify the WART (weight average reactor temperature) for each reactor and the temperature difference rise between each bed within each reactor. The nitrogen in the effluent from reactor 1 can be used instead of the WART for reactor 1. Similarly, the conversion and bottoms flow can be used instead of the WART's for reactors 2 and 3.
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5.2 Overall Operation Structure/Environment In HYSYS, the Hydrocracker operation appears as an object icon in the Main environment PFD. Figure 5.4
The Hydrocracker operation is actually a subflowsheet (HCR Environment) containing the required reactor and fractionator (if applicable) that make up a hydrocracker. Figure 5.5
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5-18
Overall Operation Structure/
5.2.1 Main Environment In the Simulation/Main environment, the following features are available for the Hydrocracker: • • • • •
create a Hydrocracker template create or add a Hydrocracker access Hydrocracker (HCR) property view access HCR environment/subflowsheet delete existing Hydrocracker
Create Hydrocracker Template HYSYS enables you to create templates of Hydrocracker operations, so you can import them in existing HYSYS process flowsheet diagram (PFD). To create a Hydrocracker template: 1. Select File | New | Hydrocracker in the menu bar. The HCR Configuration Wizard property view appears. HYSYS automatically creates a Hydrocracker fluid package with predetermined component list for the Hydrocracker template.
2. In the first page of the HCR Configuration Wizard property view, you can configure the design of the Hydrocracker. 3. Click Next. 4. In the second page of the HCR Configuration Wizard property view, you can specify the reactor parameters. 5. Click Next. 6. In the third and final page of the HCR Configuration Wizard property view, you can select or specify a set of calibration factors. 7. Click Done. Aspen HYSYS Petroleum Refining completes the Hydrocracker subflowsheet, based on the specified information from the HCR Configuration Wizard, and opens the HCR environment. 5-18
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8. In the HCR environment, you can: •
Access and modify the reactor by double-clicking the reactor object icon in the HCR PFD. • Access and modify the fractionator by double-clicking on the fractionator object icon in the HCR PFD. • Access the Calibration environment and calibrate the HCR model. 9. In the menu bar, select File | Save As or File | Save command to save the Hydrocracker template as a *.hcr file.
Create/Add Hydrocracker To add a Hydrocracker into a PFD: 1. Open the appropriate simulation case. 2. Open the UnitOps property view. 3. In the Categories group, select the Refinery Ops radio button. 4. In the Available Unit Operations group, select HCR Reactor and click Add. The HCR Template Option property view appears 5. In the HCR Template Option property view, do one of the following: •
Click Read an Existing HCR Template to add a Hydrocracker operation based on an existing template. The Hydrocracker operation appears on the PFD. • Click Configure a New HCR Unit to add a Hydrocracker operation and configure it from scratch. The HCR Configuration Wizard property view appears, and you have to configure the basic structure of the Hydrocracker operation using the features available in the HCR Configuration Wizard. After you have specified the minimum information required, the Hydrocracker operation appears on the PFD. 6. Open the Hydrocracker property view and make the necessary changes/specifications/connections for the simulation case.
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Overall Operation Structure/
Access HCR Property View To open the Hydrocracker (HCR) property view, do one of the following: • • •
On the PFD property view, right-click the Hydrocracker operation icon and select View Properties command from the Object Inspect menu. On the Workbook property view, click the Unit Ops tab, select the Hydrocracker under the Name column, and click the View UnitOp button. On the Object Navigator property view, select UnitOps radio button in the Filter group, select the applicable flowsheet in the Flowsheet group, select the Hydrocracker operation in the Unit Operations group, and click the View button.
Access HCR Environment To access the Hydrocracker subflowsheet (HCR environment): 1. In the Main PFD, open the HCR property view. 2. In the HCR property view, click the HCR Environment button.
Delete Hydrocracker Operation To delete an existing Hydrocracker operation, do one of the following: • • • •
On the PFD property view, select the Hydrocracker operation icon and press DELETE. On the PFD property view, right-click the Hydrocracker operation icon and select Delete command from the Object Inspect menu. On the HCR property view, click the Delete button. On the Workbook property view, click the Unit Ops tab, select the Hydrocracker under the Name column, and click the Delete UnitOp button.
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5.2.2 HCR Environment In the HCR environment, the following features are available for the Hydrocracker: • • • •
access the individual operation property views that make up the Hydrocracker operation access HCR Configuration Wizard select calibration factor set access Results property view
Access Operation Property View 1. In the HCR environment, open the PFD property view. 2. On the PFD, do one of the following: • •
Double-click on the operation’s icon. Right-click on the operation’s icon and select View Properties command in the object inspect menu.
Access HCR Configuration Wizard To access the HCR Configuration Wizard, do one of the following: • •
In the HCR environment, select HCR | Configuration Wizard command in the menu bar. Open the HCR Reactor Section property view, click the Design tab, select the Configuration page, and click the Configuration Wizard button.
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Overall Operation Structure/
Select Calibration Factor Set To select the Calibration Factor Set for the Hydrocracker operation: 1. Select HCR| Calibration Factor command from the menu bar. The Calibration Factor Set property view appears. Figure 5.6
2. Open the Select a calibration factor set to use for simulation drop-down list and select a calibration factor set. You can click the Library button to open the Calibration Set Library Property View to create, clone, and modify a calibration factor set.
Access Results Property View To access the Results property view, select HCR | Results command in the menu bar. The Results property view displays the Hydrocracker simulation summary.
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Hydrocracker
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5.3 HCR Configuration Wizard The HCR Configuration Wizard enables you to quickly set up the Hydrocracker operation. The HCR Configuration Wizard is made up of three sequential pages. You are required to enter information in a page, then move on to the next page in order. The following table lists the common buttons available at the bottom of the HCR Configuration Wizard property view: Button
Description
Next>
Enables you to move forward to the next page.
Enables you to move backward to the previous page.
Cancel
Enables you to exit the HCR Configuration Wizard without saving any changes or creating a Hydrocracker operation.
Close
Enables you to exit the HCR Configuration Wizard and keep any specifications or changes made to the Hydrocracker operation.
Done
Enables you to exit the HCR Configuration Wizard and finish configuring the Hydrocracker operation.
To access the HCR Configuration Wizard: 1. In the HYSYS desktop menu bar, select FILE | New | HCR command. HYSYS automatically completes the Simulation Basis environment specifications and then enters the Simulation environment. The HCR Configuration Wizard property view appears. or 1. In the Main Environment, press the F12 to open the UnitOps property view. 2. In the Available Unit Operations group, select Hydrocracker and click Add. The HCR Template Option property view appears. 3. Click the Configure a New HCR Unit button.
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HCR Configuration Wizard
The HCR Configuration Wizard property view appears. or 1. In the HCR Environment, select HCR | Configuration Wizard command from the menu bar. The HCR Configuration Wizard property view appears. or 1. In the HCR Reactor Section Property View, click the Design tab and select the Configuration page. 2. Click the Configuration Wizard button. The HCR Configuration Wizard property view appears.
5.3.1 Configuration Page The Configuration page (first page) of the HCR Configuration Wizard property view enables you to specify the configuration of the Hydrocracker. Object
Description
Basic Configuration group
Contains two radio buttons that enables you to select a single or two stage Hydrocracker unit operation.
Number of Reactors drop-down list
Enables you to select the number of reactors per stage in the Hydrocracker.
Number of Treating Beds drop-down list
Enables you to select the number of treating beds per stage in the Hydrocracker.
Number of beds row
Enables you to select the number of beds per reactor in the Hydrocracker.
Number of high pressure separators drop-down list
Enables you to select the number of separators in the Hydrocracker.
Include amine scrubber checkbox
Enables you to toggle between including or excluding amine scrubber to the separator in the Hydrocracker.
Naphtha Cuts dropdown list
Enables you to select the number of naphtha cuts in the separator.
Distillation Cuts drop-down list
Enables you to select the number of distillation cuts in the separator.
Cut column
Displays and enables you to modify the names of the cuts in the separator.
Recycle column
Enables you to toggle between including or excluding a recycle stream to the cut.
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Object
Description
PA column
Enables you to toggle between including or excluding a pump around to the cut.
Side Stripper column
Enables you to toggle between adding or removing a side stripper to the cut.
Energy column
Enables you to select the type of heat transfer method (reboiled or steam stripped) used in the side stripper. The drop-down list is only available in this column for cuts with side stripper.
Figure 5.7
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HCR Configuration Wizard
5.3.2 Geometry Page The Geometry page (second page) of the HCR Configuration Wizard property view enables you to specify the internal diameter, catalyst load, catalyst density, and bed voidage for the beds in each reactor. Figure 5.8
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5.3.3 Calibration Factors Page The Calibration Factors page (third page) of the HCR Configuration Wizard property view enables you to select or specify a calibration factor. Figure 5.9
Object
Description
Use an existing set of calibration factors radio button
Enables you to activate the feature used to select an existing calibration factor set.
Drop-down list
Enables you to select an existing calibration factor set. The default selection is the default calibration factor set provided by HYSYS.
Library button
Enables you to access the Calibration Set Library Property View.
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HCR Property View
5.4 HCR Property View The Hydrocracker (HCR) property view contains features used to manipulate the overall Hydrocracker operation and enable you to enter the HCR environment. To access the HCR property view: 1. In the Main environment, open the PFD property view. 2. In the PFD property view, double-click on the Hydrocracker object icon. Figure 5.10
The following table lists and describes the common features in the HCR property view: Object
Description
Delete button
Enables you to delete the Hydrocracker operation.
HCR Environment button
Enables you to enter the HCR Environment.
Status bar
Displays the status of the Hydrocracker operation.
Ignore checkbox
Enables HYSYS to ignore the Hydrocracker operation during the process flowsheet calculation.
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5.4.1 Design Tab The Design tab contains features used to configure the overall structure of the Hydrocracker operation. The features are grouped into the following pages: • • •
Connections Tuning Factors Notes
Connections Page The Connections page enables you to configure the stream flowing into and out of the Hydrocracker and specify the name of the Hydrocracker unit operation. Figure 5.11
Object
Description
Hydrogen Makeup table
Enables you to select or specify the hydrogen makeup stream flowing into the stages of the Hydrocracker.
Fractionated Products table
Enables you to specify or connect the product stream from the Hydrocracker subflowsheet to the external product streams of the main flowsheet. This table is only available if the Hydrocracker operation contains a fractionator.
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HCR Property View
Object
Description
Reactor Effluent table
Enables you to specify or connect the reactor effluent stream from the Hydrocracker subflowsheet to an external stream in the main flowsheet. This table is not available if the Hydrocracker contains a fractionator.
Name field
Enables you to modify the name of the Hydrocracker unit operation.
Feed Type Library button
Enables you to access the Feed Type Library Property View and modify the feed type available for the Hydrocracker.
Feeds table
Enables you to select or specify the feed stream flowing into the Hydrocracker. You can also select the feed type of the feed stream.
Recycle Gas Purge table
Enables you to specify or connect the purge stream from the hydrocracker subflowsheet to the external purge streams of the main flowsheet.
Tuning Factors Page The Tuning Factors page enables you to create, edit, view, and apply a calibration factor set to the Hydrocracker. Figure 5.12
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Object
Description
Calibration Factor Set drop-down list
Enables you to select and apply a calibration factor set to the Hydrocracker. Initially, Aspen HYSYS Petroleum Refining provides a default calibration factor set. The calibration factors in the default set are read only. If you want to manipulate the factor values, you have to create your own calibration factor set.
Calibration Factors Library button
Enables you to access the Calibration Set Library Property View. The Calibration Set Library property view enables you to create, import, clone, edit, export, and delete a calibration factor set.
Reactor Section table
Displays the following calibration factors: • Global activity • HDS activity • HDN activity • SAT activity • Cracking activity • Ring opening activity • Light gas tuning factors • Catalyst deactivation • Reactor pressure drop factors
Fractionator Key Parameters table
Displays the top and bottom index of the zones in the fractionator. This table does not appear if the Hydrocracker does not contain a fractionator.
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
5.4.2 Reactor Section Tab The Reactor Section tab contains features used to configure the reactor in the Hydrocracker operation. The features are grouped into the following pages: • • •
Feed Specification Recycle Gas Loop
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HCR Property View
• • •
Catalyst Deactivation Solver Options Solver Console
Feed Page The Feed page enables you to modify the properties of the feed streams entering and exiting the Hydrocracker. Figure 5.13
Object
Description
Feed Conditions table
Enables you to modify the following properties of the feed stream(s) entering the Hydrocracker: • volume flow rate • mass flow rate • temperature • pressure • entry location If you select Split option, the Select Feed Location Property View appears and enables you to specify the feed stream flow ratio between the reactors.
Total Feed table
Enables you to modify the following properties of the reactors: • total feed preheat duty • total feed pressure • gas to oil ratio
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Select Feed Location Property View The Select Feed Location property view enables you to select the entry location of the feed stream and (if applicable) specify the fraction of the feed stream entering each reactor. Figure 5.14
Displays the selected feed stream.
Object
Description
Reactor radio buttons
Enables you to select the reactor for feed stream to enter.
Split radio button
Enables you to activate the split option.
Split table
Enables you to specify the fraction of the feed stream entering each reactor.
Normalize button
Enables you to normalize the sum of the feed fraction to equal 1.
Accept button
Enables you to apply the specifications in the Select Feed Location property view to the Hydrocracker and close the Select Feed Location property view.
Cancel button
Enables you to exit the Select Feed Location property view without accepting the specifications.
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HCR Property View
Specification Page The Specification page enables you to modify the temperature of the beds in each reactor of the Hydrocracker. Figure 5.15
Recycle Gas Loop Page The Recycle Gas Loop page enables you to configure the parameters of the Hydrogen makeup and recycle gas streams. Figure 5.16
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Object
Description
HPS and Recycle Gas Compressor table
Enables you to modify the following properties of the recycle gas loops: • stream temperature • stream pressure • outlet pressure of the stream exiting the compressor • pressure difference between the stream and the reactor stage
Product Heater table
Enables you to modify the following properties of the heater: • temperature of exiting stream • duty • pressure of exiting stream • pressure difference in heater
Hydrogen Makeup Stream table
Enables you to modify the following properties of the hydrogen makeup stream: • mole flow rate • temperature • pressure • composition • hydrogen purge fraction
Catalyst Deactivation Page The Catalyst Deactivation page enables you to modify two catalyst deactivation parameters: weight average bed temperature at the end of a cycle and Day on Stream. Figure 5.17
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HCR Property View
Solver Options Page The Solver Options page enables you to modify the calculation variables used to determine the reaction results of the reactor. Figure 5.18
Object
Description
Convergence Tolerance group
Contains the Residual field that enables you to specify the maximum residual value allowed for the convergence calculation.
Iteration Limits group
Contains two fields that enable you to control the iteration range for the OOMF Solver performance: • Maximum Iterations field enables you to specify the maximum number of iterations. • Minimum Iterations field enables you to specify the minimum number of iterations.
Creep Step Parameters group
Contains three fields that enable you to configure the creep function of the OOMF Solver: • On/Off Switch drop-down list. Enables you to select On (enable) or Off (disable) option for the creep feature. • Iterations field. Enables you to specify the number of iterations per creep step. • Step Size field. Enables you to specify the size of each creep step.
Completeness Checking group
Contains the Override Spec Group Completeness checkbox that enables you to toggle between: • Overriding the normal calculation behaviour. • Retaining the normal calculation behaviour. The normal calculation behaviour requires the spec groups be completed before solving the unit operation.
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Object
Description
SQP Hessian Parameters group
Contains features used to manipulate the SQP Hessian parameters: • Initialization drop-down list. Enables you to select one of four options to initialize the Hessian value: Normal (default). Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and online problems that start very far from a solution. Aggressive. Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few Degrees of Freedom at solution. Ideal applications are well-posed online realtime optimization problems. Scaled. A combination of the Aggressive and Advanced modes. This setting is recommended for highly constrained optimization problems with few Degrees of Freedom at solution and a nonlinear objective function. Advanced. Hessian initialized with 2nd order information. This setting is recommended for problems with many Degrees of Freedom at solution and/or quadratic objective function. Ideal for data reconciliation problems, both online and offline. • Scaling factor field. Enables you to specify the scaling factor. • Updates stored field. Enables you to specify the number of updates stored during calculation (default value is 10).
Line Search Parameters group
Contains features used to configure the line search parameters: • Algorithm drop-down list. Enables you to select one of four methods for the line search algorithm: Normal (default). A proprietary line search designed to balance robustness with efficiency. Exact. A well-known exact penalty line search. It is too conservative for most practical problems. Residual. A proprietary line search designed to initially favour the convergence of residuals over the objective function improvement. Square. A line search designed to attempt to enforce bounds on cases with no Degrees of Freedom. It should be used only in cases where there are multiple solutions to a problem, and the desired solution lies within the bounds. • Step Control drop-down list. Enables you to select one of three options for the step size: Normal (default). The original method. Aggressive. A modified method that tends to take larger steps. Conservative. A modified method that tends to take smaller steps. • Step Control Iterations field. Enables you to specify the number of step iterations.
Variable Scaling Parameter group
Contains the On/Off Switch drop-down list that enables you to select one of the following options: • On. Activates the variable scaling parameter. • Off. Deactivates the variable scaling parameter.
Failure Recovery Action dropdown list
Enables you to select one of the following action in case of failure: • Do nothing. • Revert to the previous results before the solve (this is the default option). • Revert to the default input and results.
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HCR Property View
Solver Console Page The Solver Console page enables you to view the solver message generated by the reactor and run script commands. Figure 5.19
Object
Description
Simulation Engine Message and Script Commands field
Displays the messages and commands from the solver of the FCC reactor.
Enter Script Command field
Enables you to enter the text code for a command for the solver.
Clear Message button
Enables you to clear the messages in the Simulation Engine Message and Script Commands field.
Get Prev. Command button
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script Command field.
Get Next Command button
Enables you to retrieve the next command from the command history and place the text code in the Enter Script Command field.
Run Command button
Enables you to run the command code in the Enter Script Command field.
Clear Command button
Enables you to clear the command history.
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5.4.3 Fractionator Tab The Fractionator tab contains options for the fractionator in the Hydrocracker. The options are split into the following pages: • •
Zone Pressures Specs
If the Hydrocracker does not contain a fractionator the above pages appear blank.
Zone Pressures Page The Zone Pressures page enables you to specify the top pressure values for the fractionator zones and the bottom pressure of the fractionator. Figure 5.20
Specs Page Refer to Specs Page section from Chapter 6 Petroleum Column for more information.
The Specs page enables you to specify the values of the product output streams of the fractionator. These are the values that the Column algorithm tries to meet.
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HCR Property View
There are two specs options to choose from: TBP Cut Point or Product Flow Fraction. Depending on which option you select in the Spec Option group, the features available in the Specs page varies. •
TBP Cut Point option
Figure 5.21
•
Product Flow Fraction option
Figure 5.22
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5.4.4 Results Tab The Results tab displays the calculated simulation results of the Hydrocracker. The information is grouped in the following pages: • • • • • • •
Feed Blend Product Yields Product Properties Reactor Hydrogen System Fractionator Hydrogen Balance
Feed Blend Page The Feed Blend page displays the detailed characterization of each individual feed and the blend of feeds going to each reactor. Figure 5.23
If there is more than one reactor, there will be a drop-down list that allows you to select the reactor and view the values corresponding to the selected reactor.
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HCR Property View
Product Yields Page The Product Yields page displays the standard cut yields from the simulation. Figure 5.24
If the Hydrocracker contains a fractionator, there will be two radio buttons: Standard Cut Products and Fractionated Products. Depending on the radio button selected, the Yields group displays the yields for standard cuts or the fractionated yields. The liquid product cuts for the Fractionated Products option correspond to those specified in the Specs Page of the Fractionator tab.
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Product Properties Page The Product Properties page displays the properties of liquid cuts from the simulation. Figure 5.25
If the Hydrocracker contains a fractionator, there will be two radio buttons: Standard Cut Products and Fractionated Products. Depending on the radio button selected, the Product Properties group displays the properties for standard cuts or the properties for the fractionated products. The liquid product cuts for the Fractionated Products option correspond to those specified in the Specs Page of the Fractionator tab.
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HCR Property View
Reactor Page The Reactor page displays the calculated parameter results of the reactors in the Hydrocracker operation. Figure 5.26
Hydrogen System Page The Hydrogen System page displays the calculated results of the hydrogen makeup stream and recycle gas stream. Figure 5.27
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Fractionator Page The fractionator page displays the calculated results of the product stream cut points from the fractionator. Figure 5.28
If the Hydrocracker does not contain a fractionator, this page is blank.
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Feed Type Library Property View
Hydrogen Balance Page The Hydrogen Balance page displays the calculated results of the hydrogen balance and hydrogen consumption. Figure 5.29
5.5 Feed Type Library Property View The Feed Type Library property view enables you to import, export, delete, and configure the feed type data. You cannot delete the default feed type provided by Aspen HYSYS Petroleum Refining.
To access the Feed Type Library property view: 1. Open the HCR Property View. 2. Click the Design tab and select the Connections page. 3. Click the Feed Type Library button.
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The Feed Type Library property view appears. Figure 5.30
The following table lists and describes the options available in the Feed Type Library property view. Object
Description
Feed Types list
Displays the names of the feed type available in the Hydrocracker
Import button
Enables you to import feed types (from *.csv files) into the Hydrocracker.
Export button
Enables you to export a selected feed type, in the Feed Types list, to a *.csv file.
Delete button
Enables you to delete a selected feed type, in the Feed Types list, from the Hydrocracker.
Properties of Selected Feed Type table
Enables you to modify the property information of a selected feed type in the Feed Types list.
Lump Weight Percents radio button
Enables you to modify the percent lump weight value of the selected feed type.
Biases radio button
Enables you to modify the following properties of the selected feed type: • light, medium, and heavy WABP • light, medium, and heavy WABP bias • Light and heavy cut point bias • total Ca and Cn bias
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HCR Reactor Section Property View
5.6 HCR Reactor Section Property View The HCR Reactor Section property view enables you to configure and modify the reactor part of the Hydrocracker operation. To access the HCR Reactor Section property view: 1. Enter the HCR environment. 2. Access the PFD by clicking the PFD icon. PFD icon
3. On the PFD property view, right-click the Reactor Section object icon. 4. Select View Properties command from the object inspect menu. The HCR Reactor Section property view appears. Figure 5.31
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The following table lists and describes the common features in the HCR Reactor Section property view: Object
Description
Delete button
Enables you to delete the reactor section.
Status bar
Displays the status of the reactor section of the Hydrocracker operation.
Ignore checkbox
Enables HYSYS to ignore the reactor section during the process flowsheet calculation.
5.6.1 Design Tab The Design tab contains the features used to configure the reactor section of the Hydrocracker operation. These features are grouped into the following pages: • • •
Configuration Geometry Notes
Configuration Page The Configuration page enables you to specify the reactor name, and displays the reactor type and number of reactor beds. Figure 5.32
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HCR Reactor Section Property View
To modify the configuration, click the Configuration Wizard button to access the HCR Configuration Wizard property view.
Geometry Page The Geometry page enables you to specify the following parameters of each reactor beds: • • • •
internal diameter catalyst loading catalyst density bed voidage
Figure 5.33
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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5.6.2 FeedData Tab The FeedData tab contains features used to configure and modify the feed stream properties entering the HCR Reactor Section. The features are grouped into the following pages: • •
Library Properties
Library Page The Library page enables you to modify, import, export, and delete feed data types entering the reactor operation. Figure 5.34
Object
Description
Feed Types group
Displays the list of feed data types available for the reactor.
Import button
Enables you to import a feed data from a file. The feed data are saved in *.csv type files.
Export button
Enables you to export the selected feed data (from the Available Feed Types group) into a *.csv file. The exported feed data can be imported into a different applicable operation.
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HCR Reactor Section Property View
Object
Description
Delete button
Enables you to delete the selected feed data in the Available Feed Types group.
Properties of Selected Feed Type table
Enables you to modify the property information of a selected feed type in the Feed Types list.
You can also access the features in the Library page by clicking the Feed Type Library button in the Connections page of the HCR property view.
Properties Page The Properties page enables you to specify properties for virtual feeds. The virtual feeds are feeds not represented by internal or external streams in the subflowsheet and flowsheet respectively. Figure 5.35
Object
Description
Feeds group
Displays both real and virtual feed streams connected to the Hydrocracker.
Add button
Enables you to create a virtual feed stream. Aspen HYSYS Petroleum Refining automatically assigns a default name to the virtual feed stream and treats the virtual stream as an internal stream.
Delete button
Enables you to delete the selected feed stream from the Feeds group. If the selected feed stream is a real stream, then both the internal and external streams will be deleted. 5-52
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Object
Description
Assay radio button
Enables you to specify assay properties of the selected feed type in the Feed Type list.
Bulk Properties radio button
Enables you to specify bulk properties of the selected feed type in the Feed Type list.
Kinetic Lumps radio button
Enables you to specify kinetic lumps properties of the selected feed type in the Feed Type list.
Assay drop-down list
Enables you to select the assay associated to the selected feed type in the Feed Type list. This drop-down list is only available if you select the Assay radio button.
Feed Properties group
Contains a table that displays the list of properties available for you to view or modify of the selected feed stream. The variables available in this table vary depending on which radio button you select in the Selected Feed group.
5.6.3 Operation Tab The Operation tab contains features used to manipulate the operation parameters of the Hydrocracker operation. The features are grouped into the following pages: • • • • • •
Feeds Specifications Recycle Gas Loop Catalyst Deactivation Solver Options Solver Console
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HCR Reactor Section Property View
Feeds Page Refer to Feed Page section for more information.
The Feeds page enables you to modify the physical properties of the feed streams entering and exiting the reactor section of the Hydrocracker operation. Figure 5.36
Specifications Page The Specifications page enables you to modify the reactor bed parameters of the Hydrocracker operation. Figure 5.37
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Recycle Gas Loop Page Refer to Recycle Gas Loop Page section for more information.
The Recycle Gas Loop page enables you to modify the recycle gas parameters of the Hydrocracker operation. Figure 5.38
Catalyst Deactivation Page Refer to Catalyst Deactivation Page section for more information.
The Catalyst Deactivation page enables you to modify the catalyst parameters of the Hydrocracker operation. Figure 5.39
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HCR Reactor Section Property View
Solver Options Page The Solver Options page enables you to modify the calculation variables used to determine the reaction results of the reactor. Figure 5.40
Object
Description
Convergence Tolerance group
Contains the Residual field that enables you to specify the maximum residual value allowed for the convergence calculation.
Iteration Limits group
Contains two fields that enable you to control the iteration range for the OOMF Solver performance: • Maximum Iterations field enables you to specify the maximum number of iterations. • Minimum Iterations field enables you to specify the minimum number of iterations.
Creep Step Parameters group
Contains three fields that enable you to configure the creep function of the OOMF Solver: • On/Off Switch drop-down list. Enables you to select On (enable) or Off (disable) option for the creep feature. • Iterations field. Enables you to specify the number of iterations per creep step. • Step Size field. Enables you to specify the size of each creep step.
Completeness Checking group
Contains the Override Spec Group Completeness checkbox that enables you to toggle between: • Overriding the normal calculation behaviour. • Retaining the normal calculation behaviour. The normal calculation behaviour requires the spec groups be completed before solving.
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Object
Description
SQP Hessian Parameters group
Contains features used to manipulate the SQP Hessian parameters: • Initialization drop-down list. Enables you to select one of four options to initialize the Hessian value: Normal (default). Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and online problems that start very far from a solution. Aggressive. Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few Degrees of Freedom at solution. Ideal applications are well-posed online realtime optimization problems. Scaled. A combination of the Aggressive and Advanced modes. This setting is recommended for highly constrained optimization problems with few Degrees of Freedom at solution and a nonlinear objective function. Advanced. Hessian initialized with 2nd order information. This setting is recommended for problems with many Degrees of Freedom at solution and/or quadratic objective function. Ideal for data reconciliation problems, both online and offline. • Scaling factor field. Enables you to specify the scaling factor. • Updates stored field. Enables you to specify the number of updates stored during calculation (default value is 10).
Line Search Parameters group
Contains features used to configure the line search parameters: • Algorithm drop-down list. Enables you to select one of four methods for the line search algorithm: Normal (default). A proprietary line search designed to balance robustness with efficiency. Exact. A well-known exact penalty line search. It is too conservative for most practical problems. Residual. A proprietary line search designed to initially favour the convergence of residuals over the objective function improvement. Square. A line search designed to attempt to enforce bounds on cases with no Degrees of Freedom. It should be used only in cases where there are multiple solutions to a problem, and the desired solution lies within the bounds. • Step Control drop-down list. Enables you to select one of three options for the step size: Normal (default). The original method. Aggressive. A modified method that tends to take larger steps. Conservative. A modified method that tends to take smaller steps. • Step Control Iterations field. Enables you to specify the number of step iterations.
Variable Scaling Parameter group
Contains the On/Off Switch drop-down list that enables you to select one of the following options: • On. Activates the variable scaling parameter. • Off. Deactivates the variable scaling parameter.
Failure Recovery Action dropdown list
Enables you to select one of the following action in case of failure: • Do nothing. • Revert to the previous results before the solve (this is the default option). • Revert to the default input and results.
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HCR Reactor Section Property View
Solver Console Page The Solver Console page enables you to view the solver message generated by the reactor and run script commands. Figure 5.41
Object
Description
Simulation Engine Message and Script Commands field
Displays the messages and commands from the solver of the FCC reactor.
Enter Script Command field
Enables you to enter the text code for a command for the solver.
Clear Message button
Enables you to clear the messages in the Simulation Engine Message and Script Commands field.
Get Prev. Command button
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script Command field.
Get Next Command button
Enables you to retrieve the next command from the command history and place the text code in the Enter Script Command field.
Run Command button
Enables you to run the command code in the Enter Script Command field.
Clear Command button
Enables you to clear the command history.
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5.6.4 Results Tab The Results tab enables you to view the calculated variable results of the Hydrocracker. The information is grouped into the following pages: • • • • • •
Feed Blend Product Yields Product Properties Reactor Hydrogen System Hydrogen Balance
Feed Blend Page The Feed Blend page displays the calculated physical properties of the feed stream entering the reactor. Figure 5.42
For multiple reactors, use the drop-down list to view the feed blend properties in each reactor.
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HCR Reactor Section Property View
Product Yields Page The Product Yields page displays the calculated yield results of the product streams exiting the Hydrocracker. Figure 5.43
Product Properties Page The Product Properties page displays the calculated physical properties of the product streams exiting the Hydrocracker. Figure 5.44
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Reactor Page The Reactors page displays the key simulation results of the reactor (s) in the Hydrocracker. Figure 5.45
Hydrogen System Page The Hydrogen System page displays the calculated results of the Hydrogen make-up streams and Hydrogen recycled gas. Figure 5.46
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HCR Reactor Section Property View
Hydrogen Balance Page The Hydrogen System page displays the calculated results of the Hydrogen consumption in the reactor(s) and Hydrogen balance in each streams. Figure 5.47
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5.7 Calibration Set Library Property View The Calibration Set Library property view enables you to manage the calibration factor sets. There are several methods to access the Calibration Set Library property view: • • •
In the HCR Configuration Wizard property view, go to the Calibration Factors (3 of 3) page and click the Library button. In the HCR Property View, select the Design tab, select the Calibration Factors page, and click the Calibration Factors Library button. In the HCR Environment, select HCR | Calibration Factor command from the menu bar, and click the Library button in the Calibration Factor Set property view.
Figure 5.48
The following table lists and describes the options available in the Calibration Set Library property view: Object
Description
Available Calibration Factor Sets list
Displays all the factor sets available in the current calibration environment.
View/Edit button
Enables you to view or modify the data of the selected factor set in the Available Calibration Factor Sets list.
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Calibration Set Library Property
Object
Description
Add button
Enables you to add a new factor set and access the Factor Set Property View.
Delete button
Enables you to delete the selected factor set in the Available Calibration Factor Sets list.
Clone button
Enables you to create a copy/clone of the selected factor set in the Available Calibration Factor Sets list.
Import button
Enables you to import a calibration factor set data from a *.csv file.
Export button
Enables you to export/save the selected factor set (in the Available Calibration Factor Sets list) to a file *.csv.
HYSYS provides a default calibration factor set with values in the Calibration Set Library. The calibration factor values, in the Default calibration factor set, are read only. To modify the calibration factors, you need to make a clone of the Default Calibration Factor set, and modify the calibration factor values in the cloned set.
5.7.1 Factor Set Property View The Factor Set property view displays the variable values that make up the calibration factor set. You can also edit the variable values in the Factor Set property view. You cannot modify the variable values of the default calibration factor set provided by HYSYS.
To access the Factor Set property view: 1. Open the Calibration Set Library Property View. 2. Do one of the following: • • •
Click the Add button to create a new calibration factor set. Select the calibration factor set you want to view in the Available Calibration Factor Sets list and click the View/ Edit button. Select the calibration factor set you want to edit in the Available Calibration Factor Sets list and click the Clone button. 5-64
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The Factor Set property view appears. Figure 5.49
The options in the Factor Set property view is grouped into two pages: • •
Reactor Fractionator
Both pages in the Factor Set property view contain the following common options: Object
Description
Name field
Enables you to specify the name of the calibration factor set.
Description field
Enables you to provide a brief description on the calibration factor set.
Date Created field
Displays the date and time when the calibration factor set was created.
Date Modified field
Displays the date and time when the calibration factor set was last modified.
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Calibration Set Library Property
Reactor Page The Reactor page enables you to access the Reactor Factors group and specify variable values associated to the reactor. Figure 5.50
Fractionator Page The Fractionator page enables you to access the Fractionator Cuts group and specify variable values associated to the stabilizer tower. Figure 5.51
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The Fractionator page is blank if the Hydrocracker does not contain a fractionator.
5.8 Results Property View The Results property view contains and displays the same information in the Results Tab of the HCR Reactor Section Property View. To access the Results property view: 1. Access HCR Environment. 2. Select HCR | Results in the menu bar. The Results property view appears. The information displayed in the Results property view will appear blank, if the Hydrocracker unit operation is not solved or completed.
5.8.1 Feed Blend Page The Feed Blend page displays the calculated physical properties of the feed stream entering the reactor. Figure 5.52
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Results Property View
For multiple reactors, use the drop-down list to view the feed blend properties in each reactor.
5.8.2 Product Yields Page The Product Yields page displays the calculated yield results of the product streams exiting the Hydrocracker. Figure 5.53
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5.8.3 Product Properties Page The Product Properties page displays the calculated physical properties of the product streams exiting the Hydrocracker. Figure 5.54
5.8.4 Reactor Page The Reactors page displays the key simulation results of the reactor (s) in the Hydrocracker. Figure 5.55
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Results Property View
5.8.5 Hydrogen System Page The Hydrogen System page displays the calculated results of the Hydrogen make-up streams and Hydrogen recycled gas. Figure 5.56
5.8.6 Hydrogen Balance Page The Hydrogen System page displays the calculated results of the Hydrogen consumption in the reactor(s) and Hydrogen balance in each streams. Figure 5.57
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5.9 Calibration Property View The calibration property view allows you to: • • • • •
Specify feeds, catalyst, operating conditions and measurements for a calibration run. Perform a calibration run. Save the calculated Calibration Factors for use in the simulation run. Push data from a calibration run to the HCR Reactor Section property view. Pull data from the HCR Reactor property view to the Calibration property view.
Figure 5.58
To access Calibration property view: 1. Access the HCR environment 2. Select HCR | Calibration command in the menu bar. The Calibration view of the active HCR operation appears.
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Calibration Property View
Note: When you access the Calibration view, you also enter the Calibration Environment. The HCR Calibration view contains the following objects below the tabs: Object
Description
Run Calibration Button
Enables you to select one or more data set for the calibration run and access the Validation Wizard property view. This button is unavailable until all necessary input data is complete.
Run Prediction button
Enables you to select one or more data set for the prediction run and access the Specification Wizard property view. This button is unavailable until all necessary input data is complete.
Data Set drop-down list
Enables you to select different data sets for entering the data or viewing the results for the calibration or the prediction run.
Manage Data Sets button
Enables you to access the Data Set Manager Property View to manage the data set.
Push Data to Simulation button
Enables you to export input data from the current data set in the calibration property view to the property view in the HCR environment. Any existing simulation data will be overwritten with the current calibration data.
Pull Data from Simulation button
Enables you to import data from the property view in the HDC environment into the current data set in the Calibration property view. Any existing calibration data will be over written with the current simulation data.
Return to Simulation
Enables you to exit the Calibration environment and return to the HCR environment.
Status Bar
Displays the current status of the calibration run.
Validation Wizard When you click the Run Calibration button, Aspen HYSYS Petroleum Refining lets you select the data set you want to use for the calibration run, and validate the selected data set before the calibration is actually run. Note: The Run Calibration button in the Calibration view is unavailable until all necessary calibration input is complete. The Select Data Sets for Calibration view displays status and names of data sets available with the calibration run. 5-72
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This view will appear only when there is more than one data set. If there’s only one data set, Validation Wizard view will appear instead. Object
Description
Run Calibration
Enables you to run the calibration using the selected data set in the Select Data Sets for Calibration group.
Stop
Enables you to stop the calculation process during a calibration run. This button is only active during the calibration run calculation.
Close
Enables you to close the Select Data Sets for Calibration view without performing any calibration run.
Select the appropriate checkbox under the Include column to select the data set you want to use in the calibration run. When you select the checkbox, the Validation Wizard view of the selected data set appears. The Validation Wizard property view displays the mass flows of feed and product streams (derived from the input data), and coke flow and wt% hydrogen in coke (calculated using air rate and flue gas analysis). The information displayed enables you to analyse the measurement data before accepting the data set for the calibration run. •
•
If the total product mass rate is greater than the total feed mass rate by about 2-3%, you should review the flow rate and gravity information of the products. If you think the error is acceptable, you can decide how you would like to distribute the mass imbalance by assigning the bias to any of the product streams (except coke). Once the bias is assigned, the Validation Wizard adjusts the mass flow of the selected product stream(s) to match the feed total mass by re-normalization. If the coke flow and wt% hydrogen in code values are not reasonable, the air rate measurement and flue gas analysis should be reviewed before calibration is run.
In the Coke and Sulfur Balance group, you must specify the following values for the Calibration of coke and sulfur balance: • • •
Wt% feed sulfur in code (default = 5%) Wt% coke from stripper (default = 15%) Stripper efficiency (default = 75%) 5-73
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Calibration Property View
When all the information in the Validation Wizard view appears satisfactory, click the OK button to accept the values in the selected data set. The Validation Wizard view closes and you return to the Select Data Sets for Calibration view. Note: You can click the Cancel button to close the Validation Wizard View without saving/accepting any changes made in the view. Once the data set has been selected and validated, you can click the Run Calibration button on the Select Data Sets for Calibration view to start the Calibration run.
Specification Wizard When you click the Run Prediction button, Aspen HYSYS Petroleum Refining lets you select a calibration factor set, and select data set you want to use for prediction calculation. Note: The Run Prediction button in the Calibration view is unavailable until all necessary input is complete. The Select Data Sets for Prediction view displays status and names of data sets available with the calibration run. The following table lists and describes the options in the Select Data Sets for Prediction view: Object
Description
Select Calibration Factor Set to Use for Prediction drop-down list.
Enables you to select a calibration factor set to use in the prediction calculation.
Library button
Enables you to access the Calibration Set Library view to manage the calibration factor set.
Run Prediction button
Enables you to run the prediction calculation using the selected calibration factor set for data sets included in the Select Data Sets for Prediction group. The button is not active until you have selected and validated a data set.
Stop button
Enables you to stop the process during a prediction calculation.
Close button
Enables you to close the Select Data Sets for Prediction view without performing any prediction calculation.
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Select the appropriate checkbox under the Include column to select the data set you want to use in the prediction. When you select the checkbox, the Specification Wizard view of the selected data set appears. • •
•
• •
The Specification Wizard property view enables you to select the variable(s) that is specified for the prediction calculation, the rest of the variables will be calculated. In the Regenerator group, select the appropriate checkbox of the variable you want the prediction calculation to accept the specified value, while the rest of the variables are calculated based on the specified value. If a fractionator is included into HCR, then the TBP cut point specs appears in the Specification Wizard view. you can modify the values in the Specify TBP Cut Points group and the new data will be used in the prediction run. Click the OK button to close the Specification Wizard view and accept the modification/selections. Click the Cancel button to close the Specification Wizard view and not accept the modification/selections.
Data Set Manager Property View The Data Set Manager property view enables you to add, modify, clone, delete, or rename the calibration data sets associate to the calibration run. The following table lists and describes the options in the Data Set Manager view: Object
Description
Available Data Sets list
Displays all the data sets available in the associate calibration/prediction run.
Add button
Enables you to add a new data set to the calibration/prediction run.
Delete button
Enables you to delete the selected data set in the Available Data Sets list.
Clone button
Enables you to clone the selected data set in the Available Data Sets list.
Rename button
Enables you to rename the selected data set in the Available Data Sets list.
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Calibration Property View
5.9.1 Design Tab The Design tab is the same as the Design tab in the HCR Reactor Section property view. This tab enables you to enter specific information about the HCR unit you are modeling. This information is used in a calibration run. Figure 5.59
Use the Design tab to view the following types of information about the HCR: Use this page
to
Configuration
View the configuration of the HCR
Geometry
View the geometry of the following elements of the HCR: • Internal Diameter • Catalyst Loading • Catalyst Density • Bed Voidage
Notes
Enter notes about calibration
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Configuration Page The Configuration page on the Design tab of the Calibration property view is a read-only page. This page displays the flowsheet configuration information: • • • • •
The The The The The
number of reactors number of HPS type AMINE Scrubber presence and type of fractionator number of beds
Note: To change configuration specifications, you need to go back to the HCR environment. Figure 5.60
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Calibration Property View
Geometry Page The Geometry page on the Design tab of the Calibration property view displays the flowsheet geometry information. Figure 5.61
Note: If you selected the Allow Midpoint Injection option on the HCR Configuration Wizard Configuration Page (page 1), Aspen HYSYS Petroleum Refining displays the Injection Point in the Reactor group. The groups in the Geometry page contains the following information: Group[
Description
Internal Diameter
The internal diameter of the reactor.
Catalyst Loading
The loading KG of the reactor.
Catalyst Density
The density of the reactor.
Bed Voidage
The Bed Voidage of the reactor.
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If mid-point injection is allowed, then: Field
Description
Total Length
The total length of the riser.
Top Section Diameter
The diameter of the top section of the riser (from injection point to riser top).
Bottom Section Diameter
The diameter of the bottom section riser (from riser bottom to injection point).
Injection Point
Location of injection point from the bottom of the riser.
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
Use the Notes page to make any notes about the calibration of the HCR and related matters. Notes can be useful for informing other people working with your case about changes and assumptions you have made. You can: • •
Enter notes in the Notes window Add objects, for example, a formatted Word document, in the Notes window.
5.9.2 Feed Data Tab Use the Feed Data tab on the Calibration property view to enter specific information about the feed(s) to the HCR unit you are modeling. This information is used in a calibration run. The following table lists and describes the pages in the Feed Data tab view: Use this page
to
Library
Specify Feed Data information for a calibration run.
Properties
Specify properties for virtual feeds, which is to say feeds that are not represented by an internal and external stream in the subflowsheet and flowsheet respectively.
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Calibration Property View
Library Page Use the Library page on the Feed Data tab of the Calibration property view to manage the Feed Type Library. Figure 5.62
A library of feed types is provided in the HCR/Feed Library sub folder on your installation folder. You can import one or more of them to your simulation. The following table lists and describes the options in the Library page: Objects
Description
Feed Types
Displays the type of feeds associated with the HCR operation.
Properties of Selected Feed Types
Displays the following information: • Lump Weight Percents • Biases
Import button
Enables you to import a feed type from a file in the HCR operation.
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Objects
Description
Export button
Enables you to export a selected feed type (from the Feed Types list) into a separate file. The exported feed type can be imported into a different HCR operation.
Delete button
Enables you to delete a selected field type in the Feed Types list.
Properties Page Use the Properties page on the Feed Data tab of the Calibration property view to specify properties for virtual feeds, which is to say feeds that are not represented by an internal and external stream in the subflowsheet and flowsheet respectively. The real feed streams also appear here, but there are restrictions. Figure 5.63
The following table lists and describes the common features in
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Calibration Property View
the Properties page: Object
Description
Feeds List
Displays the feed stream associated with the HCR operation.
Add button
Enables you to create/add a new virtual feed stream and assign it a default name as if it were an internal stream.
Clone button
Enables you to create a copy of the selected feed stream in the feed list. If the selected feed stream is a real stream, the copy is flagged as a virtual feed.
Delete button
Enables you to delete the selected field stream in the feed list. If the selected feed stream is a real stream, then both the internal and external streams will be deleted.
Selected Feed group
Contains three radio buttons that enables you to select different methods to manipulate the selected feed stream in the Feeds list. The HCR model uses these feed types and Feed Type properties to generate kinetic lumps of the feed for the simulation.
Feed Properties Group
Displays all the properties of the selected feed stream in the Feeds list. Various stream properties can be modified, depending on the method you selected in the Feed Properties group.
•
If you selected the Assay radio button:
The feed properties calculated from the assay and the cut points are displayed. Field
Description
Feed Type
The feed type. Select the feed type from the dropdown list. The feed types available are those in the Feed Types list on the Library page of the Feed Data tab.
Assay
The name of the assay.
Initial Point
Initial point of the distillation.
Final Point [C]
Final point of the distillation.
API Gravity
The API gravity of the feed.
Specific Gravity (60F/60F)
The specific gravity of the feed.
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Field
Description
Distillation Type
• • • •
TBP D86 D1160 D2887
0% Point [C]
0% point of the distillation.
5% Point [C]
5% point of the distillation.
10% Point [C]
10% point of the distillation.
30% Point [C]
30% point of the distillation.
50% Point [C]
50% point of the distillation.
70% Point [C]
70% point of the distillation.
90% Point [C]
90% point of the distillation.
95% Point [C]
95% point of the distillation.
100% Point [C]
100% point of the distillation.
Total Nitrogen [ppmwt]
Total Nitrogen content in the feed, ppmwt.
Basic Nitrogen [ppmwt]
Basic Nitrogen content in the feed, ppmwt.
Total/Basic Nitrogen Ration
Ratio of total basic nitrogen content.
Sulfur Content%
Sulfur content in the feed, wt%
•
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If you selected the Bulk Properties radio button:
Field
Description
Name
The name of the feed.
Feed Type
The feed type. Select the feed type from the dropdown list. The feed types available are those in the Feed Types list on the Library page of the Feed Data tab.
API Gravity
The API gravity of the feed.
Specific Gravity (60F/60F)
The specific gravity of the feed.
Distillation Type
• • • •
TBP D86 D1160 D2887
0% Point [C]
0% point of the distillation.
5% Point [C]
5% point of the distillation.
10% Point [C]
10% point of the distillation.
30% Point [C]
30% point of the distillation.
50% Point [C]
50% point of the distillation.
70% Point [C]
70% point of the distillation.
90% Point [C]
90% point of the distillation.
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Calibration Property View
Field
Description
95% Point [C]
95% point of the distillation.
Total Nitrogen [ppmwt]
Total Nitrogen content in the feed, ppmwt.
Basic Nitrogen [ppmwt]
Basic Nitrogen content in the feed, ppmwt.
Total/Basic Nitrogen Ratio
Ratio of total basic nitrogen content.
Sulfur Content%
Sulfur content in the feed, wt%
•
If you selected the Kinetic Lumps radio button:
If the feed is connected to an external stream, then you cannot choose a Property Method. You can only change the feed name and the feed type.
Operation Tab The Operation tab in the Calibration property view is the same as the Operation tab in the HCR Reactor Section property view. The Operation tab contains features used to manipulate the operation parameters of the Hydrocracker operation.
Feeds Page The Feeds page of the Operation tab of the Calibration property displays the calculated physical properties of the feed stream entering the reactor. This data is used for calibration runs. The following table lists and describes the options in the Feed page view:
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Object
Description
Feed Conditions
Enables you to modify the following properties of the feed stream(s) entering the Hydrocracker: • volume flow rate • mass flow rate • temperature • pressure • entry location If you select Split option, the Select Feed Location Property View appears and enables you to specify the feed stream flow ratio between the reactors.
Total Feed
Enables you to modify the following properties of the reactors: • total feed preheat duty • total feed pressure • gas to oil ratio
Specification Page The Specification page on the Operation tab of the Calibration property enables you to modify the reactor bed parameters of the Hydrocracker operation. Figure 5.64
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Calibration Property View
Recycle Gas Loop Page The Recycle Gas Loop page on the Operation tab of the Calibration property view enables you to modify the recycle gas parameters of the Hydrocracker operation. Figure 5.65
The Recycle Gas Loop page contains the following groups: Group
Description
HPS and Recycle Gas Compressor
Enables you to modify the following properties of the recycle gas loops: • stream temperature • stream pressure • outlet pressure of the stream exiting the compressor • pressure difference between the stream and the reactor stage
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Group
Description
Product Heater
Enables you to modify the following properties of the heater: • temperature of exiting stream • duty • pressure of exiting stream • pressure difference in heater
Hydrogen Makeup Stream
Enables you to modify the following properties of the hydrogen makeup stream: • mole flow rate • temperature • pressure • composition • hydrogen purge fraction
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Catalyst Deactivation Page The Catalyst Deactivation page enables you to modify the catalyst parameters of the hydrocraker operation. Figure 5.66
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Calibration Property View
Fractionator Page The Fractionator tab contains options for the fractionator in the Hydrocracker. The options are split into the following pages: • •
Zone Pressures Specs
If the Hydrocracker does not contain a fractionator the above pages appear blank.
Solver Options Page The Solver Options page on the Operation tab of the Calibration property view enables you to modify the calculation variable used to determine the reaction results of the reactor. Figure 5.67
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The Solver Option page contains the following information: Object
Description
Convergence Tolerance
Contains the Residual field that enables you to specify the maximum residual value allowed for the convergence calculation.
Iteration Limits
Contains two fields that enable you to control the iteration range for the OOMF Solver performance: • Maximum Iterations field enables you to specify the maximum number of iterations. • Minimum Iterations field enables you to specify the minimum number of iterations.
Creep Step Parameters
Contains three fields that enable you to configure the creep function of the OOMF Solver: • On/Off Switch drop-down list. Enables you to select On (enable) or Off (disable) option for the creep feature. • Iterations field. Enables you to specify the number of iterations per creep step. • Step Size field. Enables you to specify the size of each creep step.
Completeness Checking
Contains the Override Spec Group Completeness checkbox that enables you to toggle between: • Overriding the normal calculation behaviour. • Retaining the normal calculation behaviour. The normal calculation behaviour requires the spec groups be completed before solving.
SQP Hessian Parameters
Contains features used to manipulate the SQP Hessian parameters: • Initialization drop-down list. Enables you to select one of four options to initialize the Hessian value: Normal (default). Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and online problems that start very far from a solution. Aggressive. Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few Degrees of Freedom at solution. Ideal applications are well-posed online realtime optimization problems. Scaled. A combination of the Aggressive and Advanced modes. This setting is recommended for highly constrained optimization problems with few Degrees of Freedom at solution and a nonlinear objective function. Advanced. Hessian initialized with 2nd order information. This setting is recommended for problems with many Degrees of Freedom at solution and/or quadratic objective function. Ideal for data reconciliation problems, both online and offline. • Scaling factor field. Enables you to specify the scaling factor. • Updates stored field. Enables you to specify the number of updates stored during calculation (default value is 10).
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Calibration Property View
Object
Description
Line Search Parameters
Contains features used to configure the line search parameters: • Algorithm drop-down list. Enables you to select one of four methods for the line search algorithm: Normal (default). A proprietary line search designed to balance robustness with efficiency. Exact. A well-known exact penalty line search. It is too conservative for most practical problems. Residual. A proprietary line search designed to initially favour the convergence of residuals over the objective function improvement. Square. A line search designed to attempt to enforce bounds on cases with no Degrees of Freedom. It should be used only in cases where there are multiple solutions to a problem, and the desired solution lies within the bounds. • Step Control drop-down list. Enables you to select one of three options for the step size: Normal (default). The original method. Aggressive. A modified method that tends to take larger steps. Conservative. A modified method that tends to take smaller steps. • Step Control Iterations field. Enables you to specify the number of step iterations.
Variable Scaling Parameter
Contains the On/Off Switch drop-down list that enables you to select one of the following options: • On. Activates the variable scaling parameter. • Off. Deactivates the variable scaling parameter.
Failure Recovery Action dropdown list
Enables you to select one of the following action in case of failure: • Do nothing. • Revert to the previous results before the solve (this is the default option). • Revert to the default input and results.
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Solver Console Page The Solver Console page on the Operation tab of the Calibration property view enables you to view the solver message generated by the reaction and run script commands. Figure 5.68
The Solver Console page displays the following information: Object
Description
Simulation Engine Message and Script Commands field
Displays the messages and commands from the solver of the FCC reactor.
Enter Script Command field
Enables you to enter the text code for a command for the solver.
Clear Message button
Enables you to clear the messages in the Simulation Engine Message and Script Commands field.
Get Prev. Command button
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script Command field.
Get Next Command button
Enables you to retrieve the next command from the command history and place the text code in the Enter Script Command field.
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Calibration Property View
Object
Description
Run Command button
Enables you to run the command code in the Enter Script Command field.
Clear Command button
Enables you to clear the command history.
5.9.3 Operation Measure Tab The Operation Measures tab contains the following pages: • •
Temp./Press. Page Flow
Temp./Press. Page The Operation Measure tab in the Calibration property view allows you to input the temperature measurement that will be used in the objection function for calibration. Figure 5.69
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The Temperature page contains the following two groups: Object
Description
Temperature Rise
The rise in temperature.
Pressure Drop
The degree of pressure dropped.
Note: The number of columns depends on the number of reactors. The number of rows is the maximum number of beds among all reactors. The filed will be locked as a blank if the particular bed does not exist in the specific reactor. For example, if there are three reactors and there are two beds in Reactor 1, three beds in Reactor 2 and two beds in Reactor 3, then there will be rows for Bed 1, Bed 2 and Bed 3. However, the cells for data in Bed 3 of Reactor 1 and Reactor 3 will be blank and locked.
Flow Page Use the Flow page on the Operation Measure tab of the Calibration property view to input flow measurements in the recycle loop that will be used in the objection function for
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Calibration Property View
calibration. Figure 5.70
5.9.4 Product Measure Tab The Product Measure tab contains the options that enable you to manipulate the cuts, light ends and heavy ends in the calibration calculation.
Cuts Page The Cuts page on the Product Measure tab of the Calibration property view enables you to specify the number of GC analyses
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and liquid product cuts. Figure 5.71
The cuts available vary depending on whether the HCR has a fractionator. •
If the HCR has a fractionator: The naphtha cuts, LCO cuts and Bottom cuts are those you specified on the HCR Configuration Wizard.
•
If the HCR does not include a fractionator, then you must specify the number of liquid cuts, which correspond to the number of liquid product measurements you have.
Name of analysis or cut
What/how many you can specify
Number of fuel gas analyses
up to 5
Number of LPG analyses
up to 4
Number of naphtha cuts
up to 3
Number of Distillate Cuts
up to 2
Bottom cuts
• Bottoms • HCO and Bottoms
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Calibration Property View
Light Ends Page Use the Light Ends page on the Product Measure tab of the Calibration property view to specify the GC data for: • • •
Fuel Gases LPGs Naphthas
Figure 5.72
The table that appears in the Light Ends page enables you to input measurement data and is based on the number of fuel gas, LPC analyses and Naptha cuts specified on the Cuts Page. For example, the Heavy Naphtha column appears only if the configuration has a Heavy Naphtha draw. For each type of cut (each cut is represented by a column) you can enter the flow rate and composition in the appropriate cell. Notes: •
You only need to enter the Naphthenes, Olefins and Aromatics data for the naphtha cuts. The HCR model then extrapolates the curves to the regions where you did not specify data. 5-96
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• •
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For Fuel Gas columns, Liquid Rate variable is not available and for the other columns, Gas Rate variable is not available. When you enter a value for a composition, the Input Composition for GC Analysis dialog appears on which to enter the data.
Heavy Liquids Page Use the Heavy Liquids page on the Product Measure tab of the Calibration property view to specify measured data for fractionated streams, including flows and properties. Aspen HYSYS Petroleum Refining calculates the TBP cut for reactor parameterization. Figure 5.73
Note: You only need to enter the Naphthenes, Olefins and Aromatics data for the naphtha cuts. The HCR model adjusts the reference curve for Naphthenes, Olefins and Aromatics to match the measurements specified. The model then extrapolates the curves to the regions where you did not specify data. The streams on the Heavy Liquids page correspond to the 5-97
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Calibration Property View
fractionated draws that you specified: • •
on the HCR Configuration Wizard on the Cuts Page if the HCR does not have a fractionator
The Olefins, Naphthenes and Aromatics in naphtha cut(s) are required input. Those for other liquid cuts are optional. The temperature and pressure are used for fractionator calibration. Note: The Heavy Naphtha and Light Naphtha flows appear both on the Light Ends Page and in the Heavy Liquids Page.
5.9.5 Calibration Control Tab Use the Calibration Control tab of the Calibration property view to specify the reactor settings for: • •
Parameter Object Function
Parameters Page The Parameters page on the Calibration Control tab of the Calibration property view displays a list of parameters and a checkbox for each parameter to allow you to select which
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parameters to be used in calibrating the reactor model. Figure 5.74
This page contains several columns. The first column displays a list of parameters. The second column is the initial values of the parameters and the third column is a checkbox. The initial values of the parameters are from the default factor set but you can modify them.
Object Function Page The Object Function page on the Calibration Control tab of the Calibration property view allows the user to construct the objective function for the calibration. This page contains a matrix of two columns. The first column is the name of the
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Calibration Property View
variables, the second is the sigma values for the variable. Figure 5.75
5.9.6 Analysis Tab The Analysis tab of the Calibration property view displays the view populated with the results of a calibration run. Note: Pages on the Analysis tab, except the Worksheet page, display the calibration results of the current data set. You can select the current data set from the Data Set drop-down list.
Calibration Summary Page The Calibrations Summary page on the Analysis tab of the Calibration property view displays the calculated calibration factors. You can save these Calibration Factors as a named set that can then be used in calibration runs. you can also export
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the calibration factors to a file. Figure 5.76
There are four buttons located on the top of the Calibration Factor page and two groups. The following table outlines the buttons: Button
Action
Save for Simulation
Save the calibration factors for a simulation run, by clicking Save for Simulation. In the normal workflow, after running the calibration and reviewing the results, you will save the calculated calibration factors. Therefore, if you return to the Simulation environment, the system prompts you with the following question: Do you want to make the newly calculated calibration factors available for simulation? • If you select Yes - Aspen HYSYS Petroleum Refining proceeds as if you had clicked Save for Simulation. • If you select No - the calibration property view closes. • If you select Cancel - the Calibration property view remains open.
Export
Export the calibration factors as a file.
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Calibration Property View
Button
Action
Calibration Factors Library
View the Calibration Set Library view.
Re-initialize
The factors are split into two read-only groups. •
The Calibration Factors group displays all calculated reactor and (if it exists) fractionator calibration factors:
Factors
Default Calibration Factor set
Global Activity Reactor 1- Bed 1
0.7000
Reactor 1- Bed 2
0.7000
Reactor 2- Bed 1
0.7000
Reactor 2- Bed 2
0.7000
Overall HDS Activity Treating Bed Treating Bed to Cracking Bed Ration
9.761-eOC 0.6336
430- HDS Activity Treating Bed
1.000
Treating Bed to Cracking Bed Ration
1.000
430-950 HDS Activity Treating Bed Treating Bed to Cracking Bed Ration
0.7581 1.000
950+ HDS Activity Treating Bed
1.000
Treating Bed to Cracking Bed Ration
1.000
Overall HDN Activity Treating Bed
0.2508
Treating Bed to Cracking Bed Ration
0.8342
430- HDN Activity Treating Bed
1.217
Treating Bed to Cracking Bed Ration
1.000
950+ HDN Activity Treating Bed
1.665
Treating Bed to Cracking Bed Ration
1.000
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Factors
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Default Calibration Factor set
Overall SAT Activity Treating Bed Treating Bed to Cracking Bed Ration
7.000e-OC 1.035
430- SAT Activity Treating Bed
1.000
Treating Bed to Cracking Bed Ration
1.000
430-950 SAT Activity Treating Bed Treating Bed to Cracking Bed Ration
0.9032 1.000
950+ SAT Activity Treating Bed Treating Bed to Cracking Bed Ration
0.9182 1.000
Overall Cracking Activity Treating Bed Treating Bed to Cracking Bed Ration
0.1679 1.000e-OC
430- Cracking Activity Treating Bed
2.200
Treating Bed to Cracking Bed Ration
1.000
430-950 Cracking Activity Treating Bed
2.498
Treating Bed to Cracking Bed Ration
1.000
950+ Cracking Activity Treating Bed Treating Bed to Cracking Bed Ration
0.8000 1.000
Overall Ring Opening Activity Treating Bed
5.000e-OC
Treating Bed to Cracking Bed Ration
1.000e-OC
430- Ring Opening Activity Treating Bed
1.000
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Calibration Property View
Factors
Default Calibration Factor set
Treating Bed to Cracking Bed Ration
1.000
430-950 Ring Opening Activity Treating Bed
1.000
Treating Bed to Cracking Bed Ration
1.000
950+ Ring Opening Activity Treating Bed
1.000
Treating Bed to Cracking Bed Ration
1.000
Light Gas Tuning Factors C1
8.900
C2
5.000
C3
1.000
C4
0.1000
Catalyst Deactivation Initial Deactivation Constant
Included
Long Term Deactivation Constant
Included
Activation Energy
(Initial Value and Final Value will display if present. (Initial Value and Final Value will display if present. Included (Initial Value and Final Value will display if present.
WABT Bias
Included (Initial Value and Final Value will display if present.
Reactor Pressure Drop Factor Reactor 1- Bed 1
Included (Initial Value and Final Value will display if present.
Reactor 1- Bed 2
Included (Initial Value and Final Value will display if present.
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Factors
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Default Calibration Factor set
Reactor 2- Bed 1
Included (Initial Value and Final Value will display if present.
Reactor 2- Bed 2
Included (Initial Value and Final Value will display if present.
•
The Objective Function group displays the following information:
Factors
Default Calibration Factor set
Temperature Rise RIBI Temperature Rise [C]
1.000
RIB2 Temperature Rise [C]
1.000
R2BI Temperature Rise [C]
1.000
R2B2 Temperature Rise [C]
1.000
Recycle Quench Throws Reactor 1 Bed 1 [STD_m3/h]
720.0
Bed 1 [STD_m3/h]
720.0
Reactor 2 Bed 1 [STD_m3/h]
720.0
Bed 2 [STD_m3/h]
720.0
Purge Gas Flow - Loop 1 [STD_m3/h]
36.00
H2 Makeup 1 rate - Loop 1 [STD_m3/h]
36.00
H2 Consumption [STD_m3/m3]
1.000
Product Flow and Properties Naphtha C6-430F Vol. Flow [m3/h]
1.000
Diesel 430F-700F Vol. Flow [m3/h]
1.000
Bottoms 700-1000F Vol. Flow [m3/h]
1.000
Resid 1000F + Vol. Flow [m3/h]
1.000
C1C2 Yield [%]
1.00
C3 Yield [%]
1.00
C4 Yield [%]
1.00
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Calibration Property View
Factors
Default Calibration Factor set
Sulfur in Bottom 700+F [ppmwt]
10.00
Nitrogen in Bottom 700+F [ppmwt]
10.00
Mass Balance Page The Mass Balance page reports the errors in the mass flow rates. The page also reports the adjusted mass flows that are used in the calibration, based on how you have decided to distribute the error in the Validation Wizard. Figure 5.77
The following table list and describes the groups in the Mass Balance page: Section
Displays data on
Feed Group
• Stream Name • Mass Flow [kg/h] • Hydrogen Flow [kg/h]
Material Balance
• Closures (Measured/Adjusted)
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Section
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Displays data on
Product Group
• Stream name (Measured Mass Flow/Adjusted Mass Flow and Ass. Bias)
Chemical Hydrogen
• Consumption
Feed Blend Page The Feed Blend page on the Analysis tab of the Calibration property view displays the detailed characterization of each individual feed and the blend of feeds going to each riser location. Figure 5.78
Note: •
If there are two reactors, or there is a feed mid-point injection, you can use the Blend Properties at Selected Reactor Location list to choose the location to display.
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Calibration Property View
Product Yields Page The Product Yields page on the Analysis tab of the Calibration property view displays the standard Cut yields from the simulation. Figure 5.79
If the Hydrocracker contains a fractionator, there will be two radio buttons: Standard Cut Products and Fractionated Products. Depending on the radio button selected, the Yields group displays the yields for standard cuts or the fractionated yields. The liquid product cuts for the Fractionated Products option correspond to those specified in the Specs Page of the Fractionator tab.
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Product Properties Page The Product Properties page on the Analysis tab of the Calibration view displays the calculated physical properties of the product streams exiting the Hydrocracker. Figure 5.80
The Product Properties group displays the following values for each of the stream(s) listed: • • • • • • • • • • • • •
API Gravity Specific Gravity Sulfur [%] Total Nitrogen [ppmwt] Basic Nitrogen [ppmwt] Paraffins [%] Naphthenes [%] Aromatics [%] RON MON Smoke Point [mm} Freeze Point [C] Flash Point [C] 5-109
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Calibration Property View
• • • •
Cetane Index Four POint [C] Watson K Viscosity @ 100F [cP]
If the Hydrocracker contains a fractionator, there will be two radio buttons: Standard Cut Products and Fractionated Products. Depending on the radio button selected, the Product Properties group displays the properties for standard cuts or the properties for the fractionated products. The liquid product cuts for the Fractionated Products option correspond to those specified in the Specs Page of the Fractionator tab.
Reactor Page The Reactor page on the Analysis tab of the Calibration property view displays the key simulation results of the reactor. The results displayed depend on the configuration of the HCR. Figure 5.81
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Hydrogen System Page The Hydrogen System page displays the calculated results of the Hydrogen make-up streams and Hydrogen recycled gas. Figure 5.82
Fractionator Page The Fractionator page on the Analysis tab of the Calibration property view displays the fractionator solver tuning parameters. The Section-based solver tuning parameters group displays for each zone: • • • •
Top Index Bottom Index Top R2 Bottom R2
The TBP Cut Points group displays the calculated cut point to match the specified flow rate of each zone.
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Calibration Property View
Hydrogen Balance Page The Hydrogen Balance page on the Analysis tab of the Calibration property view displays key hydrogen balance information and hydrogen-balance-related information. Figure 5.83
The Hydrogen balance page reports the following data: Group
Displays data on
H2 Consumption
• Bed 1 [STD-m3/h] • Bed 2 [STD-m3/h] • Sum [STD-m3/h]
H2 Balance
• • • • • • • •
H2 Flow in Makeup 1 [STD-m3/h] H2 Flow in Makeup 2 [STD-m3/h] H2 Flow in Total Makeup [STD-m3/h] H2 Makeup per Feed Flow [STD-m3/m3] H2 Flow in Purge [STD-m3/h] H2 Purge per Feed Flow [STD-m3/m3] Total H2 Consumption [STD-m3/h] Total H2 Consumption per Feed Flow [STDm3/h] • Total H2 Losses [STD-m3/h] • H2 Losses per Feed Flow [STD-m3/m3]
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Worksheet Page The Worksheet page on the Advanced tab of the Calibration property view displays the summary of the calibration results. Each row in the table corresponds to each variable from every other Analysis page, and each column for every included data sets in the calibration run. Figure 5.84
5.10 References 1
"The Lower It Goes, The Tougher It Gets," Bradford L. Bjorklund, Neil Howard, Timothy Heckel, David Lindsay, and Dave Piasecki, presented at presented at the NPRA 2000 Annual Meeting, Paper No. AM-00-16, March 26-28, 2000.
2
"Improve Refinery Margins and Produce Low-Sulfur Fuels," Scott W. Shorey, David A. Lomas, and William H. Keesom, World Refining Special Edition: Sulfur 2000, Summer 1999, p. 41.
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References
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Petroleum Column
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6 Petroleum Column
6.1 Introduction................................................................................... 2 6.1.1 Petroleum Column Conventions .................................................. 3 6.2 Petroleum Column Theory.............................................................. 4 6.2.1 Zone-By-Zone Method............................................................... 4 6.2.2 Stage-By-Stage Method ............................................................ 8 6.2.3 TBP Cut Points ......................................................................... 9 6.3 Petroleum Column Installation .................................................... 12 6.3.1 Refinery Column Input Experts................................................. 13 6.4 Petroleum Distillation Column Property View .............................. 20 6.4.1 6.4.2 6.4.3 6.4.4
Design Tab ............................................................................ 22 Worksheet Tab ....................................................................... 37 Performance Tab .................................................................... 37 Calibration Tab....................................................................... 53
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6-2
Introduction
6.1 Introduction The Petroleum Column provides users with the capability to model columns in a refinery. The Petroleum Column has been specifically designed to help users with solving the following problems: •
•
Simulation of a Petroleum Column for a wide range of crude oils within an optimization or gradient generation scenario. In this situation, the column needs to be simulated over and over again, and the column should converge quickly and consistently in all scenarios. Manually calibrate the Petroleum Column from plant data.
If you require significant internal details of the column such as vapor-liquid traffic or temperature profiles matching very closely to plant data, or if you are interested in extreme flexibility in the specifications or the topology of the column, you need to use the standard HYSYS column.
The focus of the Petroleum Column is to model the imperfect separation of crude and other feeds that occur in the refining industry as possible. The modeling of imperfect fractionation plays a very important role in overall refinery economics. Conversely the focus is not to use the tool as a detailed design tool. The Petroleum Column model has the following capabilities: • • • • • • •
Allows one feed. Allows you to place reboiled or steam-striped sidestrippers. Allows you to place pump-arounds. Allows you to specify the flow-ratio of each product with respect to the feed, or the TBP cut-point of a product with respect to the feed. Calculates the composition, distillation curves, temperature and flow for each of the products. Calculates the petroleum properties for each of the products of the Petroleum Column. Calculates pump around duties.
The Petroleum Column supports the use of two solution strategies: Zone-by-zone and Stage-by-stage. 6-2
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Petroleum Column
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6.1.1 Petroleum Column Conventions Column Tray Sections, Overhead Condensers, and Bottom Reboilers are each defined as individual unit operations. Condensers and Reboilers are not numbered stages, as they are considered to be separate from the Tray Section. By making the individual components of the column separate pieces of equipment, there is easier access to equipment information, as well as the streams connecting them.
The following are some of the conventions, definitions, and descriptions of the basic columns: Column Component
Description
Tray Section
A HYSYS unit operation that represents the series of equilibrium trays in a Column.
Stages
Stages are numbered from the top down or from the bottom up, depending on your preference. The top tray is 1, and the bottom tray is N for the top-down numbering scheme. The stage numbering preference can be selected on the Connections page of the Design tab on the Column property view.
Overhead Vapor Product
The overhead vapour product is the vapour leaving the top tray of the Tray Section in simple Absorbers and Reboiled Absorbers. In Refluxed Absorbers and Distillation Towers, the overhead vapour product is the vapour leaving the Condenser.
Overhead Liquid Product
The overhead liquid product is the Distillate leaving the Condenser in Refluxed Absorbers and Distillation Towers. There is no top liquid product in simple Absorbers and Reboiled Absorbers.
Bottom Liquid Product
The bottom liquid product is the liquid leaving the bottom tray of the Tray Section in simple Absorbers and Refluxed Absorbers. In Reboiled Absorbers and Distillation Columns, the bottom liquid product is the liquid leaving the Reboiler.
Overhead Condenser
An Overhead Condenser represents a combined Cooler and separation stage, and is not given a stage number.
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Petroleum Column Theory
6.2 Petroleum Column Theory The Petroleum Column has two methods to solve and converge the column: Zone-by-zone and Stage-by-Stage.
6.2.1 Zone-By-Zone Method The Zone-by-zone solution strategy is based on fractionation indices and has the following features: • • •
Applicable over a very wide range of feeds. Consistent between simulation and calibration. Moderately accurate beyond the region of calibration.
For example: Consider a simple distillation column with one feed and two products only. For near ideal systems such as hydrocarbon systems, it is possible to correlate the distillate and bottoms flow as shown in the figure below: Figure 6.1
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6-5
If one plots the quantity ln(Di/Bi) vs. NBPi for each component i, the plot is typically bilinear. where: Di = molar component flow of component i in the distillate Bi = molar component flow of component flow of component i in the bottoms NBP = normal boiling point of the component
The slope of the curve signifies the extent of imperfect fractionation. As S tends to zero, there is virtually no separation, and inversely as S tends to negative infinity, the separation is almost perfect. The position of the curve horizontally is decided by the overall distillate and bottoms flow distribution. HYSYS assume that the slopes of the curves drawn above are only a characteristic of the structure of the column, and are independent of the feed or the pressure or other operating conditions. This assumption enables HYSYS to calculate the product composition of the distillate and bottoms streams, for a wide range of feed conditions. Furthermore, HYSYS assume that all Petroleum Columns are in indirect sequence of simple columns. Based on these assumptions the composition of the streams coming out of each sections of the column can be calculated using the following equations described below: •
For each section: d N, i –1 ln ⎛⎝ ---------⎞⎠ = ------------ ( NBP i ) + K D, N b N, i φ D, N –1 = ⎛ ----------- ( NBP i ) + K B, N⎞ ⎝ φ B, N ⎠ f N, i = d N, i + b N, i DN =
If d i > b i for all i
(6.1)
If d i < b i for all i for all i
∑ d N, i
(6.2)
(6.3)
i
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Petroleum Column Theory
BN =
∑ b N, i
(6.4)
i
F N = DN + B N
•
(6.5)
For two consecutive sections: FN – 1 = DN
(6.6)
where: N = section in the column fN,i = i component flow rate in feed for section N dN,i = i component flow rate in distillate for section N bN,i = i component flow rate in bottoms for section N φ D, N = fractionation index for the distillate section N φ B, N = fractionation index for the bottom section N KD,N = intercept for the distillate section N KB,N = intercept for the bottom section N DN = total distillate flow for section N BN = total bottom flow for section N FN = total feed flow for section N You are required to specify fractionation indices for each section, pressure for each section, and product flow fractions for each product coming out of the column including the condenser. The sections are numbered from bottom of the column to the top of the column.
The above system of equations is then solved for dN,i, bN,i, fN,i, KD,N, and KB,N.
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Water Handling The above equations are based on the assumption of a waterfree basis. As a result the quantity of water calculated through the above equations is zero. A separate water balance is performed on the whole column after the hydrocarbon component flow rates have been calculated. It is assumed that each of the product streams is 75% saturated with water. Knowing the water-free composition of each (liquid) product stream, HYSYS compute the saturation amount of water. This enables HYSYS to calculate the composition of the water in liquid product streams. The remaining water leaves from the top of the column.
Condenser Handling The condenser is dealt with separately. The feed to the condenser is the distillate from the top section. From your specification of the amount of vapor and liquid product from the condenser, HYSYS can calculate the composition of each of the vapor and liquid products as well as the quantity of the water that will be in the vapor phase and the quantity of water that will be in a separate aqueous phase. The temperature of the condenser will also be calculated.
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Petroleum Column Theory
6.2.2 Stage-By-Stage Method The Stage-by-stage solution strategy as the name suggests, uses the Stage-by-stage HYSIM IO solver to solve the mass and energy balance in the column. This solution strategy has the following features: • • • •
•
Accurate over a wide range of feeds, extrapolates well. Accounts for pressure effects of separation. Accounts for change in vapor-liquid equilibrium behaviour with the feed and other operating conditions. Will fail to solve if the specifications provided are infeasible. A typical example of an infeasible spec is a very low liquid flow in the bottom of the column, even though the feed is not hot enough. A strategy for calibrating with this solution strategy is under development and is not available in this version.
The Stage-by-stage solver uses the standard HYSIM I/O algorithm, and the Petroleum Column automatically generates all the specifications required by the HYSIM I/O solver. The Petroleum Column applies the following structural assumptions to generate the specifications: • • • •
Each pump-around draw and return is one theoretical stage. Each side-stripper draw and return is on the same theoretical stage. A pump-around may or may not exist for each separation zone. If the pump-around exists, it is placed on the stage below the side-stripper draw (and return).
The following set of specifications are generated: • • • • •
Bottoms flow rate calculated from the TBP or the flow spec that you provide. Every side-stripper product flow-rate calculated from the TBP or flow-specs that you provide. Each pump-around DT is set to 50°C. For each pump-around the liquid flow on the tray above is set to nearly zero. You must specify steam-flow or side-stripper reboiler duty.
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6.2.3 TBP Cut Points The petroleum column uses the TBP cut point specification to determine the quality of the product streams. The TBP cut point can be best described using the example in the figure below: Figure 6.2
Overhead
Naphtha
100°C
250°C
Kero
Gas Oil
280°C
Residue
320°C
500°C
In the above case, the intention is to inform the column to split the crude oil into five product streams. The five product streams will have the following qualities: • • • • •
top product is cut from the initial boiling point of the crude up to 100°C naphtha product is cut between 100°C and 250°C kero product is cut between 250°C and 280°C gasoline product is cut between 280°C and 320°C residue product is cut from 320°C to the final boiling point of the crude
These cut points are translated into molar flow fractions of the feed.
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Petroleum Column Theory
The figure below displays an example of the cut points translated into molar flow fractions: Figure 6.3
In a crude column, there are no degree of freedom to exactly achieve the specified cut points at both ends of the column. Furthermore, the column achieves perfect separation only at infinite number of stages. Aspen HYSYS Petroleum Refining is able to model the imperfect separation and therefore achieve the separation as shown in the
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figure below: Figure 6.4
Portion of Naphtha in Overhead
Overhead
Portion of Overhead in Naphtha.
Naphtha
Individual cut
The above type of cut is also exemplified in the TBP 5% and TBP 95% columns of the TBP cut point specification table (shown in the figure below): Figure 6.5
The values in the TBP 5% and TBP 95% columns are calculated by Aspen HYSYS Petroleum Refining and indicates what the product stream actually achieve in the simulation.
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Petroleum Column Installation
6.3 Petroleum Column Installation There are two ways to install a Petroleum Column to your simulation: 1. In the Flowsheet menu, click the Add Operation command. The UnitOps property view appears. You can also access the UnitOps property view by pressing the F12 hot key. 2. Click the Aspen HYSYS Petroleum Refining Ops radio button. 3. From the list of available unit operations, select Petroleum Distillation. 4. Click the Add button. OR 1. Press F6 to access the Aspen HYSYS Petroleum Refining object palette. 2. Double-click the Petroleum Distillation icon. Petroleum Distillation icon
The Refinery Column Input Experts property view appears. You do not have to install the Petroleum Column through Refinery Column Input Experts property view. You can turn off the Input Expert option and configure the Petroleum Column from the Petroleum Distillation Column property view. To deactivate the Input Expert option: 1. Click the Tools menu, and select the Preferences command. The Session Preferences property view appears. 2. In the Session Preferences property view, click the Simulation tab and select the Options page. 3. In the General Options group, clear the Use Input Experts checkbox.
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6.3.1 Refinery Column Input Experts The Refinery Column Input Experts (RCIE) guides you through the installation of a Petroleum Column. The RCIE contains a series of input pages whereby you must specify the required information for the page before advancing to the next one. When you have worked through all the pages, you have specified the basic information required to build your Petroleum Column. You are then placed in the Petroleum Column property view which gives comprehensive access to most of the column features. The following sections describe each input page in the RCIE:
Connections Page The Connections page of the RCIE allows you to specify the material and energy streams flowing into and out of the Petroleum Column. Figure 6.6
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Petroleum Column Installation
HYSYS recommends you select one of the last few trays at the bottom of the petroleum column for the Feed Stage.
Side Stripper Page The Side Stripper page of the RCIE allows you to add, configure, and delete side strippers connected to the Petroleum Column. Figure 6.7
The Basis group contains radio buttons that enables you to select the unit of the flow rate displayed in the Installed Side Strippers table. There are three units to choose from: molar, mass, or liquid volume. The Installed Side Strippers table displays the following information on each side stripper connected to the Petroleum column: • • • • • •
name of the side stripper number of stages in the side stripper draw and return stage/tray of the side stripper configuration of the side stripper (Reboiled or Steam Stripped) reboiler duty (values only available if the configuration is Reboiled) steam flow rate (values only available if the configuration is Steam Stripped) 6-14
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To add a side stripper: 1. Click the Add Side Stripper button. The Side Strippers page changes and the options for configuring a side stripper appears. Figure 6.8
2. Use the top drop-down list to select the stage where the side stripper stream is withdrawn and pump back into. 3. Enter the number of trays for the side stripper by typing the total number of trays in the k = field. 4. Select the configuration for the side stripper by clicking the appropriate radio button in the Configuration group. •
If you selected Reboiled radio button, the side stripper uses a reboiler. • If you selected Steam Stripped radio button, the side stripper requires a steam stream. In the Steam Feed field, either type in the name of the stream or if you have pre-defined your stream select it from the drop-down list. 5. In the Product Stream field, either type in the name of the stream or if you have pre-defined your stream select it from the drop-down list. 6. Click the Install button to install the side stripper. You can click the Clear button to remove all the information and start configuring the side stripper all over again.
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Petroleum Column Installation
The Side Strippers page returns to the previous property view and the information on the new side stripper appears in the Installed Side Strippers table. Figure 6.9
7. Repeat all the above steps to add another side stripper. To delete an existing side stripper: 1. In the Installed Side Strippers table, select a cell associated to the side stripper you want to modify. 2. Click the Delete Side Stripper button. 3. You will be ask to confirm the deletion: • •
Click the Yes button to delete the selected side stripper. Click the No button to not delete the selected side stripper.
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To modify an existing side stripper: 1. In the Installed Side Strippers table, select a cell associated to the side stripper you want to modify. 2. Click the View Side Stripper button. The Side Stripper property view appears. Figure 6.10
3. Make the modifications and click the Close button. You can also delete the selected side stripper by clicking the Delete button.
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Petroleum Column Installation
Zones Page The Zones page of the RCIE allows you to specify the pressure, pump around (PA), and tuning parameters in each zone of the Petroleum Column. Figure 6.11
HYSYS recommends 5 for the Top and Bottom Intercept values.
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Specs Page Refer to Section 6.2.3 TBP Cut Points for more information on TBP cut points.
The Specs page of the RCIE allows you to specify the TBP cut point or product stream flow fraction of the Petroleum Column.
Refer to Chapter 12 Session Preferences in the HYSYS User Guide for details on how to access the Session Preferences property view.
It is not necessary to use the RCIE to install a Petroleum Column. You can disable and enable the use of RCIE on the Options page in the Simulation tab of the Session Preferences property view. If you do not use the RCIE, you move directly to the Petroleum Distillation Column property view when you install a new Petroleum Column.
Figure 6.12
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Petroleum Distillation Column
6.4 Petroleum Distillation Column Property View The Petroleum Distillation Column property view is sectioned into tabs containing pages with information pertaining to the column. The Petroleum Distillation Column property view is accessible from the main flowsheet. Figure 6.13
The column property view is used to define specifications, provide estimates, monitor convergence, view Stage-by-stage and product stream summaries, add pump-arounds and sidestrippers, and define other Petroleum Column parameters such as convergence tolerances. HYSYS recommends you select one of the last few trays at the bottom of the petroleum column for the Feed Stage.
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The following table lists and describes the common objects at the bottom of the Petroleum Column property view: Object
Description
Delete button
Enables you to delete the Petroleum Column. HYSYS will ask you to confirm deletion.
Run button
Enables you to start the column calculation to converge the column. The button hides when the column convergence calculation is in progress.
Reset button
Enables you to reset all calculated values in the column to the default values. The button hides when the column convergence calculation is in progress.
Stop button
Enables you to stop the column calculation before column convergence. The button is only available when the column convergence calculation is in progress.
Status bar
Displays the status of the Petroleum Column.
To Rigorous button
Enables you to switch from Zone-by-zone solver to Stageby-stage solver method.
Ignore checkbox
Enables you to toggle between ignoring or considering the Petroleum Column during process flowsheet calculations.
Column Convergence The Run and Reset buttons are used to start the convergence algorithm and reset the Column, respectively. HYSYS first performs iterations toward convergence of the inner and outer loops (Equilibrium and Heat/Spec Errors), and then checks the individual specification tolerances.
Solver Holding icon
If you want to modify the Petroleum Column after you have converged said column, you should click the Solver Holding icon before modifying the values. By stopping the Solver option, you can change multiple values without waiting for the entire Petroleum Column to solve and converge every time a single value changes.
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Petroleum Distillation Column
6.4.1 Design Tab The Design tab contains all the options required to configure the Petroleum Column. The options are grouped into the following pages: • • • • • • •
Connections Zones Side Strippers Side Draws Specs SolverOptns Notes
Connections page The Connections page enables you to configure the streams (material or energy) flowing into and out of the column and specify the number of trays within the column. Figure 6.14
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The following table lists and describes the objects in the Connections page: Object
Description
Column Name field
Enables you to specify a name for the petroleum distillation column.
Condenser Energy Stream field
Enables you to specify or select an energy stream for the condenser.
Ovhd Outlets fields
The top field enables you to specify the vapour outlet stream of the condenser. The bottom field enables you to specify the liquid outlet stream of the condenser.
For more information on Zone-by-zone and Stageby-stage solver methods, refer to Section 6.2 Petroleum Column Theory.
Solver group
Contains radio buttons that enable you to toggle between Zone-by-zone or Stage-by-stage calculation method.
Inlet Streams table
Contains two columns that enable you to connect the streams flowing into the column. • Stream column enables you to specify or select feed streams. • Inlet Stage column enables you to select the stage/tray number the associate feed stream is entering.
# Stages n field
Enables you to specify the number of tray/stages in the column.
Edit Tray button
Enables you to access the Tray Section Details Property View.
Stripping Steam field
Enables you to specify or select the steam stream entering from the bottom of the petroleum distillation column.
Water Draw field
Enables you to specify or select the water stream flowing out of the condenser.
Optional Side Draws table
Contains columns that enable you to configure the side draw streams flowing out of the column. • Stream column enables you to specify or select the stream exiting the column. • Type column displays the phase of the associate side draw stream. • Draw Stage column enables you to select the stage/tray the associate stream is flowing out of.
Stage Numbering group
Contains two radio buttons that enable you to toggle between numbering the stages/trays in the column top-down or bottom-up format. • Top Down radio button numbers the top tray as 1 and increases the number for each tray below. • Bottom Up radio button numbers the bottom tray as 1 and increases the number for each tray above.
Residue field
Enables you to specify or select the waste stream flowing out from the bottom of the column.
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Petroleum Distillation Column
Tray Section Details Property View The Tray Section Details property view enables you to edit the number of trays in the column, and add or delete trays after or before the tray number of your choice in this property view. Figure 6.15
Zones Page In the Zone-by-zone solver method, the number of stages is no longer specifiable. So you need to specify zone information to help the column converge. The Zones page enables you to define zone pressure and tuning parameters in the Petroleum Column. Figure 6.16
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The following table lists and describes each object in the Zones page: Object
Description
Zone Information group Zone Start cell
Displays the starting point of each zone in the Petroleum Column.
Zone End cell
Displays the end point of each zone in the Petroleum Column.
PA cell
Contains a checkbox that enables you to toggle between connecting or removing a pump around with the associate zone.
Associated SS cell
Displays the name of the side stripper associated to each zone.
Zone Top Pressure cell
Enables you to specify the top pressure for each zone.
Bottom Pressure field
Enables you to specify the bottom pressure of the Petroleum Column.
Refer to Section 6.4.4 Calibration Tab for more information.
Copy Column Data to Calibration button
Enables you to export the column data to the Calibration tab.
For more information, refer to Section 6.2.1 Zone-By-Zone Method.
Top Index cell
Enables you to specify the top slope value of the imperfect fractionation for each zone. • Index value of 1 indicates perfect separation. • Larger index value indicates less perfect separation. HYSYS recommends an average tuning parameter value of 5 for the imperfect fractionation value.
Bottom Index cell
Enables you to specify the bottom slope value of the imperfect fractionation for each zone. • Index value of 1 indicates perfect separation. • Larger index value indicates less perfect separation. HYSYS recommends an average tuning parameter value of 5 for the imperfect fractionation value.
Copy Tuning Parameter from Calibration button
Enables you to import the tuning parameter data from the Calibration tab.
Refer to Section 6.4.4 Calibration Tab for more information.
Tuning Parameters group
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Petroleum Distillation Column
Side Stripper Page The Side Stripper page allows you to add, delete, and modify a reboiler or steam-stripped side stripper attached to the column. Figure 6.17
For any side stripper, you must specify the number of stages, the liquid draw-and-return stage, and the steam stream flow rate or the reboiler duty. These parameters (except for the number of stages) can be modified in the Side Stripper page and the Side Stripper property view. The following table lists and describes each object in the Side Stripper page: Object
Description
Basis group
Contains three radio buttons that enable you to toggle between the following three types of basis for the data in the tables: molar, mass, or liquid volume.
Input group first column
Displays the name of the side strippers.
# Stages column
Displays the number of trays in the associate side stripper.
Liq Draw Stage column
Enables you to select the draw-and-return stage from the main column for the associate side stripper.
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Object
Description
Configuration column
Displays the side stripper type: reboiler or steam stripped.
Reboiler Duty cell
Enables you to specify the amount of heat flowing from the reboiler.
Steam Flow cell
Enables you to specify the amount of steam flowing into the side stripper.
View button
Enables you to access the Side Stripper Property View of the selected side stripper.
Add button
Enables you to add a side stripper to the petroleum distillation column.
Delete button
Enables you to delete the selected side stripper from the petroleum distillation column.
Output group first column
Displays the name of the side strippers.
Liquid Draw Stage cell
Enables you to select the draw-and-return stage from the main column.
Outlet Flow cell
Displays the flow rate of the product stream from the side stripper.
Side Stripper Property View The Side Stripper property view can be accessed by one of the following methods: • •
On the Side Stripper page, select a cell of a side stripper and click the View button. On the Side Stripper page, click the Add button. A new side stripper is added.
Figure 6.18
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Petroleum Distillation Column
The following table lists and describes each object in the Side Stripper property view: Object
Description
Name field
Enables you to enter the name of the side stripper.
Tray Location dropdown list
Enables you to select the draw-and-return stage from the main column.
Configuration group
Enables you to select the side stripper configuration by selecting the appropriate radio button. There are two types available: reboiler and steam stripped. This group is only available when you are installing the side stripper for the first time.
k = field
Enables you to specify the number of trays in the side stripper.
Steam Feed field
Enables you to connect the steam stream to the side stripper. You can either type in the name of the stream or if you have pre-defined your streams select them from the drop-down list. This field is only available if you select the Steam Stripped radio button.
Reboiler Duty Spec field
Enables you to specify the amount of heat flow from the reboiler into the side stripper. This field is only available if you select the Reboiler radio button and click the Install button.
Product Stream field
Enables you to connect the product stream to the side stripper. You can either type in the name of the stream or if you have pre-defined your streams select them from the drop-down list.
Delete button
Enables you to delete the side stripper.
Install button
Enables you to install the side stripper. This button is only available when you are installing the side stripper for the first time.
Close button
Enables you to save the changes made in the side stripper property view. This button is only available after you have installed the side stripper.
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Side Draws Page The Side Draws page enables you to configure the location of the side draw streams and view the flow rate of the side draw streams. Figure 6.19
The following table lists and describes the objects available in the Side Draws page: Object
Description
Basis group
Contains three radio buttons that enable you to toggle between the following three types of basis for the data in the table: molar, mass, or liquid volume.
Draw Stream column
Enables you to specify or select the draw streams flowing out of the petroleum distillation column.
Draw Stage column
Enables you to select the stage/tray the associate draw stream is connected to.
Type column
Displays the phase type of the associate draw stream.
Draw Stream Flow
Displays the flow rate of the associate draw stream.
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Petroleum Distillation Column
Specs Page Refer to Section 6.2.3 TBP Cut Points for more information about TBP cut points.
The Specs page enables you to specify values used in the Petroleum Column convergence algorithm. Unlike the other Columns in HYSYS, the Petroleum Column is limited to two types of specifications: TBP End Points and Product Yields. Figure 6.20
The following table lists and describes all the objects available in the Specs page. Depending on which option you select in the Spec Option group, some of the objects are hidden. Object
Description
TBP End Points radio button
Enables you to access the TBP End Points specification options.
Product Yields radio button
Enables you to access the Product Yields specification options
first column
Displays all the streams flowing out of the petroleum distillation column.
TBP End Point column
Enables you to specify the boiling point temperature for each product stream in the Petroleum Column. This object is only available if you select the TBP Cut Point radio button.
Product Yield column
Displays the molar fraction value from the feed stream to the associate outlet stream. This object is only available if you select the TBP Cut Point radio button.
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Object
Description
TBP 5% column
Displays the boiling point temperature for each product stream at 5%. This object is only available if you select the TBP Cut Point radio button.
TBP 95% column
Displays the boiling point temperature for each product stream at 95%. This object is only available if you select the TBP Cut Point radio button.
Product Yield column
Enables you to specify the fraction of the feed stream to the product streams. This object is only available if you select the Product Flow Fraction radio button.
Total field
Displays the sum of fractions from the feed stream. The sum value must equal 1. This object is only available if you select the Product Flow Fraction radio button.
Product Yield Fraction Basis group
Enables you to select the unit basis for the specified values. There are three options: molar, mass, and volume. This option is only applicable to the Product Flow Fraction specification option.
Minimum Bottom Spec field
Displays the minimum feed fraction values for the residue product stream. If the minimum fraction value is higher than the specified fraction value, the petroleum column will not solve or converge in rigorous/Stage-by-stage solving method. To decrease the minimum fraction value, you have to increase the feed stream temperature, and vice versa.
Copy Specifications from Calibration button
Enables you to populate the specification data with the information from the Products page of the Calibration tab.
Aspen HYSYS Petroleum Refining automatically normalize the values in the Feed Fraction column, so that the sum of the values equal 1.
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Petroleum Distillation Column
SolverOptns Page The SolverOptns page enables you to manipulate how the column solves the column variables. Figure 6.21
There are two groups in the SolverOptns page: Solving Options and Solving Methods.
Solving Options Group This group contains parameters that you can manipulate to your preferences for the column solving behaviour. Figure 6.22
The Solving Options group contains options only applicable to the Stage-by-stage solving method. 6-32
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If Zone-by-zone solving method is selected, the options in the Solving Options group are hidden.
Maximum Number of Iterations The Column convergence process terminates if the maximum number of iterations is reached. The default value is 10000, and applies to the outer iterations. If you are using Newton's method, and the inner loop does not converge within 50 iterations, the convergence process terminates.
Equilibrium and Heat/Spec Tolerances Convergence tolerances are pre-set to very tight values, thus ensuring that regardless of the starting estimates (if provided) for column temperatures, flow rates, and compositions, HYSYS always converges to the same solution. However, you have the option of changing these two values if you want. Default values are: • •
Inner Loop. Heat and Spec Error: 5.000e-04 Outer Loop. Equilibrium Error: 1.000e-05
Because the default values are already very small, you should use caution in making them any smaller. You should not make these tolerances looser (larger) for preliminary work to reduce computer time. The time savings are usually minor, if any. Also, if the column is in a recycle or adjust loop, this could cause difficulty for the loop convergence.
Equilibrium Error The value of the equilibrium error printed during the column iterations represents the error in the calculated vapour phase mole fractions. The error over each stage is calculated as one minus the sum of the component vapour phase mole fractions. This value is then squared; the total equilibrium error is the sum of the squared values. The total equilibrium error must be less than 0.00001 to be considered a converged column.
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Heat and Spec Error The heat and specification error is the sum of the absolute values of the heat error and the specification error, summed over each stage in the tower. This total value is divided by the number of inner loop equations. The heat error contribution is the heat flow imbalance on each tray divided by the total average heat flow through the stage. The specification error contribution is the sum of each individual specification error divided by an appropriate normalization factor. For component(s) flow, the normalization factor is the actual component(s) flow; for composition, it is the actual mole fraction; for vapour pressure and temperature it is a value of 5000; etc. The total sum of heat and spec errors must be less than 0.0005 to be considered a converged column. The allowed equilibrium error and heat and spec error are tighter than in most programs, but this is necessary to avoid meta-stable solutions, and to ensure satisfactory column heat and material balances.
Save Solution as Initial Estimate This option is on by default, and it saves converged solutions as estimates for the next solution.
Super Critical Handling Model Supercritical phase behaviour occurs when one or more Column stages are operating above the critical point of one or more components. During the convergence process, super critical behaviour can be encountered on one or more stages in the Column. If HYSYS encounters super critical phase behaviour, appropriate messages appear in the Trace Window.
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HYSYS cannot use the equation of state or activity model in the super critical range, so an alternate method must be used. You can specify which method you want HYSYS to use to model the phase behaviour. There are three choices for super critical calculations:
Refer to Chapter 1 Interface in the HYSYS User Guide for details on the Trace Window.
Model
Description
Simple K
The default method. HYSYS calculates K-values for the components based on the vapour pressure model being used. Using this method, the K-values which are calculated are ideal K-values.
Decrease Pressure
When supercritical conditions are encountered, HYSYS reduces the pressure on all trays by an internally determined factor, which can be seen in the Trace Window when the Verbose option is used. This factor is gradually decreased until supercritical conditions no longer exist on any tray, at which point, the pressure in the column is gradually increased to your specified pressure. If supercritical conditions are encountered during the pressure increase, the pressure is once again reduced and the process is repeated.
Adjacent Tray
When supercritical conditions are encountered on a tray, HYSYS searches for the closest tray above which does not have supercritical behaviour. The nonsupercritical conditions are substituted in the phase calculations for the tray with supercritical conditions.
Trace Level The Trace Level defines the level of detail for messages displayed in the Trace Window, and can be set to Low, Medium, or High. The default is Low.
Initialize from Ideal K’s When this checkbox is selected, HYSYS initializes its column solution using ideal K values which are calculated from vapour pressure correlations. The ideal K-value option, which is also used by HYSIM, increases the compatibility between HYSIM and HYSYS. By default, the Initialize from Ideal K's checkbox is cleared. HYSYS uses specified composition estimates or generates estimates to rigorously calculate K-values.
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Two Liquids Check Based on This option allows you to specify a check for two liquid phases in the column. The check is based on one of the following criteria: • • •
No 2 Liq Check. Disables the two liquid check. Tray Liquid Fluid. The calculation is based on the composition of the liquid in the column. Tray Total Fluid. The calculation is based on the overall composition of the fluid in the column.
Tighten Water Tolerance When this checkbox is selected, HYSYS increases the contribution of the water balance error to the overall balance error in order to solve columns with water more accurately. The default setting for this checkbox is clear.
Auto Reset On When this checkbox is selected, HYSYS resets the column values once during convergence calculation, if during the calculation the heat and spec errors do not reduce by more than 15%.
Solving Method Group For more information on the solving method available for the Petroleum Column, refer to Section 6.2 Petroleum Column Theory.
This group contains two radio buttons that enables you to select the column solution method. Figure 6.23
The display field, which appears below the drop-down list, provides explanations for each method.
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Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation, or your simulation case in general.
6.4.2 Worksheet Tab Refer to Section 1.2.2 Worksheet Tab for more information.
The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the unit operation.
6.4.3 Performance Tab On the Performance tab, you can view the results of a converged column on the Summary page, Column Profiles page, and Feeds/Products page. You can also view the graphical and tabular presentation of the column profile on the Plots page.
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Summary Page The Summary page gives a tabular summary of the feed or product stream properties. Select the appropriate radio button to display the information you want to see. Figure 6.24
Figure 6.25
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Column Profiles Page The Column Profiles page gives a tabular summary of Column stage temperatures, pressures, flows, and duties. You can view the results in molar, mass or liquid volume, by selecting the appropriate basis radio button.
•
When you select the Flow radio button, the Column Profiles page displays the following property view:
Figure 6.26
The values under the Net Liquid and Net Vapour columns are the net flows for each stage.
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•
When you select the Energy radio button, the Column Profiles page displays the following property view:
Figure 6.27
Feeds/Products Page The Feeds/Products page gives a tabular summary of feed and product streams tray entry/exit, temperatures, pressures, flows, and duties. Figure 6.28
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You can view the results in molar, mass or liquid volume, by selecting the appropriate basis radio button.
If a stream has been split, a star (*) follows the phase designation. You can split a feed stream into its phase components on the Options page of the Simulation tab in the Session Preferences property view.
If there is a duty stream on a stage, “Energy” appears in the Type column. The direction of the energy stream is indicated by the sign of the duty.
Energy Balance Page The Energy Balance page displays the energy flow of any reboilers, pumps, and condenser within the Petroleum Column. Figure 6.29
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Petroleum Distillation Column
Plots Page On the Plots page, you can view various column profiles or assay curves in a graphical or tabular format. Figure 6.30
Select the Live Updates checkbox to update the profiles with every pass of the solver (in other words, a dynamic update). This option is deactivated by default, and performance of the column can be a bit slower if the checkbox is on and a profile is open.
Tray by Tray Properties Group The options in the Tray by Tray Properties group are disabled if the Zone by Zone solving method is selected in the SolverOptns page of the Design tab.
To view a column profile, follow this generalized procedure: 1. Select a profile from the list in the Tray by Tray Properties group. The choices include: Temperature, Pressure, Flow, Transport Properties, Composition, K Value, and Light/Heavy Key.
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2. In the Column Tray Ranges group, select the appropriate radio button: Radio Button All
Single Tower
Action Displays the selected profile for all trays connected to the column (in other words, main tray section, side strippers, reboilers, and condenser). From the drop-down list, select a tray section. The main tray section along with the condenser and reboiler are considered one section, as is each side stripper.
From/To
Use the drop-down lists to specify a specific range of the column. The first field contains the tray that is located at a higher spot in the tower (in other words, for top to bottom tray numbering, the first field could be tray 3 and the second tray 6).
3. After selecting a tray range, click either the View Graph button or the View Table button to display a plot or table respectively. Figure 6.31
Plots and tables are expandible property views that can remain open without the column property view. Refer to Section 10.4 Graph Control in the HYSYS User Guide for more information.
To make changes to the plot, right-click in the plot area, and select Graph Control from the object inspect menu.
Depending on the profile selected, you have to make further specifications. For certain profiles, there is a Properties button on both the profile plot and table. By clicking this button, the 6-43
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Petroleum Distillation Column
Properties property view appears, where you can customize the display of your profile. Changes made on the Properties property view affect both the table and plot. A description of the specifications available for each profile type are outlined in the following table. Profile Type
Description
Temperature Profile
Displays the temperature for the tray range selected. No further specification is needed.
Pressure Profile
Displays the pressure of each tray in the selected range. No further specification is needed.
Flow Profile
Displays the flow rate of each tray in the selected range. You can customise the data displayed using the Properties property view. In the Basis group, select molar, mass or liquid volume for your flow profile basis. In the Phase group, select the checkbox for the flow of each phase that you want to display. Multiple flows can be shown. If three phases are not present in the column, the Heavy Liquid checkbox is not available, and thus, the Light Liquid checkbox represents the liquid phase. In the Tray Flow Basis group, you can specify the stage tray flow basis by selecting the appropriate radio button: • Net. The net basis option only includes interstage flow. • Total. The total basis option includes draw and pump around flow.
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Profile Type
Description
Transport Properties Profile
Displays the selected properties from each tray in the selected range. You can customise the data displayed using the Properties property view:
In the Basis group, select molar or mass for the properties profile basis. In the Phase group, select the checkbox for the flow of each phase that you want to display on the graph. Multiple flows can be shown. If three phases are not present in the column, the Heavy Liquid checkbox is not available. In the Axis Assignment group, by selecting a radio button under Left, you assign the values of the appropriate property to the left y-axis. To display a second property, choose the radio button under Right. The right y-axis then shows the range of the second property. If you want to display only one property on the plot, select the None radio button under Right. The Properties Profile table displays all of the properties for the phase(s) selected.
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Profile Type
Description
Composition
Displays the selected component’s mole fraction of each tray in the selected range. You can customise the data displayed using the Properties property view.
In the Basis group, select molar, mass or liquid volume for the composition profile basis. In the Phase group, select the checkbox for the flow of each phase that you want to display. Multiple flows can be shown. If the three phases are not present in the column, the Heavy Liquid checkbox is not available, and thus, the Light Liquid checkbox represents the liquid phase. Choose either Fractions or Flows in the Comp Basis group by selecting the appropriate radio button. The Components group displays a list of all the components that enter the tower. You can display the composition profile of any component by selecting the appropriate checkbox. The plot displays any combination of component profiles.
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Profile Type
Description
K Values Profile
Displays the K Values of each tray in the selected range. You can select which components you want included in the profile using the Properties property view.
Light/Heavy Key Profile
Displays the fraction ratio for each stage. You can customise the data displayed using the Properties property view.
In the Basis group, select molar, mass or liquid volume for the profile basis. In the Phase group, select Vapour, Light Liquid or Heavy Liquid for the profile phase. In the Light Key(s) and Heavy Key(s) groups, you can select the key component(s) to include in your profile.
Assay Curves Group Figure 6.32
From the Assay Curves group, you can create plots and tables for the following properties: • • • •
Boiling Point Assay Molecular Weight Assay Density Assay User Properties
For each of the options, you can display curves for a single tray or multiple trays. To display a plot or table, make a selection from the list, and click either the View Graph button or the View Table button.
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Petroleum Distillation Column
The figure below is an example of how a Boiling Point Properties plot appears. Figure 6.33
Data Control Property View Click the Profile Data Control button, which is located on bottom left corner of every plot and table, to open the Data Control property view. This property view is common to all plots and tables on the Curves page. For a selected curve, all changes made on the Data Control property view affect the data of both the plot and table.
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The Data Control property view consists of four groups as shown in the figure below. Figure 6.34
The following table describes each data control option available according to group name.
Refer to Chapter 4 HYSYS Oil Manager in the HYSYS Simulation Basis guide for details on boiling point curves.
Group
Description
Style
Select either the Multi Tray or Single Tray radio button. The layout of the Data Control property view differs slightly for each selection. • For the Single Tray selection, you must open the dropdown list and select one tray. • For the Multi Tray selection, the drop-down list is replaced by a list of all the trays in the column. Each tray has a corresponding checkbox, which you can select to display the tray property on the plot or table.
Properties
This group is only available if you select the Single Tray radio button, and displays the properties available for the plot or table. You can select properties to appear in the plot of table, by selecting the appropriate checkbox in this group. If Multi Tray radio button has been selected, the group is replaced by a drop-down list. You can only choose one property on the graph or table when displaying multiple trays. Each curve option has its own distinct Properties group.
Basis
Select molar, mass or liquid volume for the composition basis.
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Group
Description
Phase
Select the checkbox for the flow of each phase that you want displayed. Multiple flows can be shown. If there are not three phases present in the column, the Heavy Liquid checkbox is not available, and thus, the Light Liquid checkbox represents the liquid phase.
Visible Points
The radio buttons in the Visible Points group apply to the plots only. Select either the 15 Points or 31 Points option to represent the number of data points which appear for each curve.
Volume Interchange Button The Volume Interchange button enables you to access the Volume Interchange property view. Figure 6.35
The Volume Interchange Curves property view contains a volume interchange plot. The volume interchange plot displays two types of information: Cumulative and Incremental. You can toggle between Cumulative and Incremental by selecting the appropriate radio button in the Volume Interchange group.
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Cumulative Volume Interchange Plot In the Cumulative plot, the complete picture of stream separation in the entire column appears. The distilled volume percent values (of all the feed and product streams) with respect to temperature appear as curves on the plot. Each curve shows the live boiling point behaviour for each stream. The curves from the product streams are normalized with respect to the feed stream, and the curves are arranged in increasing order of heaviness. Figure 6.36
The volume interchange curves on the plot allows you to interpret the amount of material from the feed stream is exiting each product stream. For example, a product curve which starts boiling at 10% and ends the boiling at 30% implies that 20% of the material from the feed stream is allocated to this product curve. The product curve also implies that 10% of the feed stream material has been allocated to the lighter product curves, and 70% of the feed stream material has been allocated to the heavier product curves. The temperature associated to the volume interchange curves indicates the temperature of when the material in a stream curve starts and finishes boiling. The greater the overlap of temperature between the product and feed curve, the better the separation and vice versa.
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Petroleum Distillation Column
An overlap in temperature between two adjacent product curves indicates that some material from the light product stream will enter the heavy product stream and vice versa. This overlap is referred to as "tails".
Incremental Volume Interchange Plot In the Incremental plot, the derivative curve of the cumulative volume interchange plot appears. The volume rate values (of all product streams) with respect to temperature appear as curves on the plot. The area under a product curve in the Incremental plot equals the flow rate of the product stream. Figure 6.37
The degree of imperfect fractionation appears more clearly in the Incremental plot. The overlaps in the plot, as shown in the figure above, indicate the imperfect separation between the two adjacent product streams. The spikes in the product curves are the result of the discrete nature of the HYSYS modeling of crude oil thermodynamics. A crude, which typically has several thousand components, is modelled using only 50 to 80 lumps (where each lump represent a group of components with similar characteristics). This lumping of components causes the spikes in the Increment plot.
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6.4.4 Calibration Tab The Calibration tab contains calibration options that enables you to calculate the parameters (fractionation indices) of the Zoneby-zone model. The calculated parameter values can be use to configure the column in the simulation case. The required input values of the calibration option are: • • • •
Feed temperature Product temperature, pressure, flow rate, and composition Steam flow rate, pressure, and temperature Reboiler duty (if applicable)
To converge the column based on calibration calculation: 1. Go to the Feeds page and specify the required feed stream information. 2. Go to the Products page and specify the required product stream information. 3. Go to the Energy page and specify the required energy information. 4. Click the Calibrate button at the bottom of the Petroleum Distillation Column property view. 5. After HYSYS has completed the calculations, you can see the results in the following two pages: • •
Tabular Results page displays the calculated results in tabular format. Plotted Results page displays the calculated results in plot format.
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Petroleum Distillation Column
Feeds Page The Feeds page enables you to calibrate the feed stream entering the Petroleum Column. Figure 6.38
The following table lists and describes the objects available in the Feeds page: Object
Description
Number of Zones cell
Displays the number of zones available in the Petroleum Column.
Feed Temperature cell
Enables you to specify the temperature of the feed stream entering the Petroleum Column.
Pressure cell
Enables you to specify the pressure for each zone.
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Products Page The Products page enables you to calibrate the product streams exiting the Petroleum Column. Figure 6.39
The following table lists and describes the objects available in the Products page: Object
Description
Top Vapour Flow Basis group
Enables you to select the top vapor flow basis by clicking the appropriate radio button. There are two selections to choose from: Molar Wet or Molar Dry.
Zone drop-down list
Enables you to select the product stream zone you want to modify.
Top Table Temperature column
Enables you to specify the temperature of each product stream zone.
Flow column
Enables you to specify the flow rate of each product stream.
Composition column
Enables you to select the composition type of each product stream zone. If you select TBP composition, you will have to specify the yield and temperature of the zone in the lower left table.
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Object
Description
Light Ends column
Contains checkboxes that enable you to toggle between activating or deactivating the option to specify volume fraction for the light ends composition. • Selected checkbox indicates you can specify the volume fraction of the light ends for the zone. • Clear checkbox indicates you cannot specify the volume fraction of the light ends for the zone.
Bottom Left Table Yield column
Enables you to specify the percentage yield reference point for the calibration calculation.
Temperature column
Enables you to specify the temperature associated to the temperature yield reference point.
Bottom Right Table Vol Fraction column
Enables you to specify the light ends component volume fraction associated to the normal boiling point. For example, if a product stream has a flow rate of 100 m3/hr and the propane flow rate in the product stream is 1 m3/hr. Then the volume fraction of propane is 0.01. The value in the Vol Fraction column is the volume fraction based on the total volume of the entire product stream, and not just the total volume of the light ends.
NBP column
Displays the normal boiling point of the light end components.
Energy Page Energy page enables you to specify the energy flowing in and out of the Petroleum Column for the calibration calculation. Figure 6.40
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The following table lists and describes the object available in the Energy page: Object
Description
Reboiler Duty column
Enables you to specify the reboiler duty for the applicable product stream zone.
Steam Flow column
Enables you to specify the steam flow rate for the applicable product stream zone.
Steam Pressure column
Enables you to specify the steam pressure for the applicable product stream zone.
Steam Temperature
Enables you to specify the steam temperature for the applicable product stream zone.
Tabular Results Page The Tabular Results page displays the section-based solver parameter values based on the calibration calculation. Figure 6.41
You use copy the values under the Top Index and Bottom Index columns, and use the values to configure the column for the simulation case.
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Plotted Results Page The Plotted Results page displays the calculated calibration results in plot format. Figure 6.42
The following table lists and describes the object available in the Plotted Results page: Object
Description
Plotted Results dropdown list
Enables you to select the product stream zone you want to view in the plot.
Manual Tuning button
Available only if the Slope Results radio button is selected. Enables you to manually enter tuning-parameter slope values.
Slope Results radio button
Enables you to display the tuning parameter slope values on the plot.
Plant vs. Calculated radio button
Enables you to display the plant data and calculated calibration results data on the plot.
Feed Curve radio button
Enables you to display the feed curve on the plot. The feed curve is the plotted values of distilled volume percent values from the feed stream with respect to temperature.
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Petroleum Feeder
7-1
7 Petroleum Feeder
7.1 Introduction................................................................................... 2 7.2 Petroleum Feeder Property View ................................................... 2 7.2.1 7.2.2 7.2.3 7.2.4
Connections Tab....................................................................... 4 Parameters Tab ........................................................................ 5 Worksheet Tab ......................................................................... 6 User Variables Tab .................................................................... 6
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Introduction
7.1 Introduction The Petroleum Feeder is a logical unit operation that allows flexibility over how the crude proportions are defined and allows you to mix petroleum assays from the Basis Environment with assays from other streams in the flowsheet. In addition, you can setup feeds as blends and/or cuts of petroleum assays. Streams can also be setup to represent spiked or partial crudes.
7.2 Petroleum Feeder Property View There are two methods to add a Petroleum Feeder to your simulation: 1. From the Flowsheet menu, select Add Operation [or press F12]. The UnitOps property view appears. 2. Click the Aspen HYSYS Petroleum Refining Ops radio button. 3. From the list of available unit operations, select Petroleum Feeder. 4. Click the Add button. OR 1. Press F6 to access the Aspen HYSYS Petroleum Refining Object Palette. 2. Double-click the Petroleum Feeder icon. Petroleum Feeder icon
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The Petroleum Feeder property view appears. Figure 7.1
There are three common objects at the bottom of the Feeder property view, the following table describes these objects: Object
Description
Delete button
Allows you to delete the operation.
Status bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Ignored checkbox
Allows you to ignore the operation during calculations. When the checkbox is selected, HYSYS completely disregards the operation (and cannot calculate the outlet stream) until you clear the checkbox.
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Petroleum Feeder Property View
7.2.1 Connections Tab The Connections tab contains the following pages: • •
Connections Notes
Connections Page On the Connections page, you can specify the assays, feed streams, and product stream attached to the Petroleum Feeder. You can change the name of the operation in the Name field, and the fluid package associated to the operation in the Fluid Package drop-down list. Figure 7.2
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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7.2.2 Parameters Tab The Parameters tab contain one page, the Parameters page. This page allows you to specify the feed ratio of assays and streams entering the product stream. Petroleum Feeder does not consider the temperature, pressure, or flow rate of any material streams connected to the unit operation. The Petroleum Feeder only considers the petroleum properties and composition from the associated petroleum assays and material streams.
Parameters Page The Parameters page contains a drop-down list and one or two table depending on your selection of feed type entering the Petroleum Feeder. Figure 7.3
The Balance Type drop-down list allows you to select the unit basis for the specified values. There are three types of unit for you to choose from mole, mass, and volume.
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Petroleum Feeder Property View
The table in the Flow Ratio and Boiling Range group contains the following: Column
Description
First column
Displays the names of the assays and feed streams connected to the Petroleum Feeder.
Ratio
You can specify the flow ratio of the petroleum assay(s) and stream assay(s) that makes up the petroleum feeder product stream. For example, if you selected Mole as the unit basis of the flow ratio, and you specify the Arab assay to have a ratio of 0.25. Then 25% of the product stream's mole composition is from the Arab assay. The sum values under the Ratio column must equal 1.
IBP
You can specify a different initial boiling point temperature for the Petroleum Feeder blending calculation. You cannot specify values lower than the HYSYS default temperature. The default values of the IBP and FBP are the boiling temperature of the lightest and heaviest components in the component list, respectively. These are not the initial and final points of the TBP curve of the assay.
FBP
You can specify a different final boiling point temperature for the Petroleum Feeder blending calculation. You cannot specify values higher than the HYSYS default temperature.
7.2.3 Worksheet Tab Refer to Section 1.2.2 Worksheet Tab for more information.
The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the Petroleum Feeder. You must specify the temperature, pressure, and flow rate of the product stream exiting the Petroleum Feeder. You can specify these values in the Worksheet tab or the product stream’s property view.
7.2.4 User Variables Tab For more information on implementing the User Variables, refer to Section 1.2.4 - User Variables Page/Tab.
The User Variables tab contains the User Vars page. This page allows you to create and implement variables in the HYSYS simulation case. 7-6
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Petroleum Yield Shift Reactor
8-1
8 Petroleum Yield Shift Reactor 8.1 Introduction................................................................................... 2 8.1.1 Theory.................................................................................... 2 8.2 Petroleum Yield Shift Reactor Property View ................................. 3 8.2.1 8.2.2 8.2.3 8.2.4
Design Tab .............................................................................. 4 Product Spec Tab ..................................................................... 7 Product Properties Tab .............................................................. 7 Worksheet Tab ....................................................................... 11
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8-2
Introduction
8.1 Introduction If you do not have the Aspen HYSYS Petroleum Refining license, you cannot add a Petroleum Yield Shift Reactor.
The Petroleum Yield Shift reactor unit operation supports efficient modeling of reactors by using data tables to perform shift calculations. The operation can be used for complex reactors where no analytical model is available, or where models that are too computationally expensive.
8.1.1 Theory Shift reactor models are empirical models representing the response of the output of a reactor to changes in its operating conditions. These models are not based upon the underlying scientific theory for the reactor, or upon the chemistry of the reaction, but simply upon an observation of how the output responds to certain stimuli. The models are generally linear and are only applicable within a fairly tight range of a particular base condition. The petroleum yield shift unit operation calculates the flow rates of a defined set of product streams based upon the difference between the current value of an independent variable and a supplied base value. Dependent variables other than the flow rates can also be specified. The following general equations are used for the calculation of a dependent variable yk: Δy k 0 dyk ,j = -------- ⋅ ( x j – x j ) Δx j 0
yk = yk +
∑ dyk ,j
(8.1)
(8.2)
j=0
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where: dyk,j = shift for dependent variable yk with respect to independent variable xj 0
y k = base value for dependent variable yk at base conditions of the independent variables x0 Δ -----y- = rate of change of dependent variable yk with respect to Δx unit change in independent variable xj xj = current value of independent variable
8.2 Petroleum Yield Shift Reactor Property View There are two methods to add a Petroleum Yield Shift Reactor to your simulation: 1. From the Flowsheet menu, select Add Operation [or press F12]. The UnitOps property view appears. 2. Click the Aspen HYSYS Petroleum Refining Ops radio button. 3. From the list of available unit operations, select Petroleum Shift Reactor. 4. Click the Add button. or 1. Press F6 to access the Aspen HYSYS Petroleum Refining Object Palette. 2. Double-click the Petroleum Shift Reactor icon. Petroleum Shift Reactor icon
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Petroleum Yield Shift Reactor
The Petroleum Yield Shift Reactor property view appears. Figure 8.1
There are three common objects at the bottom of the Petroleum Yield Shift Reactor property view, the following table describes these objects: Object
Description
Delete button
Lets you delete the operation.
Status bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Ignored checkbox
Lets you ignore the operation during calculations. When the checkbox is selected, HYSYS disregards the operation (and cannot calculate the outlet stream) until you clear the checkbox.
8.2.1 Design Tab Use the Design tab to configure the Petroleum Yield Shift reactor. The options are grouped in the following pages: • • • •
Connections Model Data User Variables (Lets you create and implement your own variables for the current operation) Notes (Lets you add comments which are exclusively associated with the unit operation) 8-4
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Connections Page The Connections page (Figure 8.1) lets you configure the material and energy streams flowing in and out of the reactor. The following table describes the objects in the Connections page: Object
Description
Name field
Modify the name of the reactor.
Fluid Pkg field
Select the fluid package associated with the reactor.
Main Feed field
Specify or select the main petroleum feed flowing into the reactor. This stream is split into the cuts specified in the Cuts table.
Energy Stream field (optional)
Connect or create an energy stream if one is required for the operation.
Supplementary Feeds table (optional)
Specify or select additional feed streams to the reactor. The total flow rate of the product streams is determined from the sum of all feed streams into the reactor.
Cuts table
Specify or select the product streams to associate with the cuts of the main feed.
Bottom cut
Specify or select a product stream to associate with the highest boiling cut of the main feed.
Supplementary Products table (optional)
Specify or select product streams that are not cuts of the main petroleum feed.
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Petroleum Yield Shift Reactor
Model Data Page Use the Model Data page to enter the base yield flow rates, define the independent parameters of the model, and specifiy the parameters base and shift values.. Figure 8.2
The parameters are optional and you do not have to supply any parameter information to get the reactor to solve.
The following table lists and describes the options available in the Model Data page: Object
Description
Icons Panel
Green Plus - add a HySYS defined variable as an independent parameter. Yellow folder - edit an independent parameter. Red “X” - delete an independent parameter. Grey Stacks - add an independent parameter not defined in HySYS - e.g. age of catalyst.
Base Yield Flow Rates Column.
Specify the base yield flow rates, i.e. product flow rates either when there are no independent variables defined in the model, or if they are defined but are at their base values.
Independent Variable Columns
All other columns in the table. The values in the columns (except the first cell) define the rate at which the yield flow rates change with respect to the changes in the independent variable.
Property Base row
Base values of the independent variables.
Yield Basis field
Choose to specify the yield flow rates either on a flow rate basis or on a feed flow fraction basis.
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User Variables Page For more information on implementing the User Variables, refer to Section 1.2.4 - User Variables Page/Tab.
The User Variables page lets you create and implement variables in the HYSYS simulation case.
For more information refer to Section 1.2.3 Notes Page/Tab.
Use the Notes tab record any comments or information regarding the specific unit operation or the simulation case in general.
Notes Page
8.2.2 Product Spec Tab The Product Spec tab has a Conditions page which lets you specify the initial and final boiling points of the product cuts. Figure 8.3
8.2.3 Product Properties Tab Use the Product Properties tab to specify additional properties of the product streams or the reactor that are dependent on variations in the independent variables. The options are contained on the following pages: • • •
Assay Properties Base Shift TBP Curves 8-7
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Petroleum Yield Shift Reactor
Assay Properties Page The Assay Properties page lets you specify assay properties in the product streams that are affected by the reactor. These properties can vary with changes in the values of the independent variables. Figure 8.4
•
•
Assay Properties Selection group Assay properties to be modified can be selected using the options in the Assay Properties Selection table. The table lists the available product streams. Clicking in a cell in a column lets you select an assay property that you want to manipulate for that stream. Assay Properties Definition group The Assay Properties Definition group lets you select the assay property for a stream and specify its base value.
Object
Description
Cut
Select the cut stream containing the assay property that you want to manipulate.
Assay Properties
Select the assay property for which you want to specify a base value. Only properties selected for the cut stream in the Assay Properties Selection table are available.
Base Value
Specify the base value for the assay property. This is the value of property that the reactor would produce at the condition represented by the base values of the independent variables.
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Object
Description
Use Feed
Toggle between using or ignoring the assay property values from the feed stream.
Use Assay
Open a drop-down list and select the assay property values from a petroleum assay.
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Base Shift Page Use the Base Shift page to view and edit the base values of the independent variables and the dependent product properties. You can also edit the shift values for each of the product properties with respect to each of the independent variables. Figure 8.5
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Petroleum Yield Shift Reactor
TBP Curves Page The TBP Curves page lets you manipulate the product composition. Referencing a user-provided TBP profile for the product stream(s), Aspen HYSYS Petroleum Refining can characterize the outlet stream composition based on the entered boiling point curve data. Figure 8.6
The following table lists and describes the options available in the TBP Curves page: Object
Description
Use TBP Curve to Calculate Stream Composition checkbox
Toggle between activating or ignoring the modified variable for the product stream composition.
Stream drop-down list
Select the product stream associated to the available TBP curve data.
Volumetric Yield column
Specify the volume percent yield associated to the specified temperature for the product stream.
TBP column
Specify the TBP associated with the volumetric yield.
Insert button
Add a volumetric yield between 0% and 100% and corresponding TBP data to the table.
Delete button
Remove a selected volumetric yield and corresponding TBP data from the table. You cannot remove the default data set of 0% and 100%.
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8.2.4 Worksheet Tab Refer to Section 1.2.2 Worksheet Tab for more information.
The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the Petroleum Yield Shift Reactor.
8.3 About PIMS Submodel Calculator The PIMS Submodel can be added into the Aspen HYSYS Petroleum Refining Petroleum Yield Shift Reactor either manual or by importing a file. Currently Aspen HYSYS Petroleum Refining does not have all the necessary models to fully simulate a refinery. With this new feature, Aspen HYSYS Petroleum Refining users will be able to create the missing models as needed. users can take the equivalent PIMS model’s dat (in the form of a smc file) and import it either manually or automatically into a Petroleum Yield Shift Reactor (PYS Reactor). The PYS Reactor will behave as a simplified version of refinery reactors such as a hyrdrotreater. Another purpose of this feature is to allow the Aspen HYSYS Petroleum Refining user to simplify and speed up some parts of the plant simulation. For areas where a reigour model is not needed, the user can use a simplified version imported in from PIMS to represent the rigorous model instead. This feature is intended to help bridge the gap between refinery planning and engineering/operations. PIMS Models are ubiquitous within the refining customer base, this project will provide a way for re-use of these models to the benefit of planners and engineers.
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About PIMS Submodel Calculator
8.3.1 Importing PIMS Submodel Calculator File In Aspen HYSYS Petroleum Refining you can add an PIMS Submodel Calculator by importing it from another source. To import a PIMS Submodel Calculator: 1. Add a Petroleum Yield Shift Reactor to the flowsheet. 2. Click Load Pims SMC. 3. Select the smc file and click OK. The PIMS Submodel Unit/Mapping view will appear. In this view, all the weight and volume balance rows will be listed in the Streams matrix. All the PIMS properties retrieved from the equality rows will be listed in he Properties matrix. 4. Map the PIMS properties to the Aspen HYSYS Petroleum Refining properties by selecting the items from the dropdown list. 5. Note: Not all PIMS properties will have corresponding Aspen HYSYS Petroleum Refining properties. These properties are ignored. 6. Map the PIMS streams to the Aspen HYSYS Petroleum Refining Streams. use the drop-down list to select existing streams or create a new stream. 7. Select a stream type. The available stream types are: Feed, Upper Cut, Bottom Cut, Supplementary Feed and supplementary Product. Only one bottom cut is allowed. 8. Click OK. Note: Mapped streams will be populated in the Connections view in the Petroleum Yield Shift Reactor. Additional information such as Feed stream etc. must be supplied if it was not supplied in froms PIMS. The mapped properties and values will display in the MOdel Data view in the Petroleum Yield Shift Reactor. Fill in the Cut point information.
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8.3.2 Manually Enter PIMS Submodel Calculator File 1. Add a Petroleum Yield Shift Reactor to the flowsheet. 2. In the Connections page, create a corresponding Aspen HYSYS Petroleum Refining stream. Add the streams as Cuts, Bottom Cut and Feed. In the PIMS table, the column SXXXFFF (where XXX is smc model name) which has a value 1 in corresponding VBALFFF is a feed stream FFF. The remaining VBALPPP rows correspond to product streams PPP of the Petroleum Shift Reactor (PSR). 3. Click Model Data view. All the Product streams are shown as rows. 4. Click Insert Independent Var. The Select Associated Object and Variable page appears. 5. Navigate through the variable list and click Calculator properties. 6. Click Ok. A new column is added to the matrix. Rename the column. 7. Once all the Independent Variables have been added, fill in their base values and the base yields and shifted values. The base value of the independent variable YYY is the value in the cell (EYYYXXX, SXXXFFF). The base yields are the values in column Balance corresponding to rows VBALPPP. For the shifted values take the property values under Column SXXXYYY for each of the WBALZZZ or VBALZZZ rows and multiple by -1 and then divided by value under the same column for Row EYYYXXX. Take these values and enter it into the Stream and Property cell of PSR's model data. •
The -ve sign in PIMS means production. IN Aspen HYSYS Petroleum Refining, the +ve sign means production. Take the values from the BAS column and multiply by -1. • -999 represent 0 8. Fill in the Base yields, shifted values, cut information and property base values.
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About PIMS Submodel Calculator
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Product Blender
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9 Product Blender
9.1 Introduction................................................................................... 2 9.2 Theory ........................................................................................... 3 9.2.1 Simulation Calculation Mode ...................................................... 3 9.2.2 Optimization Calculation Mode ................................................... 3 9.3 Product Blender Property View ...................................................... 5 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5
Connections Tab....................................................................... 7 Parameters Tab ........................................................................ 8 Optimization Tab .................................................................... 10 Worksheet Tab ....................................................................... 26 User Variables Tab .................................................................. 26
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Introduction
9.1 Introduction The Product Blender allows you to mix several streams together, and calculate a blended property value or optimize the properties in the product stream by back calculation and determine the optimum mix ratios for the inlet streams. This unit operation is like a black box consisting of splitters and mixers. Each inlet stream enters a Tee or splitter, which splits the stream based on the specified flow ratio. Then the split streams enter the appropriate mixer. Each mixer represents the blended product stream. The Product Blender also has a surplus stream that is used to maintain mass balance in the unit operation system. For example, consider the figure below of a Product Blender with three inlet streams, two product streams, and one surplus stream. Figure 9.1
Product streams E and D are a mixture of inlet streams C, B, and A as indicated by the colored lines. The surplus stream provides an exit flow for left over fluid from the inlet streams, as shown in the above figure for inlet streams A, C, and B.
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9.2 Theory The Product Blender has two different calculation mode to determine the flow rate in the product streams: Simulation and Optimization.
9.2.1 Simulation Calculation Mode In the Simulation calculation mode, the inlet streams entering the Product Blender must be completely solved, in other words the status bar at the bottom of the Material Stream property view must read OK. Refer to Section 9.3.2 Parameters Tab for more information.
The characteristics of the product and surplus streams are based on the specified flow ratio from the inlet streams and the automatic pressure assignment option.
9.2.2 Optimization Calculation Mode In the Optimization calculation mode, the Hyprotech SQP optimizer is used to determine the optimum values required to achieve the specified objective functions. For more information about the SQP optimization calculation refer to Chapter 7 Optimizer Operation in the HYSYS Operations Guide.
The Hyprotech SQP is a sequential quadratic programming (SQP) algorithm incorporating an L1-merit function and a BFGS approximation to the Hessian of the Lagrangian. The algorithm features step size restriction, decision variable and objective function scaling, a basic watchdog method, and a problemindependent and scale-independent relative convergence test. The algorithm also ensures that the model is evaluated only at points feasible with respect to the variable bounds.
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Theory
Switching from Simulation to Optimization When you switch from Simulation to Optimization calculation mode, HYSYS automatically place a stream cutter between the Product Blender outlet streams and the connected downstream operations. The figure below display a Product Blender in Simulation mode with a valve connected to the product stream C. When the Product Blender switch to Optimization mode, a stream cutter is added to stream C. Figure 9.2
The cutter is added to reduce the calculation time required during the PFD calculation process. If all the operations and streams in the PFD need to be recalculated every time the optimizer generates a possible solution, then the entire calculation would take too long or lose required information for the entire PFD to solve. So HYSYS place a cutter that will temporary separate the Product Blender from the rest of the PFD during the optimization calculation. When the optimum value is found, the value is propagated back into the PFD. The stream cutter is also inactive only during the optimization calculation process in the Product Blender. Before and after the 9-4
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calculation process, the stream cutter is active and allows information from the Product Blender’s output streams to flow to the rest of the process flowsheet diagram. The stream cutter is only placed when there is an operation downstream to the Product Blender (in other words, an operation connected to the outlet streams of the Product Blender).
9.3 Product Blender Property View There are two methods to add a Product Blender to your simulation: 1. From the Flowsheet menu, select Add Operation [or press F12]. The UnitOps property view appears. 2. Click the Aspen HYSYS Petroleum Refining Ops radio button. 3. From the list of available unit operations, select Product Blender. 4. Click the Add button. The Product Blender property view appears. OR 1. Press F6 to access the Aspen HYSYS Petroleum Refining Object Palette. 2. Double-click the Product Blender icon. Product Blender icon
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Product Blender Property View
The Product Blender property view appears. Figure 9.3
There are four common objects at the bottom of the Product Blender property view, the following table describes these objects:
Refer to Section 9.2 Theory for more information.
Object
Description
Status bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Delete button
Allows you to delete the operation.
Calculation Mode dropdown list
Allows you to toggle between simulation and optimization calculation modes. If you select the optimization mode without first adding any variables (optimization variable, process constraints, or objective functions), HYSYS will auto generate derivatives and optimizer for optimum product flow rate with inlet stream flow ratios as the optimization variables. If you select the optimization mode after adding any variables (optimization variable, process constraints, or objective functions), HYSYS will keep the previous variable values.
Ignored checkbox
Allows you to ignore the operation during calculations. When the checkbox is selected, HYSYS completely disregards the operation (and cannot calculate the outlet stream) until you clear the checkbox.
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9.3.1 Connections Tab The Design tab contains the following pages: • •
Connections Notes
Connections Page On the Connections page, you can specify the feed and product streams attached to the Product Blender. You can change the name of the operation in the Name field, and the fluid package associated to the operation in the Fluid Package drop-down list. Figure 9.4
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor where you can record any comments or information regarding the specific unit operation or the simulation case in general.
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Product Blender Property View
9.3.2 Parameters Tab The Parameters tab contains the Parameters page. This page allows you to specify the inlet streams split ratio among the product streams, and select the type of automatic pressure assignment option.
Parameters Page Figure 9.5
Feed Stream Flow Ratios To specify the inlet stream split ratio, type in the split ratio value (of the inlet stream) in the appropriate cell where both the inlet stream row and product stream column intersect. For example, consider a Product Blender with inlet streams A and B, and product streams C, D, and Surplus. Figure 9.6
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If 50% of stream A is entering stream C and 25% of stream A is entering stream D. Type 0.50 in the cell along row A and under column C, and type 0.25 in the cell along row A and under column D. HYSYS automatically calculates the amount of stream ratio left for stream A, which is 25%, and sends the amount to the Surplus stream. The values in the rows of the Flow Ratio table represent split ratios of the inlet streams, so the sum of values along each row must equal 1.
Automatic Pressure Assignment To select the automatic pressure assignment, click the appropriate radio button in the Automatic Pressure Assignment group. • •
The default is Set Outlet to Lowest Inlet, HYSYS assigns the lowest inlet pressure to all the outlet stream pressures. If you specify Equalize All, HYSYS gives all attached streams the same pressure.
If you are uncertain of which pressure assignment to use, choose Set Outlet to Lowest Inlet. Only use Equalize All if you are completely sure that all the attached streams should have the same pressure.
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Product Blender Property View
9.3.3 Optimization Tab For more information on the optimizer used by Product Blender, refer to Chapter 7 - Optimizer Operation in the HYSYS Operations Guide.
You must be in Optimization calculation mode, in order to apply any of the options in the Optimization tab.
The Optimization tab contains a tree browser that lets you access the following pages: • • • • • • • • •
Variables Configuration Page. This page allows you to modify initial values of the optimization variables used in the optimization calculation. Variables Inputs Page. This page allows you to configure the optimization variables in the optimization calculation. Variables Results Page. This page displays the calculated results of the optimization variables from the optimization calculation. Constraints Configuration Page. This page allows you to modify the initial values of the constraints in the optimization calculation. Constraints Inputs Page. This page allows you to configure the constraints in the optimization calculation. Constraints Results Page. This page displays the calculated results of the constraints from the optimization calculation. Objectives Page. This page allows you to configure the goals of the optimization calculation. Optimizer Configuration Page. This page allows you to configure the calculation process of the optimization calculation. Optimizer Results Page. This page displays the results of the calculation process from the optimization calculation.
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The following table describes the four common objects at the bottom of the Optimization tab: Object
Description
Create Derivative Util button
Allows you to add derivative utilities or generate default derivative utilities. The default utilities are: • The flow ratios between the inlet and product streams for the optimization variables. • The flow ratios between the inlet and surplus streams for the process constraints. • The actual volume flow rates of the product streams for the objective functions.
Refer to Chapter 14 Utilities in the HYSYS Operations Guide for more information on the Derivative Utility property view. Refer to Chapter 7 Optimizer Operation in the HYSYS Operations Guide for more information on the Optimizer property view.
View Derivative Utility button
Allows you to access the Derivative Utility property view. The Derivative Utility property view contains detailed information and option on the variables and constraints.
Create Optimizer button
Allows you to create an optimizer with default optimizer parameter settings.
View Optimizer button
Allows you to access the Optimizer property view. The Optimizer property view contains detailed information and options on the optimizer configuration.
Add button
Allows you to add optimization variables, constraints, or objectives for the optimization calculation. The type of optimizer parameters you can add, depends on what is selected in the drop-down list.
Types of Parameters drop-down list
Allows you to select the type of optimizer parameter to add to the optimization calculation. You have three choices: optimization variable, constraint, or objective.
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Product Blender Property View
Variables Configuration Page The Variables Configuration page allows you to specify the name and initial value of the optimization variables. The optimization variables are variables that will be modified to achieve the specified goal in the optimization calculation. Figure 9.7
To access the Variables Configuration page, expand the Variables branch in the tree browser and select Config. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
The table in the Variables Configuration page contains the following information: Column
Description
Opt Variable
Allows you to change the name of the optimization variable. You can access the Optimization Object Property View of the variable by double-clicking on the variable name.
Hooked Object
Displays the object associated to the optimization variable.
Hooked Property
Displays the property associated to the optimization variable.
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Column
Description
Current Value
Allows you to change the current optimization variable value.
Use checkbox
Allows you to toggle between using or ignoring the optimization variable during optimization calculation. A selected checkbox indicates the variable is being used in the calculation.
To remove a optimization variable, select the variable under the Opt Variable column and press DELETE.
Variables Inputs Page The Variables Inputs page allows you to specify the range of values allowed for each optimization variable during the optimization calculation. Figure 9.8
To access the Variables Inputs page, expand the Variables branch in the tree browser and select Inputs. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
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Product Blender Property View
The table in the Variables Inputs page contains the following information: Column
Description
Minimum
Allows you to specify the lower bound property for the variable during the optimization process. This value might be different from its global minimum, if the change in the variable is restricted to its allowed amount, set by the maximum rate of change, during the period in the optimization process.
Current Value
Allows you to specify the current variable value before optimization calculation.
Maximum
Allows you to specify the upper bound property for the variable during the optimization process. This value might be different from its global maximum, if the change in the variable is restricted to its allowed amount, set by the maximum rate of change, during the period in the optimization process.
Range
Allows you to specify an alternative for the span. The purpose of the range is to scale the gradients of the cost function and constraints, to give similar gradient magnitude for each variable. The gradients of the objective function (and constraints) vary inversely with the variable ranges.
Global Min.
Allows you to specify the absolute minimum value for which the variable is operated.
Global Max.
Allows you to specify the absolute maximum value for which the variable is operated.
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Variables Results Page The Variables Results page displays the optimum values of the optimization variables used to achieve the goals you specified. Figure 9.9
To access the Variables Results page, expand the Variables branch in the tree browser and select Results. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
The table in the Variables Results page contains the following information: Column
Description
Start Value
Displays the initial value of the variable before optimization calculation.
Current Value
Allows you to specify the current variable value before optimization calculation.
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Product Blender Property View
Column
Description
Status
Displays the current status of the variable, which is calculated by the Optimizer. Unlike constraints, opt. variables are not allowed to move out of their bounds. The Status property is set to one of: • Not Evaluated. Status of the variable is not evaluated by the Optimizer. • Inactive. Variable Output property lies between the Minimum and Maximum properties, but not on one of the bounds. • Equality. Maximum and minimum properties of the variable, Minimum and Maximum, are equal, and the Output property has the same value as well. • Active Low. Variable Output property value is equal to that of the Minimum. • Active High. Variable Output property value is equal to that of the Maximum.
Price
Displays the shadow price (Lagrange multiplier) for the given opt. variable, calculated by the Optimizer. The shadow price is used to estimate the effect which small changes to variable bounds have on the plant cost function.
Span
Displays the difference between the Global Minimum and Global Maximum values for the variable and is calculated by the variable set-up. The role of the span is to convert every variable into the range (0, 1), to use uniform numerical perturbations and convergence tests.
Output
Displays the current value of the variable in the plant model. The output value is determined by the optimizer during the optimization process.
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Product Blender
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Constraints Configuration Page The Constraints Configuration page allows you to specify the name and initial value of the constraints. The constraints are variables used to simulate real life limitations to the optimization calculation. Figure 9.10
To access the Constraints Configuration page, expand the Constraints branch in the tree browser and select Config. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
The table in the Constraints Configuration page contains the following information: Column
Description
Constraints
Allows you to change the name of the constraint variable. You can access the Optimization Object Property View of the constraint by double-clicking on the variable name.
Hooked Object
Displays the object associated to the constraint.
Hooked Property
Displays the property associated to the constraint.
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Product Blender Property View
Column
Description
Current Value
Displays the current value of the constraint.
Use checkbox
Allows you to toggle between using or ignoring the constraint variable during optimization calculation. A selected checkbox indicates the constraint is being used in the calculation.
To remove a constraint, select the constraint under the Constraint column and press DELETE.
Constraints Inputs Page The Constraints Inputs page allows you to specify the amount of deviation allowed for each constraint during the optimization calculation. Figure 9.11
To access the Constraints Inputs page, expand the Constraints branch in the tree browser and select Inputs. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
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The table in the Constraints Inputs page contains the following information: Column
Description
Minimum
Allows you to specify the lower bound of the constraint value.
Current Value
Displays the current constraint value.
Maximum
Allows you to specify the upper bound of the constraint value.
Scale
Allows you to specify the number scale on which the feasibility of the constraint is measured. This property is used in conjunction with the Optimizer Zeta property, which is a relative feasibility tolerance. In general, a constraint is said to be feasible if:
Minimum – Scale × Zeta ≤ Current ≤ Maximum + Scale × Zeta where: Minimum = lower bound properties of the constraint Maximum = upper bound properties of the constraint Current = current constraint value (equivalent to Hooked Property for constraints, which have the Use checkbox selected) Min Chi^2
Displays whether or not a chi-square test is done for the constraint.
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Product Blender Property View
Constraints Results Page The Constraints Results page displays the constraint values after optimization calculation. Figure 9.12
To access the Constraints Results page, expand the Constraints branch in the tree browser and select Results. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
The table in the Constraints Results page contains the following information: Column
Description
Current Value
Displays the current value of the constraint.
Status
Displays the current status of the constraint, which is calculated by the Optimizer. The Status property is set to one of the following: • Not Evaluated. The status of the constraint has not been evaluated by the Optimizer. • Inactive. The constraint current property lies between the Minimum and Maximum properties, but is neither Active High nor Active Low. • Violated Low. The constraint current property is less than Minimum Scale x Zeta, where Scale is the constraint Scale property and Zeta is the Optimizer Zeta tolerance property. • Violated High. The current property is greater than Maximum + Scale x Zeta. • Active Low. The constraint current property is less than Minimum + Scale x Zeta, but greater than Minimum - Scale x Zeta. • Active High. Constraint current property is greater than Maximum Scale x Zeta, but less than Maximum + Scale x Zeta.
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Column
Description
Normalization
When the Jacobian matrix is first calculated (first pass evaluation) the Normalization property for the constraint is set to be the largest Jacobian entry in the row (Sparse Row) of the Jacobian matrix corresponding to this constraint. This number is used to normalize the rest of the given Jacobian row, for all remaining Optimizer search steps (in other words, it is not recalculated).
Base Value
When calculating the gradient of a given constraint with respect to each variable, the internal scaled variable is perturbed away from the current point by adding the number specified in the Optimizer Perturbation property. The new value of the constraint is found corresponding to the new variable value, and the change in constraint, divided by the change in the variable, is the corresponding Jacobian element. The constraint Base property stores the pre-perturbation value of the constraint. Under certain circumstances, however, the Base property itself can change during the Jacobian calculation. This is due to the fact that removing a perturbation from a perturbed variable, and re-running the plant model, will not reproduce the previous Base property within the constraint Current property; this is due to noise in the model arising from non-zero convergence tolerances (in other words, the de-perturbed constraint Current differs slightly from the pre-perturbed Current). Therefore, under certain circumstances (when the Pert_Reset flag property of the Optimizer is checked) the Optimizer will remove the perturbation from the variable, rerun the plant model, and then re-set the Base property of the constraint to match the re-calculated Current property. This eliminates associated noise from the Jacobian matrix.
Price
Displays the shadow price (Lagrange multiplier) for the given constraint, calculated by the Optimizer. If a feasible solution is found by the Optimizer, then a simple interpretation of the Lagrange multiplier is that it gives the gradient of the cost function along the corresponding constraint normal. Thus, the shadow price indicates the approximate change to the objective function when increasing (in other words, relaxing) the given active bound by a unit amount.
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Product Blender Property View
Objectives Page The Objectives page allows you to specify the name and price of the objectives. The objectives are the goals you specified for the optimization calculation. Figure 9.13
To access the Objectives page, select Objectives branch from the tree browser. The table in the Objectives page contains the following information: Column
Description
Objective
Allows you to change the name of the objective. You can access the Optimization Object Property View of the objective by double-clicking on the variable name.
Hooked Object
Displays the object associated to the objective.
Hooked Prop
Displays the property associated to the objective.
Current Value
Displays the current value of the objective.
Weighted Value
Displays the difference between the previous objective value and the new optimized objective value.
Price
Allows you to specify the price value. The objective function value is calculated using the following equation and price value:
Objective Function Value = Price Value × Current Value For minimum objective value, price value = 1. For maximum objective value, price value = -1.
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To remove an objective, select the objective under the Objective column and press DELETE.
Optimizer Configuration Page The Optimizer Configuration page allows you to configure the optimization calculation process and assumptions. Figure 9.14
To access the Optimizer Configuration page, expand the Optimizer branch in the tree browser and select Config. To expand a tree browser, click the Plus icon tree browser, click the Minus icon .
. To shrink a
The following table describes the objects in the Optimizer Configuration page: Object
Description
Maximum Iteration field
Allows you to specify the maximum number of major iterations. A major iteration consists of a sequence of minor iterations that minimize a linearly constrained sub-problem.
Objective Scaling Factor field
Allows you to scale the objective function. Positive values are used as-is, negative values use the factor abs(scale*F) (where F is the initial objective function value) and a value of 0.0 a factor is generated automatically.
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Product Blender Property View
Object
Description
Gradient Calculation Method dropdown list
Allows you to select one-sided (forward) or two-sided (central) differences for gradient calculations. In both cases, the perturbation size used for the Optimizer internal variables is given by the Perturbation property.
Diagnostic Print Level drop-down list
Allows you to select the amount of information to include in the Optimizer diagnostic file.
Accuracy Tolerance field
A relative accuracy tolerance used in the test for convergence. The following convergence test is used,
ConvergenceSum ≤ OptimalityTolerance × max ( F ( x ) , 1.0 ) where: M r
ConvergenceSum = ∇F ( x ) d +
∑
uj Cj ( x )
j=1
The ConvergenceSum is a weighted sum of possible objective function improvement and constraint violations, and has the same units as the objective function. This allows the same tolerance parameter to be used for different problems, and makes the convergence test independent of objective function scaling. Step Restriction field
A line search step-size restriction factor used during the first 3 iterations. Values greater than 1.0 result in no step restriction. Set the factor to 1.0, 10-1, 10-2, etc. to impose larger restrictions.
Perturbation Size field
The change in size of the scaled variables is used in gradient evaluation. Individual variables are scaled according to the variable Minimum and Maximum properties (or the Range property if the Fix Variable Spans property checkbox is selected).
Maximum Feasible Points field
If the Optimizer algorithm is set to MDC_SQP / MDC_SLP, this parameter gives the maximum number of Optimizer iterations allowed to find the first feasible solution. If the Optimizer algorithm is set to NAG_SQP, this parameter gives the maximum number of minor iterations. A minor iteration in this case represents a sequence of local improvements to the linearized problem within a major iteration.
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Optimizer Results Page The Optimizer Results page displays the optimization calculation results. Figure 9.15
The following table describes the display fields in the Optimizer Results page: Field
Description
Starting Objective Value
Displays the starting objective function value before optimization calculation.
Final Objective Value
Displays the current objective function value as calculated by the Optimizer.
Termination Reason
Displays the termination status of the Optimizer. Values include Running, Step convergence, Unbounded, Impossible, Not run, and Stopped.
Feasible Point Iterations
Displays the number of minor iterations since the last major iteration.
Solution Phase
Displays the current phase of the Optimizer algorithm. Values include Initialize, Setup, OPT Deriv, OPT Search, and Results.
Gradient Evaluations
Reports the number of gradient evaluations performed during the course of the optimization.
Actual Optimizer
Displays the number of major iterations.
Model Evaluations
Reports the number of model evaluations performed during the course of the optimization.
Code Version
The version of Optimizer.
Total CPU Time
Reports the time taken to solve the optimization problem.
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Product Blender Property View
Optimization Object Property View Refer to Section 5.9 Optimization Objects in the HYSYS.RTO Reference Guide for more information.
The Optimization Object property view contains the following three tabs: • • •
Connection tab. Displays the connections of the optimization object to the flowsheet Object name. Properties tab. Displays the properties of the optimization object. Transfer tab. Displays the transfer options/flags of the optimization object.
9.3.4 Worksheet Tab Refer to Section 1.2.2 Worksheet Tab for more information.
The Worksheet tab contains a summary of the information contained in the stream property view for all the streams attached to the operation.
9.3.5 User Variables Tab For more information on implementing the User Variables, refer to Section 1.2.4 - User Variables Page/Tab.
The User Variables tab contains the User Vars page. This page allows you to create and implement variables in the HYSYS simulation case.
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Aspen HYSYS Petroleum Refining Utilities 10-1
10 Aspen HYSYS Petroleum Refining Utilities 10.1 Introduction................................................................................. 2 10.2 Delta Base Utility ......................................................................... 3 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7
Delta Base Property View......................................................... 5 Derivative Analysis Tab............................................................ 6 Variables Tab ....................................................................... 11 Select Variable Property View ................................................. 16 Target Objects Property View ................................................. 18 Generating Derivative Values ................................................. 20 Exporting Generated Derivatives............................................. 23
10.3 Petroleum Assay Utility.............................................................. 23 10.3.1 Design Tab .......................................................................... 25 10.3.2 Results Tab .......................................................................... 28 10.3.3 Dynamics Tab ...................................................................... 30 10.4 Swing Cut Utility ........................................................................ 32 10.4.1 10.4.2 10.4.3 10.4.4
Specification Tab .................................................................. 34 Light Ends Tab ..................................................................... 36 Assay Table Tab.................................................................... 37 PIMS Format Tab .................................................................. 39
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Introduction
10.1 Introduction The utility commands are a set of tools, which interact with a process by providing additional information or analysis of streams or operations. Similar to the HYSYS utilities, the Aspen HYSYS Petroleum Refining utilities become a permanent part of the Flowsheet and are calculated automatically when appropriate. They can also be used as target objects for Adjust operations. Aspen HYSYS Petroleum Refining utilities can be added through the Available Utilities property view or the Utilities page on the Attachments tab of a stream's property view. Figure 10.1
A utility added through either route is automatically updated in the other location. For example, if you attach an Envelope utility to a stream using the Available Utilities property view, the Envelope utility automatically appears on the Utilities page of the Attachments tab in the property view of the stream to which it was attached.
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10.2 Delta Base Utility The Delta Base utility generates the required derivatives for use in delta base linear programming models, which in turn provides a simplified model that can be imported into programs such as PIMS. PIMS is a program that allows you to determine the best operating conditions at minimum cost using numerical optimization method. PIMS calculation consists of linear models and simplified assumptions. Sets of independent and dependent variables are selected from within the flowsheet. Base values are specified for the independent variables and HYSYS will calculate the change in the dependent variables with respect to changes in the independent variables. The utility works by perturbing each of the independent variables from the assigned base value, solving the flowsheet at the perturbed value, and determining the delta change in each of the specified dependent variables.
Adding a Delta Base Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. You can also access the Available Utilities property view by pressing CTRL U. 2. From the list of available utilities, in the right pane, select the Delta Base utility. 3. Click the Add Utility button. The Delta Base utility property view appears.
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Delta Base Utility
Editing a Delta Base Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, in the left pane, select the Delta Base utility you want to view. 3. Click the View Utility button. The selected utility’s property view appears. From here, you can modify any of the utility’s properties.
Deleting a Delta Base Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, in the left pane, select the utility you want to delete. 3. Click the Delete Utility button. HYSYS will ask you to confirm the deletion. You can also delete a utility by clicking the Delete button on the utility’s property view.
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10.2.1 Delta Base Property View The following figure is an example of the Delta Base property view without scoped objects or variables. Figure 10.2
The following table lists and describes each button located at the bottom of the Delta Base property view: Button
Description
Delete
Deletes the Delta Base utility. HYSYS request for confirmation before deleting the utility.
Tear
Places material stream cutters for all streams entering and exiting the scope objects that are connected to objects outside the scope.
UnTear
Removes all the material stream cutters created by the Tear option.
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Delta Base Utility
Button
Description
Isolate
Disables the transition of variables across the cutters for all stream cutters placed by the Tear option. After clicking Isolate, if you close the Delta Base utility without clicking Propagate, the cutters will be left in nontransitional state. So any changes made in the flowsheet will not be transferred into or out of the scoped objects.
Propagate
Enables the transition of variables across the cutters for all stream cutters placed by the Tear option. Value changes in the flowsheet are able to propagate through the scope objects and to the entire process flow diagram.
Close
Closes the Delta Base utility property view.
10.2.2 Derivative Analysis Tab The Derivative Analysis tab allows you to: • • • •
Scope objects to be included in the Delta Base utility. Select variables for the Delta Base utility. Generate derivatives by perturbation of independent variables. Export the derivatives to a *.csv file.
The table layout of the Derivative Analysis tab is similar to the Excel spread sheet layout from the PIMS program.
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Figure 10.3
The following table lists and describes the objects available in the Derivative Analysis tab: Object
Description
Name field
Allows you to change the name of the Delta Base utility.
Scope Objects button
Allows you to scope objects to be included in the Delta Base utility by opening the Target Objects Property View.
Add Independent Variable button
Allows you to add independent variables by opening the Select Variable Property View.
Add Dependent Variable button
Allows you to add dependent variables by opening the Select Variable Property View.
Top right table
Contains the tag name, unit type, perturbation value, and proxy variable toggle of the independent variables. The unit type selected for the independent variable is the unit that will be used to calculate the derivative value.
Middle left table
Contains the tag name, description, unit type, and base value of the dependent variables.
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Delta Base Utility
Object
Description
Middle right table
Contains the derivative value for the dependent variables with respect to the independent variables. For example, the derivative value for independent variable X and dependent variable Y, is located in the intersecting cell of column X and row Y.
Bottom left table
Contains the tag name, description, unit type, and base value of the independent variable.
Cancel Solve button
Allows you to stop the solver, cancelling the calculation of derivatives or the refreshing of dependent variable values.
Generate Derivatives button
Allows you to start the calculation to generate derivative values based on the independent variable perturbation.
Export Data button
Allows you to export the generated derivative values to a *.cvs file. This file can be imported into the PIMS program.
Configuring Independent Variables To configure an independent variable: 1. Open the Delta Base Utility property view and go to the Derivative Analysis tab. 2. Click the Add Independent Variable button to Select the Variable. After you have selected a variable, the description of the selected independent variable appears in the top right and bottom left tables of the Derivative Analysis tab. 3. Select the unit type you want to enter the value in by doing one of the following: • •
In the top right table, use the drop-down list in the appropriate cell in the Units row to select and view the variable values in different units. In the bottom left table, use the drop-down list in the appropriate cell under the Units column to select and view the variable values in different units.
The unit selected for the independent variable is the unit that will be used to calculate the derivative value.
4. In the top right table, change the independent variable's name by selecting and typing the new name in the appropriate cell in the Tag row. 10-8
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Aspen HYSYS Petroleum Refining Utilities 10-9
5. Specify the absolute value by which you want the variable to be changed, the perturbation value, by typing the value in the appropriate cell in the Pert row. The value entered will have the units selected in the Units cell. 6. In the bottom left table, change the independent variable's description by selecting and typing the new description in the appropriate cell under the Desc column. 7. Specify a tag for the row containing the independent variable by selecting and typing a name in the appropriate cell under the Tag column. This name will be exported as the tag for the 'balance row' in the PIMS model. 8. You can change the base variable value by selecting and typing the new value in the appropriate cell under the Base column. The value entered will have the units selected in the Units cell.
Configuring Proxy Variables To select and configure a proxy variable: 1. Open the Delta Base Utility property view, and go to the Derivative Analysis tab. 2. Select the Use proxy checkbox of an independent variable that requires a proxy variable. 3. Open the Independent Var property view by double-clicking on any cell of the selected independent variable. Figure 10.4
4. (Optional) You can modify the selected independent variable by double-clicking the Independent Variable field and following the Select the Variable procedure. 5. Select the proxy variable by double-clicking on the Proxy Variable field and following the Select the Variable procedure.
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Delta Base Utility
6. Specify the units, base value, and perturbation value for the proxy variable in the appropriate field. 7. Click the Close icon property view.
to close the Independent Var
Configuring Dependent Variables To configure a dependent variable: 1. Open the Delta Base Utility property view and go to the Derivative Analysis tab. 2. Click the Add Dependent Variable button to Select the Variable. After you have selected a variable, the description of the selected dependent variable appears in the middle table of the Derivative Analysis tab. 3. Change the dependent variable's tag name by selecting and typing the new name in the appropriate cell under the Tag column. 4. Change the dependent variable's description by selecting and typing the new description in the appropriate cell under the Desc column. 5. Use the drop-down list in the appropriate cell under the Units column to select and view the variable values in different units. 6. The base value for a dependent variable is the value of the variable when the flowsheet is solved at the base values of all the independent variables. To refresh the dependent variable values, right-click on the property view and select Refresh dependent variables from the object inspect menu.
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10.2.3 Variables Tab The Variables tab has similar functions as the Derivative Analysis tab. You can scope objects and select variables for the Delta Base utility. Figure 10.5
The table layout of the Variables tab is the standard HYSYS layout.
The following table lists and describes the objects available in the Variables tab: Object
Description
Name field
Allows you to change the name of the Delta Base utility.
Scope Objects button
Allows you to scope objects to be included in the Delta Base utility by opening the Target Objects Property View.
Independent Variable group Insert button
Allows you to add independent variables by opening the Select Variable Property View.
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Delta Base Utility
Object
Description
Edit button
Allows you to edit the selected independent variables by opening the Select Variable Property View.
Delete button
Allows you to remove the selected independent or proxy variables from the Delta Base utility. When you delete a proxy variable, HYSYS automatically deletes the independent variable associated to the proxy variable.
Refresh button
Allows you to set all independent and proxy variables to the current values in the flowsheet.
Independent Variable table
Contains the tag name, description, unit type, base value, current value, perturbation value, and proxy toggle checkbox of the independent variables. The unit type selected for the independent variable is the unit that will be used to calculate the derivative value.
Dependent Variable group Insert button
Allows you to add dependent variables by opening the Select Variable Property View.
Edit button
Allows you to edit the selected dependent variables by opening the Select Variable Property View.
Delete button
Allows you to remove the selected dependent variables from the Delta Base utility.
Refresh button
Allows you to set all dependent variables to the values corresponding to the base values for the independent variables.
Cancel button
Allows you to stop the solver, cancelling the refreshing of dependent variable values or the calculation of derivatives.
Dependent Variable table
Contains the tag name, description, unit type, base value, and current value of the dependent variables.
Configuring Independent Variables To configure an independent variable: 1. Open the Delta Base utility property view. 2. Go to the Variables tab. 3. Click the Scope Objects button to select the objects containing the variables you want to export. 4. In the Independent Variables group, click the Insert button to Select the Variable.
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Aspen HYSYS Petroleum Refining Utilities 10-
The description of the selected independent variable appears in the table. 5. Change the variable's name by typing the new name in the appropriate cell under the Tag column. 6. Change the independent variable's description by selecting and typing the new description in the appropriate cell under the Description column. 7. Use the drop-down list in the appropriate cell under the Units column to select and view the variable values in different units. 8. Change the base variable value by selecting and typing the new value in the appropriate cell under the Base column. The value entered will have the units selected in the Units column. The current value of the variable in the flowsheet is displayed in the appropriate cell under the Current column. 9. Specify the absolute perturbation value by typing the new value in the appropriate cell under the Pert column. The value entered will have the units selected in the Units column. 10. (Optional) If a proxy variable is required to vary the independent variable, select the checkbox in the appropriate cell under the Pert column. Information about the proxy variable appears in a row below the associated independent variable.
Configuring Proxy Variables To select a proxy variable on the Variables tab: 1. Open the Delta Base Utility property view, and go to the Variables tab. 2. In the Independent Variables group, select any cell in the row containing the proxy variable (any variable that has the description Proxy for the independent variable name), and click the Edit button.
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Delta Base Utility
The Select proxy variable for… property view appears. Figure 10.6
You can also access the Select proxy variable for… property view by double-clicking any of the cells in the row containing the proxy variable. 3. Select the proxy variable by following the Select the Variable procedure. 4. Specify the units, base value, and perturbation value for the proxy variable directly in the row containing the proxy variable. 5. (Optional) Change the independent variable associated with the proxy variable. Select any cell in the row containing the proxy variable, and double-click in the cell or click the Edit button. 6. (Optional) Change the name of the independent and proxy variables by typing a new name in the appropriate cell. Proxy variables that are not connected to a variable will display no var in the Proxy Variable field. The Description for proxy variables is not modifiable and indicates which independent variable is associated to the proxy variable.
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Configuring Dependent Variables To configure a dependent variable: 1. Open the Delta Base utility property view. 2. Go to the Variables tab. 3. Click the Scope Objects button to select the objects containing the variables you want to export. 4. In the Dependent Variables group, click the Insert button to Select the Variable. The description of the selected dependent variable appears in the table. 5. Change the dependent variable's name by selecting and typing the new name in the appropriate cell under the Tag column. 6. Change the dependent variable's description by selecting and typing the new description in the appropriate cell under the Description column. 7. Use the drop-down list in the appropriate cell under the Units column to select and view the variable values in different units. The current value of the variable in the flowsheet is displayed in the appropriate cell under the Current column.
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Delta Base Utility
10.2.4 Select Variable Property View The Select Variable property view is used to browse for and select variables from a single or multi-level process flowsheet diagram. Figure 10.7
The following table lists and describes each object in the Select Variable property view: Object
Description
Flowsheet list
Allows you to select a flowsheet from a list of all available flow sheets in the simulation.
Object list
Allows you to select an object from the list of all objects available from the selected flowsheet.
Variable list
Allows you to select the variable from the list of all variables available from the selected object.
Variable Specifics list
Allows you to select a specific variable qualification from the list of all specifics from the selected variable.
Variable Description field
Allows you to type in a description for the selected variable.
OK button
Allows you to add the selected variable to the Delta Base utility.
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Object
Description
Object Filter
Allows you to filter the list of objects available for the variable selection. There are seven filter options: • All. Makes all the objects in the selected flowsheet available. • Streams. Makes only streams in the selected flowsheet available. • UnitOps. Makes only unit operations in the selected flowsheet available. • Logicals. Makes only logical operations in the selected flowsheet available. • Utilities. Makes only utility operations in the selected flowsheet available. • ColumnOps. Makes only objects in the selected column environment available. • Custom. Makes only the objects from the customized filter available.
Custom button
Allows you to configure the customized filter option, by accessing the Select Type property view and setting the type of objects to be included in the filter.
Disconnect button
Allows you to remove the selected variable from the Delta Base utility.
Cancel button
Allows you to exit the Select Variable property view without saving any changes.
Select the Variable When selecting a variable, work through the lists from left to right. To select a variable: 1. Open the Select Variable property view. Click the Cancel button at any time to close the Select Variable property view without accepting any changes. 2. From the Flowsheet list, select the flowsheet which the variable is located. 3. From the Object list, select the object with the variable you want to use. 4. From the Variable list, select the variable you want to use. 5. Certain variables (such as component specific variables), require further specification. From the Variable Specifics list, select the qualifier for the variable. 6. Enter a more detailed description of the variable in the Variable Description field or leave the default description. 7. Click OK to accept the variable.
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Delta Base Utility
To disconnect a variable from an object, click the Disconnect button. The Variable Navigator remains open, allowing you to make a new variable selection.
10.2.5 Target Objects Property View The Target Objects property view allows you to scope objects to be included in the Delta Base utility. Figure 10.8
The following table lists and describes in the objects in the Target Objects property view: Object
Description
FlowSheets group
Allows you to select a flowsheet from a list of top-level and sub-level flowsheets available to the Delta Base utility.
Object Filter group
Allows you to filter the list of objects available for scoping into the Delta Base utility. There are five filter options: • All. Makes all the objects in the selected flowsheet available. • Streams. Makes only streams in the selected flowsheet available. • UnitOps. Makes only unit operations in the selected flowsheet available. • Logicals. Makes only logical operations in the selected flowsheet available. • FlowSheet Wide. Makes the entire selected flowsheet available.
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Object
Description
Unit Operations group
Allows you to select the operations you want to scope into the Delta Base utility.
>>>>>> button
Allows you to move the selected objects from the Objects Available group to the Scope Objects group.
<<<<<< button
Allows you to remove the selected objects from the Scope Objects group.
Scope Objects group
Displays the objects you have selected to scope into the Delta Base utility.
Accept List button
Allows you to include the selected scope objects into the Delta Base utility, and close the Target Objects property view.
Cancel Changes button
Allows you to close the Target Objects property view, without accepting any changes made in the property view.
The name of the right group in the Objects Available group varies depending on the option selected in the Object Filter group.
Scoping Objects To scope objects for the Delta Base utility: 1. Open the Delta Base utility property view. 2. Go to the Derivative Analysis tab. 3. Click the Scope Objects button. The Target Objects property view appears. 4. In the FlowSheets group, select the flow sheet that contains the object you want to scope. 5. In the available objects group (list on left side), select the objects you want to consider in the Delta Base utility. 6. Click the >>>>>> button to move the selected objects into the Scope Objects group. 7. Click the Accept List button to scope the selected unit operations and exit the Target Objects property view. Changing the scope in the Target Objects property view will automatically remove variables (that are no longer attached to the objects in the Scope Objects list) from the Delta Base utility.
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Delta Base Utility
10.2.6 Generating Derivative Values To generate derivative values of dependent variables with respect to changes in the values of independent variables: 1. Open the Delta Base utility property view. 2. Go to the Derivative Analysis tab. 3. In the top right table, select the type of units you want to use by using the drop-down list in the appropriate cell along the Units row. 4. Type the absolute perturbation (amount of changes) values for the independent variables in the appropriate cells along the Pert row. If the independent variable you have selected is a calculated variable (in other words, the variable value is not specified but calculated by HYSYS), HYSYS will not let you vary the value of the selected independent variable. You have to either add tear around the scoped objects or select the appropriate checkbox in the Use proxy row, and use a proxy variable to vary the calculated independent variable value. 5. (Optional) Click the Isolate button to isolate the scope object. When the independent variable values change, the new values are ignored by the rest of the objects in the process flow diagram. 6. Click the Generate Derivatives button to calculate the new dependent variable values and the derivative values.
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The derivative values are displayed in the middle table with respect to the independent variable columns. Figure 10.9
The derivatives are displayed in the delta units of the dependent variable with respect to the delta units of the independent variable. Selecting different units will display the derivatives in the new unit set, but the values are only valid at the base values of the independent variables in the unit sets at which the analysis was performed.
Click the Cancel Solve button, if you want to stop the derivative calculations. 7. (Optional) Click the Propagate button to deactivate the stream cutters. This allows changes in the flowsheet to propagate through the scope objects to the entire process flow diagram, but may cause independent variables to become un-modifiable.
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Delta Base Utility
Equations to Calculate Derivatives The following is an example on calculating the derivatives from independent variables: y1 – y0 Derivative value = Δy ------ = --------------Δx x1 – x0
(10.1)
where: x 1 = x 0 + Δx y1 = new dependent variable value based on x1 x0 = base value of the independent variable y0 = base value of the dependent variable Δx = perturbation value of the independent variable
The following is an example on calculating the derivatives from proxy variables: Derivative value = Δy -----Δx
(10.2)
where: w 1 = w 0 + Δw w0 = base value of the proxy variable Δw = perturbation value of the proxy variable Δx = x 1 – x 0 x0 = base value of the independent variable x1 = new independent variable value based on w1 Δy = y 1 – y 0 y0 = base value of the dependent variable y1 = new dependent variable value based on w1
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10.2.7 Exporting Generated Derivatives To export the Delta Base data to PIMS, you have to save the derivative data as a *.csv file. 1. Open the Delta Base utility property view. 2. Click the Derivative Analysis tab. 3. Click the Export Data button. The File Selection for Exporting Delta Base Data property view appears. 4. Use the Save in drop-down list to select the location for the variable *.csv file. 5. In the File name field, type in the name of the *.csv file. 6. Click the Save button. You can now retrieve the variable data in PIMS by opening the *.csv file in the PIMS program.
10.3 Petroleum Assay Utility The Petroleum Assay utility is only available for use when you have added a petroleum assay in the simulation environment. When there is a petroleum assay in the simulation environment, the Boiling Point Curves utility is unavailable.
The Petroleum Assay utility, which is used in conjunction with characterized assays from the Petroleum Assay, allows you to obtain the results of a laboratory style analysis for your simulation streams. Simulated distillation data including TBP, ASTM D86, D2887, D1160(Vac), and D1160(Atm), as well as petroleum properties for each cut point are calculated. The data can be viewed in a tabular format or graphically. The object for the analysis can be a material stream, a stream phase in any stage of a tray section, a stream phase in a separator, a stream phase in a condenser, or a stream phase in a reboiler. 10-23
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Petroleum Assay Utility
Figure 10.10
To ignore this utility during calculations, select the Ignored checkbox on the utility’s property view. HYSYS disregards the utility entirely until you restore it to an active state by clearing the checkbox.
Adding a Petroleum Assay Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. You can also access the Available Utilities property view by pressing CTRL U. 2. From the list of available utilities, in the right pane, select the Petroleum Assay utility. 3. Click the Add Utility button. The Petroleum Assay utility property view appears.
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Editing a Petroleum Assay Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, in the left pane, select the Petroleum Assay utility you want to view. 3. Click the View Utility button. The selected utility’s property view appears. From here, you can modify any of the utility’s properties.
Deleting a Petroleum Assay Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, in the left pane, select the Petroleum Assay utility you want to delete. 3. Click the Delete Utility button. HYSYS will ask you to confirm the deletion. You can also delete a utility by clicking the Delete button on the utility’s property view.
10.3.1 Design Tab The Design tab contains two pages: • •
Connections Notes
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Petroleum Assay Utility
Connections Page On the Connections page, you can select the parameters for the Petroleum Assay utility. Figure 10.11
To set the Petroleum Assay utility parameters: 1. On the Connections page of the Design tab, change the Name of the utility, if desired. 2. From the Object Type drop-down list, select the object type you want. The options are Stream, Tray Section, Separator, Condenser, or Reboiler. For a tray section, the petroleum assay properties can be accessed on the Profiles tab of the Column Runner.
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3. Click the Select Object button, the Select (object type) property view appears. Figure 10.12
The title of the Select (object type) property view depends on the object type you selected. For example, if you select the condenser, the Select Condenser property view appears. 4. Choose the appropriate object from the Object list, and click the OK button to add the selected object to the utility. The Object list can be filtered by selecting one of the radio buttons in the Object Filter group. 5. For all object types except the Stream selection, from the Phase drop-down list you can select the phase for the analysis as either Vapour or Liquid. 6. If the Object Type which you have selected is a Tray Section, from the Stage drop-down list select a stage.
Notes Page For more information refer to Section 1.2.3 Notes Page/Tab.
The Notes page provides a text editor, where you can record any comments or information regarding the utility, or to your simulation case in general.
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Petroleum Assay Utility
10.3.2 Results Tab The Results tab contains three pages: • • •
Boiling Curves Properties Plots
Boiling Curves Page You can view the results of the boiling point curve calculations in tabular format on the Boiling Curves page. Figure 10.13
Simulated distillation profiles are provided for the following assay types: • • • • •
TBP ASTM ASTM ASTM ASTM
D86 D2887 D1160 (Vac.) D1160 (Atm.)
The ASTM D86 boiling point curve corresponds to the true boiling points of the oil, which assumes no cracking has occurred. 10-28
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When the oil is characterized by a ASTM D86 distillation assay with no cracking option, the ASTM D86 boiling point curve corresponds to raw lab data, with no cracking correction applied. When the oil is characterized by a ASTM D86 distillation assay with cracking option, the ASTM D86 boiling point curve corresponds to the assay input data.
Properties Page The Properties page displays the petroleum assay properties. Figure 10.14
Plots Page The Plots page displays the plots of the boiling point curves, molecular weight, standard liquid density, and the petroleum properties in graphical form. Examine the plot of your choice by making a selection from the Property drop-down list. Refer to Section 10.4 Graph Control in the HYSYS User Guide for details concerning the customization of plots.
You can customize a plot by right-clicking in the plot area, and selecting Graph Control from the object inspect menu.
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Petroleum Assay Utility
The figure below shows an example of the Plots page. Figure 10.15
10.3.3 Dynamics Tab The Dynamics tab allows you to control how often the utility gets calculated when running in Dynamic mode. Figure 10.16
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The Control Period field is used to specify the frequency that the utility is calculated. A value of 10 indicates that the utility be recalculated every 10th pressure flow step. This can help speed up your dynamic simulation since utilities can require some time to calculate. The Use Default Periods checkbox allows you to set the control period of one utility to equal the control period of any other utilities that you have in the simulation. For example, if you have five utilities, and require them all to have a control period of 5 and currently the value is 8, with this checkbox selected if you change the value in one utility all the other utilities change. Alternatively, if you want all the utilities to have different values you would clear this checkbox. The Enable in Dynamics checkbox is used to activate this feature for use in Dynamic mode.
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Swing Cut Utility
10.4 Swing Cut Utility The Swing Cut utility, which is used in conjunction with the Petroleum Distillation column, allows you to generate and export assay tables with user-specified swing cuts in PIMS format. Aspen PIMS (Process Industry Modeling System) is a production planning and optimization tool that is widely used in the refinery industry. It allows you to determine the best operating conditions at minimum cost using Linear Programming (LP) and simplified assumptions. The Swing Cut utility provides tighter integration between Aspen Aspen HYSYS Petroleum Refining and Aspen PIMS to achieve a wider refinery modeling solution. LP crude assays consist of yields and properties of heart cuts and swing cuts. Heart cuts refer to material that must always be allocated to a given refinery stream. For example, the kerosene heart cut is material that will always be taken from the crude column kerosene draw. Swing cuts represent material that can be allocated to two adjacent crude column draws. For example, the naphtha/kerosene swing cut is material that can be drawn out of the crude column with the naphtha stream, or kerosene stream. The allocation of the swing cut is determined by the cut point on the actual crude column; this is set by specifying the TBPs.
Adding a Swing Cut Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. You can also access the Available Utilities property view by pressing CTRL U. 2. From the list of available utilities, shown in the right pane, select the Swing Cut Utility. 3. Click the Add Utility button. The Swing Cut utility property view appears.
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Editing a Swing Cut Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, shown in the left pane, select the Swing Cut utility you want to view. 3. Click the View Utility button. The selected utility’s property view appears. From here, you can modify any of the utility’s properties.
Deleting a Swing Cut Utility 1. In the Tools menu, click the Utilities command. The Available Utilities property view appears. 2. From the list of installed utilities, shown in the left pane, select the Swing Cut utility you want to delete. 3. Click the Delete Utility button. HYSYS will ask you to confirm the deletion. You can also delete a utility by clicking the Delete button on the utility’s property view.
Exporting Assay Properties from Swing Cut Utility You can only export assay properties after you have run the Swing Cut calculation option.
1. Open the Swing Cut Utility property view. 2. Scope the appropriate objects. 3. Select the light end components for the Swing Cut calculation. 4. Select the assay properties for the Swing Cut calculation. 5. Specify a tag name in the Crude tag field. 6. Click the Run button. 7. Click the Export Assay Table button to export the calculated assay properties data to a *csv file.
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Swing Cut Utility
10.4.1 Specification Tab The Specification tab allows you to specify the heart and swing cuts that you want to calculate in the Petroleum Distillation column. Figure 10.17
The following table lists and describes the objects available in the Specifications tab: Object
Description
Name field
Allows you to change the name of the Swing Cut utility.
Scope Objects button
Allows you to select a Petroleum Distillation column to be attached to the Swing Cut utility by opening the Target Objects Property View.
Calculation Basis drop-down list
Allows you to select Volume Basis or Mass Basis for your calculations.
Once you have connected the Swing Cut utility to a Petroleum Distillation column, the product streams of the column are shown in the Heart and Swing Cut table.
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You can select the products you want to include in the printed report in the Swing Cut utility by selecting their corresponding checkboxes in the Include column. The TBP Cut data for each product stream are retrieved from the column. You need to specify a maximum TBP cut temperature to define a swing cut. The maximum TBP Cut must be a temperature value in between two adjacent product streams and it must satisfy the following condition: ( T2 – T1 ) T 1 + 1.0 < TBP < T 1 + -----------------------2
(10.3)
T2 > T1
(10.4)
where: T1, T2 = temperature values for product stream 1 and 2 TBP = maximum TBP cut for the product stream 1
Since there is no specific TBP cut point for the last product stream, the last maximum TBP cut must satisfy the following condition: T 1 + 1.0 < TBPLast < T 1 + 50.0
(10.5)
where: T1 = temperature of the product stream before the last product stream TBPLast = swing cut TBP for the last product stream
You will not be allowed to enter a value if the value is out of range.
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Swing Cut Utility
10.4.2 Light Ends Tab The Light Ends tab contains a table that displays the petroleum light ends properties (yield by weight and volume, NBP, molecular weight, and SG) of the components in the selected/ scoped objects. You can select or clear the checkboxes under the Include column to consider or ignore the component properties during calculation. Figure 10.18
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10.4.3 Assay Table Tab The Assay Table tab allows you to select and view the assay properties from the product stream used in the calculation. Figure 10.19
• • • •
Calculation Basis drop-down list enables you to select Volume Basis or Mass Basis for your calculations. Crude Tag field enables you to specify a PIMS tag for the assay table. Run button enables you to run the Swing Cut calculation option. Export Assay Table button enables you to export the calculated assay properties data into a *.csv format file.
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Swing Cut Utility
Selecting an Assay Property To select an assay property for a product stream: 1. Under the Assay Property column, place the mouse cursor over an empty cell. The down arrow icon
appears in the cell as shown.
Figure 10.20
2. Click the down arrow icon to open the drop-down list and select an assay property.
Property Calculation for Swing Cuts After you have selected the desired cut properties for each product stream, click on the Run button to run the utility. Swing Cuts utility generates assay tables with user-specified swing cuts. For each individual crude, the column will run once using the default product cut points, and once again using the maximum cut point for each product, where a swing cut was selected. For instance, in a Kero-LGO swing, the column will run with Kero cut point set to maximum Kero TBP cut, and then the following formulas are used to calculate properties (Ps) of Kero-LGO swing.
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From LGO: Vs ⋅ Ps + V1 ⋅ P1 = ( Vs + V1 ) ⋅ P2
(10.6)
[(V + V ) ⋅ P – V ⋅ P ] s 1 2 1 1 P = ---------------------------------------------------------------s V s
(10.7)
where: V = volume (or weight) P = property s = swing cut 1, 2 = state (low, high cut point)
The Swing Cut utility is available in steady state mode. You can perform the calculations on the petroleum distillation column without propagation of the perturbation to other unit operations. The utility will be available within the subflowsheet environment as well as at the main flowsheet level. Each instance of the utility will be independent. There may be several instances of the utility active in a flowsheet.
10.4.4 PIMS Format Tab The PIMS Format tab allows you to associate a unique PIMS tag for each product stream and cut property. When you export the assay tables, these PIMS tags are used to represent the product streams and cut properties in the csv file. You can type directly in the cell to specify a PIMS tag.
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Swing Cut Utility
Figure 10.21
Comma Separated Values (csv) file is a simple structured data file. The file contains a table of product streams and their corresponding properties data. The data in the file can be accessed through Microsoft Excel application. Aspen Aspen HYSYS Petroleum Refining uses csv files to contain petroleum properties of individual assays. The following describes the general layout of the csv file: • • • •
In the first column, the PIMS tags for the product streams and cut properties are displayed in combination. In the second column, the full name of the product stream and the associated cut property are displayed. The third column displays the numerical data information. The crude tag is displayed in the first cell of the third column. You can have multiple crude data displayed on the same spreadsheet.
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Petroleum Methods & Correlations A-1
A Petroleum Methods & Correlations A.1 Introduction .................................................................................. 2 A.2 Physical Property Calculation ........................................................ 2 A.2.1 A.2.2 A.2.3 A.2.4
Calculation for Molecular Weight................................................. 3 Calculation for Centroid Boiling Point........................................... 3 Calculation for Specific Gravity................................................... 4 Heat of Formation .................................................................... 4
A.3 Petroleum Property Calculation ..................................................... 5 A.3.1 A.3.2 A.3.3 A.3.4 A.3.5 A.3.6
Mass Blend.............................................................................. 6 Mole Blend .............................................................................. 6 Volume Blend .......................................................................... 7 Healy Method for RON and MON ................................................. 8 Component Level Calculations.................................................... 9 Stream Level Calculations ....................................................... 16
A.4 Comma Separated Value Files...................................................... 40 A.4.1 Format of CSV Files ................................................................ 40 A.5 Petroleum Assay XML Files .......................................................... 44 A.5.1 A.5.2 A.5.3 A.5.4
File Versions .......................................................................... 46 File Types.............................................................................. 46 Crude and Component Information........................................... 47 Individual Component Information............................................ 48
A.6 PET Files ...................................................................................... 49 A.7 Spiral Files ................................................................................... 51 A. 8 References................................................................................... 47
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A-2
Introduction
A.1 Introduction This appendix is contains the blending rules of the physical and petroleum properties in petroleum assays, the definition of a Comma Separated Value (CSV) file, and the format of an XML file containing a petroleum assay data. If you do not have the Aspen HYSYS Petroleum Refining license, you will not be able to access the petroleum properties.
A.2 Physical Property Calculation For more information on physical property calculations, refer to Appendix A - Property Methods & Calculations in the HYSYS Simulation Basis guide.
All the physical properties of a stream with petroleum assays are calculated/estimated based on three critical information: molecular weight, centroid boiling point, and specific gravity. These three property values are often provided with the petroleum properties values of a petroleum assay. If the three critical property values are not provided, estimated values are calculated based on blending the components’ property values. The components considered are the components that are active in the petroleum assay.
When two petroleum assays are blended together, their physical properties are recalculated/re-estimated using the blended value of the molecular weight, centroid boiling point, specific gravity, and heat of formation.
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Petroleum Methods & Correlations A-3
A.2.1 Calculation for Molecular Weight The following equation is used to calculate the blended molecular weight value:
∑
MW blend =
MFlowS × MW S S = stream ---------------------------------------------------------------
∑
(A.1)
MFlow S
S = stream
where: MWblend = mixed molecular weight MFlow = mass flow rate of stream S MW = molecular weight in each stream
A.2.2 Calculation for Centroid Boiling Point The following equation is used to calculate the blended centroid boiling point value:
∑
CBP blend =
VFlow S × CBP S S = streams ------------------------------------------------------------------
∑
(A.2)
VFlow S
S = streams
where: CBPblend = mixed centroid boiling point VFlow = volumetric flow rate of stream S CBP = centroid boiling point in each stream
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A-4
Physical Property Calculation
A.2.3 Calculation for Specific Gravity The following equation is used to calculate the blended liquid density/specific gravity value:
∑
MFlow S
= streams SG blend = S--------------------------------------------VFlow S ∑
(A.3)
S = streams
where: SGblend = mixed specific gravity VFlow = volumetric flow rate of stream S The volumetric flow conditions is at standard 60°F. MFlow = mass flow rate of stream S
A.2.4 Heat of Formation The following equation is used to calculate the blended heat of formation value:
∑
HofF blend =
MolFlow S × HofF S S = stream ------------------------------------------------------------------------
∑
(A.4)
MolFlow S
S = stream
where: HofFblend = mixed heat of formation MolFlow = molar flow rate of stream S HofF = heat of formation in each stream A-4
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Petroleum Methods & Correlations A-5
A.3 Petroleum Property Calculation In Aspen HYSYS Petroleum Refining there are two levels of calculation for the petroleum properties: •
Component Level. In this calculation method, individual component properties in a stream are used to calculate the petroleum property.
Component level blending occurs in all situations when two or more streams enter a unit operation. For example, in mixers, separators, and distillation columns with two or more feeds.
For example, consider the streams mixing in the figure below. To calculate the blended Aniline Point for component B in stream 3, the Component Level method uses the B component property from stream 1 and 2. You can also select the type of blending rule (mass, mole, or volume) to calculate the new Aniline Point. Figure A.1
•
Stream Level. In this calculation method, the overall stream properties are used to calculate the petroleum property. For example, consider the streams mixing in the figure above. To calculate the blended Aniline Point for stream 3, the Stream Level method uses the petroleum property from component A, B, and C. In the case of Stream Level there is only one type of blending equation available.
There are three main blending calculations that most of the petroleum properties use: Mass, Mole, and Volume.
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A-6
Petroleum Property Calculation
A.3.1 Mass Blend This blending rule4 is used to blend properties based on mass fraction using the following relation:
∑
Mixprop =
MFlow S × prop S S = streams -------------------------------------------------------------------
∑
(A.5)
MFlowS
S = streams
where: MFlow = mass flow rate of stream S prop = property to be blended in each stream Mixprop = mixed value of the targeted property
A.3.2 Mole Blend The Mole Blend rule4 is used to blend properties based on mole fraction using the following relation:
∑
MolFlow S × prop S
= streams Mixprop = S-----------------------------------------------------------------------MolFlow S ∑
(A.6)
S = streams
where: MolFlow = molar flow rate of stream S prop = property to be blended in each stream Mixprop = mixed value of the targeted property
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Petroleum Methods & Correlations A-7
A.3.3 Volume Blend The Volume Blend rule4 is used to blend properties based on volume fraction using the following relation:
∑
Mixprop =
VFlow S × prop S S = streams ------------------------------------------------------------------
∑
(A.7)
VFlow S
S = streams
where: VFlow = volumetric flow rate of stream S prop = property to be blended in each stream Mixprop = mixed value of the targeted property
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A-8
Petroleum Property Calculation
A.3.4 Healy Method for RON and MON The Healy Method9 blending rules for RON and MON are: RON = RON sum + 0.05411 ( ΔRONMON 1 – RON sum × ΔRONMON ) 2
2
+ 0.00098 ( Olfsum2 – Olf sum ) – 0.00074 ( Arom sum2 – Arom sum ) MON = MON sum + 0.03908 ( ΔRONMON 2 – MON sum × ΔRONMON ) 2
–7
– 7.03 × 10 ( Arom sum2 – Arom sum )
2
(A.8)
(A.9)
where:
∑ RONi × Vi
RON sum =
S
∑ MONi × Vi
MON sum =
S
∑ Olfi × Vi
Olfsum =
S
Olfsum2 =
2
∑ Olfi × Vi S
Arom sum =
∑ Aromi × Vi S
Arom sum2 =
2
∑ Aromi × Vi S
ΔRONMON =
∑ ( RONi – MONi ) × Vi S
ΔRONMON 1 =
∑ RONi ( RONi – MONi ) × Vi S
ΔRONMON 2 =
∑ MONi ( RONi – MONi ) × Vi S
VFlow i V i = -------------------------------------------VFlow S ∑ S
t
A-8
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Petroleum Methods & Correlations A-9
A.3.5 Component Level Calculations The following sections describe the Blend rules and equations at Component Level calculation for the assay properties in Aspen HYSYS Petroleum Refining.
Aniline Point The Aniline Point16,6 is calculated using the following blending rules: • • •
Mass Blend Mole Blend Volume Blend
Aromatics By Volume The Aromatics By Volume6 is calculated using Volume Blend.
Aromatics By Weight The Aromatics By Weight16 is calculated using Mass Blend.
Asphaltene Content The Asphaltene Content3 is calculated using Mass Blend.
Basic Nitrogen Content The Basic Nitrogen Content3 is calculated using Mass Blend.
C To H Ratio The C to H Ratio is calculated using Mass Blend.
A-9
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A-10
Petroleum Property Calculation
Cloud Point The mass, mole, and volume blending calculations are also available.
Cloud Point Blending6,16 is calculated using the following equations: n
( ∑ v i × CI i ) CIB i = --------------------------------1.8
CI i = ( 1.8 × C i )
1 --n
(A.10)
(A.11)
where: CIBi = Cloud Point of the blended component i CIi = Cloud Point index of individual components vi = Volume fraction of individual components Ci = Cloud Point of individual components n = default constant value of 0.55, for heavier cut point HYSYS recommends 0.6
Conradson Carbon Content The Conradson Carbon Content3 is calculated using Mass Blend.
Copper Content The Copper Content6 is calculated using Mass Blend.
A-10
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Petroleum Methods & Correlations A-11
Flash Point The mass, mole, and volume blending calculations are also available.
Flash Point Blending6,10,16 is calculated using the following equations: – 0.6
( ∑ v i × FIi ) FIB i = -------------------------------------1.8
FI i = ( 1.8 × F i )
– 1-----0.6
(A.12)
(A.13)
where: FIBi = Flash Point of the blended component i FIi = Flash Point index of individual components vi = Volume fraction of individual components Fi = Flash Point of individual components
Freeze Point (Temperature) The Freeze Point6,16 is calculated using the following blending methods: • • •
Mass Blend Mole Blend Volume Blend
Molecular Weight The Molecular Weight is calculated using Mass Blend.
A-11
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A-12
Petroleum Property Calculation
MON Clear The MON Clear6 is calculated using Healy Method for RON and MON.
Naphthenes By Volume The Naphthenes By Volume6 is calculated using Volume Blend.
Naphthenes By Weight The Naphthenes By Weight3,16 is calculated using Mass Blend.
Ni Content The Ni Content6 is calculated using Mass Blend.
Nitrogen Content The Nitrogen Content6 is calculated using Mass Blend.
Olefins By Volume The Olefins By Volume is calculated using Volume Blend.
Olefins By Weight The Olefins By Weight3 is calculated using Mass Blend.
Paraffins By Volume The Paraffins By Volume6 is calculated using Volume Blend.
A-12
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Petroleum Methods & Correlations A-13
Paraffins By Weight The Paraffins By Weight3,16 is calculated using Mass Blend.
Pour Point The mass, mole, and volume blending calculations are also available.
Pour Point Blending6,16 is calculated using the following equations: PI i = exp ( 73.0883 + 12.885 × In ( P i × 1.8 ) ) ⎛ ln ( ∑ PI i × V i ) – 73.0883⎞ exp ⎜ --------------------------------------------------------------⎟ 12.885 ⎝ ⎠ PIB i = ----------------------------------------------------------------------------1.8
(A.14)
(A.15)
where: Pi = Pour Point of individual components PIi = Pour Point index of individual components Vi = Volume fraction of individual components PIBi = Pour Point of the blended component i
Refractive Index The Refractive Index is calculated using the following blending rules: • • •
Mass Blend Mole Blend Volume Blend
A-13
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A-14
Petroleum Property Calculation
RON Clear The RON Clear6 is calculated using the Healy Method for RON and MON.
RON Leaded The RON Leaded calculated using the following blending rules: • • •
Mass Blend Mole Blend Volume Blend
Reid Vapor Pressure (RVP) The mass, mole, and volume blending calculations are also available.
RVP Blending1,8,14,15 is calculated using the following equations:
( ∑ V i × RVPI i ) RVPB i = --------------------------------------0.145
RVPI i = ( RVP i × 0.145 )
0.8
1.25
(A.16)
(A.17)
where: RVPi = RVP of individual components RVPIi = RVP index of individual components Vi = Volume fraction of individual components RVPBi = RVP of the blended component i
A-14
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Petroleum Methods & Correlations A-15
SG (60/60F) The SG (60/60°F)7 is calculated using Volume Blend.
Smoke Point The Smoke Point2 calculated using the following blending rules: • • •
Mass Blend Mole Blend Volume Blend
Sulfur Content The Sulfur Content12 is calculated using Mass Blend.
Vanadium Content The Vanadium Content6 is calculated using Mass Blend.
Viscosity The Viscosity is calculated using an indexing method, and there are two methods available. One method uses 0.8 as the parameter constant and the second method uses 0.08 as the parameter constant.
U b = 10
U mix =
10Vmix
–c
∑ xi × log ( log [ Vi + c ] )
(A.18)
(A.19)
where: Ub = viscosity of blend Ui = viscosity of component i
A-15
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A-16
Petroleum Property Calculation
Xi = composition fraction of component i C = parameter constant
Wax Content The Wax Content6 is calculated using Mass Blend.
A.3.6 Stream Level Calculations The following sections contains the Blend rules and equations at Stream Level calculation for the assay properties in Aspen HYSYS Petroleum Refining.
Acetaldehyde (toxic emission) Toxic emissions from Acetaldehyde11 is calculated using the following equations: Acet B ( T 1 – B1 ) ( T2 – B2 ) ( 0.444e + 0.556e ) ToxEmi Acet = -------------6 10
(A.20)
where: T 1 = 0.0002631 ( Sulf T ) + 0.039786 ( RVP T ) – 0.012157 ( E300 T ) – 0.005525 ( Arom T ) – 0.009594 ( MTBE T ) + 0.31658 ( ETBE T ) + 0.24925 ( Ethanol T ) B 1 = 0.0002631 ( Sulf B ) + 0.039786 ( RVP B ) – 0.012157 ( E300 B ) – 0.005525 ( Arom B ) – 0.009594 ( MTBE B ) + 0.31658 ( ETBE B ) + 0.24925 ( Ethanol B ) T 2 = 0.0002627 ( Sulf T ) – 0.012157 ( E300 T ) – 0.005548 ( Arom T ) – 0.05598 ( MTBET ) + 0.3164665 ( ETBE T ) + 0.2493259 ( Ethanol T ) B 2 = 0.0002627 ( Sulf B ) – 0.012157 ( E300 B ) – 0.005548 ( Arom B ) – 0.05598 ( MTBEB ) + 0.3164665 ( ETBE B ) + 0.2493259 ( Ethanol B ) SulfT = sulfur content, range 0 to 500 A-16
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Petroleum Methods & Correlations A-17
AromT = aromatics content, range 0 to 50 RVP T = Reid Vapor Pressure × 0.145 MTBET =
∑ 34.7 ( Mass of componenti ) i
ETBE T =
∑ 34.7 ( Mass of componenti ) i
Ethanol T =
∑ 34.7 ( Mass of componenti ) i
AcetB = 7.25 for winter, 4.44 for summer SultB = 338.0 for winter, 339.0 for summer RVPB = 11.5 for winter, 8.7 for summer E300B = 83.0 for winter, 83.0 for summer AromB = 26.4 for winter, 32.0 for summer
Aniline Point The Aniline Point6,16 is calculated using Volume Blend. Note: AP values in HYSYS are computed in K. Because some components may be missing AP values, Σx i ≠ 1 . That means AP ( @K ) ≠ AP ( @C ) + 273.15
Aromatics By Volume The Aromatics By Volume6 is calculated using Volume Blend.
Aromatics By Weight The Aromatics By Weight16 is calculated using Mass Blend.
Asphaltene Content The Asphaltene Content3 is calculated using Mass Blend.
A-17
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A-18
Petroleum Property Calculation
Basic Nitrogen Content The Basic Nitrogen Content3 is calculated using Mass Blend.
Benzene (toxic exhaust emission) Toxic emissions from Benzene11 is calculated using the following equations:
ExBenz B ( T1 – B1 ) ( T2 – B2 ) ( 0.444e + 0.556e ) ToxEmi ExBenz = ---------------------6 10
(A.21)
where: T 1 = 0.0006197 ( Sulf T ) – 0.003376 ( E200 T ) + 0.02655 ( Arom T ) + 0.22239 ( Benz T ) B 1 = 0.0006197 ( Sulf B ) – 0.003376 ( E200 B ) + 0.02655 ( Arom B ) + 0.22239 ( Benz B ) T 2 = 0.000337 ( Sulf T ) + 0.011251 ( E300 T ) + 0.011882 ( Arom T ) + 0.222318 ( Benz T ) – 0.096047 ( OxyT ) B 2 = 0.000337 ( Sulf B ) + 0.011251 ( E300 B ) + 0.011882 ( Arom B ) + 0.222318 ( Benz B ) – 0.096047 ( Oxy B ) SulfT = sulfur content, range 0 to 500 AromT = aromatics content, range 0 to 50 Oxy T =
∑ 34.7 ( Mass of componenti ) i
Benz T =
∑ 34.7 ( Mass of componenti ) i
EXBenzB = 77.62 for winter, 53.54 for summer SulfB = 338.0 for winter, 339.0 for summer E200B = 50.0 for winter., 41.0 for summer AromB = 26.4 for winter, 32.0 for summer A-18
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Petroleum Methods & Correlations A-19
BenzB = 1.53 for winter, 1.64 for summer E300B = 83.0 for winter, 83.0 for summer OxyB = 0.0 for winter, 0.0 for summer
Benzene (toxic non-exhaust emission) Toxic non-exhaust emissions from Benzene11 is calculated using the following equations: ToxEmi NonExBenz = BenzE HotS + BenzE Diu + BenzE RunLos + BenzE Reful
(A.22)
where: BenzEHotS = 10 ( Benz T × VOC HotS ) × ( 1.4448 – 0.0342 [ MTBE T ] – 0.080274 [ RVP T ] ) BenzEDiu = 10 ( Benz T × VOC Diu ) × ( 1.3758 – 0.029 [ MTBE T ] – 0.080274 [ RVP T ] ) BenzERunLos = 10 ( Benz T × VOC RunLos ) × ( 1.4448 – 0.0342 [ MTBE T ] – 0.080274 [ RVP T ] ) BenzEReful = 10 ( Benz T × VOC Reful ) × ( 1.3974 – 0.0296 [ MTBE T ] – 0.081507 [ RVP T ] ) Region 1: VOC HotS = 1000 ( 0.006654 [ RVP 2 ] – 0.08009 [ RVP T ] + 0.2846 ) VOC Diu = 1000 ( 0.007385 [ RVP 2 ] – 0.08981 [ RVP T ] + 0.3158 ) VOC RunLos = 1000 ( 0.017768 [ RVP 2 ] – 0.18746 [ RVP T ] + 0.6146 ) VOC Reful = 1000 ( 0.0004767 [ RVP T ] + 0.011859 ) Region 2: VOC HotS = 1000 ( 0.006078 [ RVP 2 ] – 0.07474 [ RVP T ] + 0.27117 ) VOC Diu = 1000 ( 0.004775 [ RVP 2 ] – 0.05872 [ RVP T ] + 0.21306 )
A-19
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A-20
Petroleum Property Calculation
VOC RunLos = 1000 ( 0.016169 [ RVP 2 ] – 0.17206 [ RVP T ] + 0.56724 ) VOC Reful = 1000 ( 0.004767 [ RVP T ] + 0.011859 ) RVP T = Reid Vapor Pressure × 0.145 RVP 2 = ( RVP T ) Benz T =
2
∑ 34.7 ( Mass of componenti ) i
MTBET =
∑ 34.7 ( Mass of componenti ) i
Butadiene (toxic emission) Toxic emissions from Butadiene11 is calculated using the following equations: But B (T – B ) (T – B ) - ( 0.444e 1 1 + 0.556e 2 2 ) ToxEmi But = ----------6 10
(A.23)
where: T 1 = 0.0001552 ( Sulf T ) – 0.007253 ( E200 T ) – 0.014866 ( E300 T ) – 0.004005 ( Arom T ) + 0.028235 ( Olef T ) B 1 = 0.0001552 ( Sulf B ) – 0.007253 ( E200 B ) – 0.014866 ( E300 B ) – 0.004005 ( Arom B ) + 0.028235 ( Olef B ) T 2 = 0.043696 ( Olef T ) – 0.060771 ( OxyT ) – 0.007311 ( E200 T ) – 0.008058 ( E300 T ) – 0.004005 ( Arom T ) B 2 = 0.043696 ( Olef B ) – 0.060771 ( Oxy B ) – 0.007311 ( E200 B ) – 0.008058 ( E300 B ) – 0.004005 ( Arom B ) SulfT = sulfur content, range 0 to 500 AromT = aromatics content, range 0 to 50 OlefT = olefins content, range 0 to 25 Oxy T =
∑ 34.7 ( Mass of componenti ) i
A-20
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Petroleum Methods & Correlations A-21
ButB = 15.84 for winter, 9.38 for summer SulfB = 338.0 for winter, 339.0 for summer E200B = 50.0 for winter, 41.0 for summer E300B = 83.0 for winter, 83.0 for summer AromB = 26.4 for winter, 32.0 for summer OlefB = 11.9 for winter, 9.2 for summer OxyB = 0.0 for winter, 0.0 for summer
C To H Ratio The C to H Ratio is calculated using Mass Blend.
Cetane Index (D976) Cetane Index (D976)17 is calculated using the following equation: 2
CetIdx 976 = – 420.34 + 0.016 ( API ) + 0.192 ( API ) log 10 ( D86T50F ) 2
+ 65.01 ( log [ D86T50F ] ) – 0.0001809 ( D86T50F )
2
(A.24)
where: D86T50F = D86 value in F at 50% volume
Cetane Index (D4737) Cetane Index (D4737)17 is calculated using the following equation: CetIdx 4737 = 45.2 + 0.0892 ( T10Dif ) + ( 0.131 + 0.901 [ SG Corr ] ) × T50Dif + ( 0.0523 – 0.42 [ SG Corr ] ) × T90Dif 2
(A.25)
2
+ 0.00049 ( [ T10Dif ] – [ T90Dif ] ) + 107.0 ( SG Corr ) + 60.0 ( SG Corr )
2
A-21
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A-22
Petroleum Property Calculation
where: SG Corr = exp ( – 3.5 [ SG – 0.85 ] ) – 1.0 T10Dif = D86T10 - 215.0 D86T10 = D86 value in C at 10% volume T50Dif = D86T50 - 260.0 D86T50 = D86 value in C at 50% volume T90Dif = D86T90 - 310.0 D86T90 = D86 value in C at 90% volume
Cetane Number Cetane Number17 is calculated using the following equation: Cetane Number = 5.28 + 0.371 ( CetIdx 4737 ) + 0.0112 ( CetIdx 4737 )
2
(A.26)
where: CetIdx4737 = Cetane Index (4737), see Equation (A.25)
Cloud Point Cloud Point Blending6,16 uses two options: The Aspen HYSYS Petroleum Refining Indexing Method uses the following equations: 0.55
( ∑ vi × Ci ) CIB = -----------------------------------1.8
CI = ( 1.8 × CIB )
1--------0.55
(A.27)
(A.28)
where: CIB = Blended Cloud Point index CI = Cloud Point index of stream in F A-22
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Petroleum Methods & Correlations A-23
vi = Volume fraction of individual components Ci = Cloud Point of individual components in K
The Crude Manager Indexing Method for Cloud Point uses the following equations: CIB = Σ ( V i exp ( 0.035 × C i ) )
(A.29)
CIB )CI = log (--------------0.035
(A.30)
There is also a backup method equation:
CIB i = 10.0
– 7.41 + 5.49 log 10 ( BP i ) – 0.712 ( BP i )
0.315
– 0.133 ( SG i )
(A.31)
where: BP = average boiling point (° R) SG = specific gravity
Conradson Carbon Content The Conradson Carbon Content3 is calculated using Mass Blend.
Copper Content The Copper Content6 is calculated using Mass Blend.
DON (Clear) DON is calculated at the Aspen HYSYS Petroleum Refining stream level using the following formula:
RON + MONDON ( Clear ) = -------------------------------2
(A.32)
A-23
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A-24
Petroleum Property Calculation
Driveability Index The driveability index is calculated at the Aspen HYSYS Petroleum Refining stream level using the following formula:
DI = 1.5 × TBP10F + 3.0 × TBP50F + TBP90F
(A.33)
where: DI = Driveability Index TBP10 = 10 vol % TBP F TBP50 = 50 vol % TBP F TBP90 = 90 vol % TBP F
Flash Point Flash Point Blending6,10,16 is calculated using the following methods: Flash Point: Indexing Method: – 0.6
FIB =
∑ ( v i × FIi ) ---------------------------------------
(A.34)
1.8
FI = ( 1.8 × F i )
–1 ------0.6
(A.35)
where: FIB = Blended Flash Point FIi = Flash Point of component i in K vi = Volume fraction of component i FI = Flash Point of stream in K
A-24
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Petroleum Methods & Correlations A-25
Flash Point: API2B7.1 Method 1 FP = ---------------------------------------------------------------------------------------------------------------------------------------------2.84947 – 0.024209 + ------------------------------ + 3.4254e-3 × log ( d86temp10 ) D86temp10
(A.36)
where: FP = Flash point in K D86temp10 = 10 vol% D86 temperature in K
This is also a back up method for calculating the flash point when the indexing method fails (due to not having the Flash point of individual components). Flash Point: Riazi Cuts Method This method calculates the Flash point of individual component by following equation
1 FP i = -------------------------------------------------------------------------------------------------------------------2.84947 – 0.024209 + ------------------- + 3.4254e-3 × log ( NBP i ) NBP i
(A.37)
where: NBPi = Normal boiling point of component i in K FPi = Flash point of component i in K
It then blends the flash point of individual components using the Wickey18 method. – 6.1188 + 2414.0 Flash Point Index = ⎛⎝ pow ⎛⎝ 10.0, ⎛⎝ -------------------------------------------⎞⎠ ⎞⎠ FP i + 230.56
(A.38)
2414.0 FP = -------------------------------------------------------------------------------------- – 230.56 ( 6.1188 + log 10 ( FlashPointIndex ) )
(A.39)
A-25
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A-26
Petroleum Property Calculation
where: FP = Flash point of stream in K
Flash Point: Linear D86 Based Method The Linear D86 based method uses a simple correlation:
FP = param1 + param2 × D86_IBP + param3 × D86_5
(A.40)
where: D86_IBP = D86 IBP in C, D86_5 = 5 vol % D86 in C FP = Flash point of stream in C
Param1, param2, param3 and D86 IBP can be specified from the correlation manager.
Freeze Point (Temperature) Freeze Point temperature6,16 is calculated using the following methods: Freeze Point: Aspen HYSYS Petroleum Refining Indexing Method 1 --3
FP = ( Vf max ) × ( F max – F min ) + F max
(A.41)
where: Fmax = maximum freeze point of all components in K Fmin = minimum freeze point of all components in K Vfmax = maximum volume fraction among all components
A-26
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Petroleum Methods & Correlations A-27
Freeze Point: CrudeManager Indexing Method
FIB i = exp ( 2.35 + 0.03638 × FI i )
(A.42)
FI = ( Ln ( FIB ) – 2.35 ) ⁄ 0.03638 where: FIi = Freeze Point of component i in F FIBi = Freeze Point Index for component i FI = Freeze Point of stream in F
Formaldehyde (toxic emission) Toxic emissions from Formaldehyde11 is calculated using the following equations: Form B (T – B ) (T – B ) - ( 0.444e 1 1 + 0.556e 2 2 ) ToxEmi Form = ---------------6 10
(A.43)
where: T 1 = – 0.010226 ( E300 T ) – 0.007166 ( Arom T ) + 0.0462131 ( MTBE T ) B 1 = – 0.010226 ( E300 B ) – 0.007166 ( Arom B ) + 0.0462131 ( MTBE B ) T 2 = – 0.10226 ( E300 T ) – 0.007166 ( Arom T ) + 0.0462131 ( MTBE T ) – 0.031352 ( Olef T ) B 2 = – 0.10226 ( E300 B ) – 0.007166 ( Arom B ) + 0.0462131 ( MTBE B ) – 0.031352 ( Olef B ) AromT = aromatics content, range 0 to 50 OlefT = olefins content, range 0 to 25 MTBET =
∑ 34.7 ( Mass of componenti ) i
FormB = 15.34 for winter, 9.7 for summer
A-27
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A-28
Petroleum Property Calculation
E300B = 83.0 for winter, 83.0 for summer AromB = 26.4 for winter, 32.0 for summer OlefB = 11.9 for winter, 9.2 for summer
Luminometer Number The Luminometer Number is calculated using the following formula: L = – 12.03 + 3.009 ( Smoke ) – 0.0104 ( Smoke )
2
(A.44)
where: L = The Luminometer Number Smoke = the smoke point in mm.
Molecular Weight The Molecular Weight is calculated using Mass Blend.
MON Clear The MON Clear is calculated using Volume Blend.
Naphthenes By Volume The Naphthenes By Volume6 is calculated using Volume Blend.
Naphthenes By Weight The Naphthenes By Weight6,16 is calculated using Mass Blend.
Ni Content The Ni Content6 is calculated using Mass Blend. A-28
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Petroleum Methods & Correlations A-29
Nitrogen Content The Nitrogen Content6 is calculated using Mass Blend.
NOx (emission) Emissions from NOx11 is calculated using the following equations: NOx B ( T1 – B1 ) ( T2 – B2 ) NOx = -------------( 0.738e + 0.262e ) 6 10
(A.45)
where: T 1 = 0.0018571 ( Oxy T ) + 0.0006921 ( Sulf T ) + 0.0090744 ( RVP T ) + 0.000931 ( E200 T ) + 0.00846 ( E300 T ) + 0.0083632 ( Arom T ) –7
2
– 0.002774 ( Olef T ) – 6.63 × 10 ( Sulf T ) – 0.000119 ( Arom T ) + 0.0003665 ( Olef T )
2
2
B 1 = 0.0018571 ( Oxy B ) + 0.0006921 ( Sulf B ) + 0.0090744 ( RVP B ) + 0.000931 ( E200 B ) + 0.00846 ( E300 B ) + 0.0083632 ( Arom B ) –7
2
– 0.002774 ( Olef B ) – 6.63 × 10 ( Sulf B ) – 0.000119 ( Arom B ) + 0.0003665 ( Olef B )
2
2
T 2 = 0.000252 ( Sulf T ) – 0.00913 ( Oxy T ) – 0.01397 ( RVP T ) + 0.000931 ( E200 T ) – 0.00401 ( E300 T ) + 0.007097 ( Arom T ) –5
2
– 0.00276 ( Olef T ) – 7.995 × 10 ( Arom T ) + 0.0003665 ( Olef T )
2
B 2 = 0.000252 ( Sulf B ) – 0.00913 ( Oxy B ) – 0.01397 ( RVP B ) + 0.000931 ( E200 B ) – 0.00401 ( E300 B ) + 0.007097 ( Arom B ) –5
2
– 0.00276 ( Olef B ) – 7.995 × 10 ( Arom B ) + 0.0003665 ( Olef B )
2
SulfT = Sulphur content, range 0 to 500 AromT = Aromatics content, range 0 to 50 OlefT = Olefins content, range 0 to 25
A-29
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A-30
Petroleum Property Calculation
OxyT = Oxy mod × mass component × 100 (For ethanol Oxymod = 0.347, MTBE Oxymod = 0.187, ETBE Oxymod = 0.157, and TAME Oxymod = 0.157) RVPT = 8.7 for winter, RVP × 0.145 for summer If you do not specify a Reid Vapor Pressure value, Aspen HYSYS Petroleum Refining automatically use 8.7 (the Winter value). NOxB = 1540.0 for winter, 1340.0 for summer RVPB = 8.7 OxyB = 0.0 SulfB = 338.0 for winter, 339.0 for summer E200B = 50.0 for winter, 41.0 for summer E300B = 83.0 AromB = 26.4 for winter, 32.0 for summer OlefB = 11.9 for winter, 9.2 for summer
Olefins By Volume The Olefins By Volume is calculated using Volume Blend.
Olefins By Weight The Olefins By Weight3 is calculated using Mass Blend.
Paraffins By Volume The Paraffins By Volume6 is calculated using Volume Blend.
Paraffins By Weight The Paraffins By Weight3,16 is calculated using Mass Blend.
A-30
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Petroleum Methods & Correlations A-31
Polycyclic (toxic emission) Toxic emissions from Polycyclic11 is calculated using the following equations: Poly B T –B T –B - ( 0.444e 1 1 + 0.556e 2 2 ) ToxEmi Poly = -------------6 10
(A.46)
where: T 1 = 0.0005219 ( Sulf T ) – 0.0003641 ( Oxy T ) + 0.0289749 ( RVP T ) 2
+ 0.01447 ( E200 T ) + 0.0001072 ( E200 T ) – 0.068624 ( E300 T ) 2
+ 0.0004087 ( E300 T ) + 0.0323712 ( Arom T ) – 0.002858 ( Olef T ) – 0.0003481 ( Arom T × E300 T ) B 1 = 0.0005219 ( Sulf B ) – 0.0003641 ( Oxy B ) + 0.0289749 ( RVP B ) 2
– 0.01447 ( E200 B ) + 0.0001072 ( E200 B ) – 0.068624 ( E300 B ) 2
+ 0.0004087 ( E300 B ) + 0.0323712 ( Arom B ) – 0.002858 ( Olef B ) – 0.0003481 ( Arom B × E300 B ) T 2 = 0.043295 ( RVP T ) – 0.003626 ( Oxy T ) – 0.000054 ( Sulf T ) – 0.013504 ( E200 T ) – 0.062327 ( E300 T ) + 0.0282042 ( Arom T ) 2
– 0.002858 ( Olef T ) + 0.000106 ( E200 T ) + 0.000408 ( E300 T )
2
– 0.000287 ( Arom T × E300 T ) B 2 = 0.043295 ( RVP B ) – 0.003626 ( Oxy B ) – 0.000054 ( Sulf B ) – 0.013504 ( E200 B ) – 0.062327 ( E300 B ) + 0.0282042 ( Arom B ) 2
– 0.002858 ( Olef B ) + 0.000106 ( E200 B ) + 0.000408 ( E300 B )
2
– 0.000287 ( Arom B × E300 B ) SulfT = sulfur content, range 0 to 500 AromT = aromatics content, range 0 to 50 OlefT = olefins content, range 0 to 25 OxyT =
∑ 34.7 ( Mass of componenti ) i
RVP T = Reid Vapor Pressure × 0.145
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A-32
Petroleum Property Calculation
PolyB = 4.5 for winter, 3.04 for summer SulfB = 338.0 for winter, 339.0 for summer RVPB = 11.5 for winter, 8.7 for summer E200B = 50.0 for winter, 41.0 for summer E300B = 83.0 AromB = 26.4 for winter, 32.0 for summer OlefB = 11.9 for winter, 9.2 for summer OxyB = 0.0
Pour Point The Pour Point6,16 of a stream may be calculated using either of two methods: Method 1 (Default)
PPidx = Σ ( Vol i × ( exp ( 73.0883 + 12.885 × log ( PP i × 1.8 ) ) ) PPidx – 73.0883⎞ ⎛ log ------------------------------------------------⎝ ⎠ 12.885 PP = exp ------------------------------------------------------1.8
(A.47)
(A.48)
where: PPidx = Pour Point index Voli = Volume Fraction of component i PPi = Pour point of component i in K PP = Pour point of component i in K
Method 2.
PPidx = Vol i × exp ( PP i × 0.03 )
(A.49)
( PPidx )PP = log ---------------------------0.03
(A.50)
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Petroleum Methods & Correlations A-33
where: PPi = Pour Point of component i in F Voli = Volume Fraction of component i PPidx = Pour point index PP = Pour point of stream in F
Refractive Index The Refractive Index13 is calculated using Volume Blend
Reid Vapor Pressure (RVP) For Flash at 37.5°C, RVP is assumed to be the saturation pressure.
RVP Blending1,3,8,14,15 is calculated using the following equations: pow ( ∑ V i × RVP i ,0.8 ) RVPB = --------------------------------------------------------0.145
(A.51)
RVPI i = pow ( [ RVP i × 0.145 ] ,1.25 )
(A.52)
where: RVPi = RVP of individual components in kPa RVPIi = RVP index of individual components in kPa Vi = Volume fraction of individual components RVPBi = RVP of the blended component i
As a backup, RVP calculations reference the API 5B1.1 method
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A-34
Petroleum Property Calculation
RON Clear The RON Clear6 may be calculated using the following methods: RON Clear: Indexing Method RON - Index (RONidxi) is calculated from following equation: RONidx i = a + b ( RON iC )
(A.53)
The values of parameters a, b and c are dependent upon the value of RONi. RONidx blends by volume and the RON of the blend are calculated using the following reverse formula:
RON = exp (d,Log ( RONidx – e ) ÷ f)
(A.54)
The values of parameters d, e and f are dependent upon the value of RONidx. where: RONi = RON of component i RONidxi = RON Index for component i RON = RON of blend RONidx = RON Index for blend a, b, c, d, e and f = Parameters
RON Clear: see Volume Blend RON Clear: see Healy Method for RON and MON.
RON Leaded The RON Leaded is calculated using Volume Blend.
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Petroleum Methods & Correlations A-35
SG (60/60F) The SG (60/60°F)7 is calculated using Volume Blend.
Smoke Point The Smoke Point2 is calculated using the following blend index:i 1 SPidx = Σ ⎛ Vol i × ⎛ -------- ⎞ ⎞ ⎝ ⎝ SP i ⎠ ⎠
(A.55)
1 SP = -------------SPidx
(A.56)
where: SPi =Smoke Point of Component i Voli =Liquid Volume Fraction of Component i SPidx = Smoke Point Index of Stream SP = Smoke Point of Stream
Standard Liquid Density Standard Liquid Density is calculated using following equation:
moleFrac i × MW i SLD = Σ ( moleFrac i × MW i ) ÷ Σ ⎛ ---------------------------------------------⎞ ⎝ ⎠ Den i
(A.57)
where: moleFraci = Mole Fraction of component i A-35
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A-36
Petroleum Property Calculation
MWi = Molecular Weight of component i Deni = Density of component i in kg/m3 SLD = Standard liquid density of stream in kg/m3
Sulfur Content Sulfur Content12 is calculated using Mass Blend.
Total Toxic Emission Total toxic emission11 is calculated using the following equation: ToxEmi Total = ToxEmi NonExBenz + ToxEmi Poly + ToxEmi But + ToxEmi Acet + ToxEmi Form + ToxEmi ExBenz
(A.58)
where: ToxEmiNonExBenz = toxic emission from non-exhaust Benzene, see Equation (A.22) ToxEmiPoly = toxic emission from Polycyclic, see Equation (A.46) ToxEmiBut = toxic emission from Butadiene, see Equation (A.23) ToxEmiAcet = toxic emission from Acetaldehyde, see Equation (A.20) ToxEmiForm = toxic emission from Formaldehyde, see Equation (A.43) ToxEmiExBenz = toxic emission from exhaust Benzene, see Equation (A.21)
Vanadium Content Vanadium Content6 is calculated using Mass Blend.
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Petroleum Methods & Correlations A-37
Viscosity Viscosity is calculated using standard HYSYS methods. (See The Aspen HySYS Simulation Basis Reference Guide)
VOC (exhaust) Exhaust from VOC11 is calculated using the following equations: ExVOC B ( T 1 – B1 ) ( T 2 – B2 ) ( 0.444e + 0.556e ) ExVOC = ---------------------6 10
(A.59)
where: T 1 = 0.0005219 ( Sulf T ) – 0.0003641 ( Oxy T ) + 0.0289749 ( RVP T ) 2
+ 0.01447 ( E200 T ) + 0.0001072 ( E200 T ) – 0.068624 ( E300 T ) 2
+ 0.0004087 ( E300 T ) + 0.0323712 ( Arom T ) – 0.002858 ( Olef T ) – 0.0003481 ( Arom T × E300 T ) B 1 = 0.0005219 ( Sulf B ) – 0.0003641 ( Oxy B ) + 0.0289749 ( RVP B ) 2
– 0.01447 ( E200 B ) + 0.0001072 ( E200 B ) – 0.068624 ( E300 B ) 2
+ 0.0004087 ( E300 B ) + 0.0323712 ( Arom B ) – 0.002858 ( Olef B ) – 0.0003481 ( Arom B × E300 B ) T 2 = 0.043295 ( RVP T ) – 0.003626 ( Oxy T ) – 0.000054 ( Sulf T ) – 0.013504 ( E200 T ) – 0.062327 ( E300 T ) + 0.0282042 ( Arom T ) 2
– 0.002858 ( Olef T ) + 0.000106 ( E200 T ) + 0.000408 ( E300 T )
2
– 0.000287 ( Arom T × E300 T ) B 2 = 0.043295 ( RVP B ) – 0.003626 ( Oxy B ) – 0.000054 ( Sulf b ) – 0.013504 ( E200 B ) – 0.062327 ( E300 B ) + 0.0282042 ( Arom B ) 2
– 0.002858 ( Olef B ) + 0.000106 ( E200 B ) + 0.000408 ( E300 B )
2
– 0.000287 ( Arom B × E300 B ) SulfT = Sulphur content, range 0 to 500 AromT = Aromatics content, range 0 to 50 OlefT = Olefins content, range 0 to 25
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A-38
Petroleum Property Calculation
OxyT = Oxy mod × mass component × 100 (For ethanol Oxymod = 0.347, MTBE Oxymod = 0.187, ETBE Oxymod = 0.157, and TAME Oxymod = 0.157) E200 T ≤ 65.52 E300 T ≤ 79.75 + 0.385 ( Arom T ) RVPT = 8.7 for winter, RVP × 0.145 for summer If you do not specify a Reid Vapor Pressure value, Aspen HYSYS Petroleum Refining automatically use 8.7 (the Winter value). ExVOCB = 1341.0 for winter, 907.0 for summer RVPB = 8.7 OxyB = 0.0 SulfB = 338.0 for winter, 339.0 for summer E200B = 50.0 for winter, 41.0 for summer E300B = 83.0 AromB = 26.4 for winter, 32.0 for summer OlefB = 11.9 for winter, 9.2 for summer
VOC (total non-exhaust) Total non-exhaust from VOC11 is calculated using the following equations:
NonExVOC total = VOC HotS + VOC Diu + VOC RunLos + VOC Reful
(A.60)
where: RVP T = Reid Vapor Pressure × 0.145 RVP 2 = ( RVP T )
2
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Petroleum Methods & Correlations A-39
Region 1: 0.031807 ( RVP 2 ) – 0.3568833 ( RVP T ) + 1.226859 NonExVOC total = ------------------------------------------------------------------------------------------------------------------------1000 [ 0.006654 ( RVP 2 ) – 0.08009 ( RVP T ) + 0.2846 ] VOC HotS = -----------------------------------------------------------------------------------------------------------------1000 [ 0.007385 ( RVP 2 ) – 0.08981 ( RVP T ) + 0.3158 ] VOC Diu = -----------------------------------------------------------------------------------------------------------------1000 [ 0.017768 ( RVP2 ) – 0.18746 ( RVP T ) + 0.6146 ] VOC RunLos = -----------------------------------------------------------------------------------------------------------------1000 [ 0.0004767 ( RVP T ) + 0.011859 ] VOC Reful = -----------------------------------------------------------------------------1000 Region 2: 0.027022 ( RVP 2 ) – 0.300753 ( RVP T ) + 1.063329 NonExVOC total = ---------------------------------------------------------------------------------------------------------------------1000 [ 0.006078 ( RVP 2 ) – 0.07474 ( RVP T ) + 0.27117 ] VOC HotS = --------------------------------------------------------------------------------------------------------------------1000 [ 0.004775 ( RVP 2 ) – 0.05872 ( RVP T ) + 0.21306 ] VOC Diu = --------------------------------------------------------------------------------------------------------------------1000 [ 0.016169 ( RVP2 ) – 0.17206 ( RVP T ) + 0.56724 ] VOC RunLos = --------------------------------------------------------------------------------------------------------------------1000 [ 0.004767 ( RVP T ) + 0.011859 ] VOC Reful = --------------------------------------------------------------------------1000
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A-40
Comma Separated Value Files
VOC (total) Total VOC11 is calculated using the following equations: VOC total = ExVOC + NonExVOC total (for Summer)
(A.61)
= ExVOC (for Winter)
Wax Content The Wax Content6 is calculated using Mass Blend.
A.4 Comma Separated Value Files Comma Separated Values (CSV) files are simple structured data files. The files contain a table of components, and the component’s molecular weight, normal boiling point, specific gravity, and petroleum properties. The data in the file can be accessed through Microsoft Excel application. Aspen HYSYS Petroleum Refining uses CSV files to contain petroleum properties of individual assays.
A.4.1 Format of CSV Files For Aspen HYSYS Petroleum Refining to properly read and interpret the data in a CSV file, there are some simple format rules that need to be followed. These include the correct format, precise spelling of component names, and the required units for the properties. The following describes the general layout of a .csv file for an assay: The first three lines of csv assay file contain name and date information related to the file. For example:
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Petroleum Methods & Correlations A-41
Name,Assay-4 Created,19/07/2007 10:59:07 Modified,19/07/2007 11:00:03
The fourth row defines the table heading. The first column has the heading Cpt (Component), followed by the property names listed in sequence, separated by commas. The remaining rows contain the corresponding component names and property values in sequence, separated by commas: Methane,n1,n2,n3,n4,etc,etc.
The correct case and spelling of the properties are required for Aspen HYSYS Petroleum Refining to properly import the assay values. Any change in spelling results in Aspen HYSYS Petroleum Refining reading the in properties as user properties, and the property values will be displayed in the UserProp column, instead of in the correct property name column. Below are the proper designations for Aspen HYSYS Petroleum Refining properties: Acidity, Aniline Point, Aromatics By Volume, Aromatics By Weight, Asphaltene Content, Basic Nitrogen Content, Boiling Temperature, C to H Ratio, C5 Mass, C5 Vol, Cloud Point, Conradson Carbon Content, Copper Content, Copper/Iron Content, Flash Point, Freeze Point, Mercaptan Sulfur Content, Molecular Weight, MON (Clear), MON (Leaded), Naphthenes By Volume, Naphthenes By Weight, Nickel Content, Nitrogen Content, Olefins By Volume, Olefins By Weight, Paraffins By Volume, Paraffins By Weight, Pour Point, Refractive Index, Reid Vapour Pressure, RON (Clear), RON (Leaded), Smoke Point, Sodium Content, Standard Liquid Density, Sulfur Content, True Vapour Pressure, Vanadium Content, Wax Content, Viscosity @ 50C, Benzene Content By Volume, Benzene Content By Weight, Toluene Content By Weight, Toluene Content By Volume, Isoparaffin By Weight and Isoparaffin By Volume.
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A-42
Comma Separated Value Files
Property Units in CSV Files The table below displays some of the properties in the Comma Separated Valued (CSV) file and their corresponding units: Property
Unit
Acidity
Wt/Wt
Aniline Point
Kelvin
Aromatics by Volume
Vol %
Aromatics by Weight
Weight %
Asphaltene Content
Weight %
Boiling Temperature
Kelvin
C to H Ratio
No Units
Centroid Boiling Temperature
Kelvin
Cloud Point
Kelvin
Composition
Mole Fraction
Conradson Carbon Content
Weight %
Copper Content
ppmWt
Copper/Iron Content
ppmWt
Flash Point
Kelvin
Freeze Point
Kelvin
Iron Content
ppmWt
IsoParaffins by Volume
Volume %
Luminometer Number
No Units
Mercaptan Sulfur Content
Weight %
Molecular Weight
No Units
MON (Clear)
No Units. Octane Number
MON (Leaded)
No Units
Naphthenes by Volume
Volume %
Naphthenes by Weight
Weight %
Nickel Content
ppmWt
Nitrogen Content
ppmWt
Olefins by Volume
Volume %
Olefins by Weight
Weight %
Paraffins by Volume
Volume %
Paraffins by Weight
Weight %
Pour Point
Kelvin
Refractive Index
No Units
Reid Vapor Pressure
Kilo Pascal (kPa)
RON (Clear)
No Units
RON (Leaded)
No Units A-42
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Petroleum Methods & Correlations A-43
Property
Unit
Smoke Point
Millimeters
Sodium Content
Weight %
Standard Liquid Density
Kg/m3
Sulfur Content
Weight %
True Vapor Pressure
Kilo Pascal (kPa)
Vanadium Content
ppmWt
Viscosity @ 100°C
CentiStokes (cSt)
Viscosity @ 50°C
CentiStokes (cSt)
Wax Content
Weight %
You must use the correct/required units while specifying the property values in the CSV file for Aspen HYSYS Petroleum Refining to interpret the values correctly.
Aspen HYSYS Petroleum Refining imports the following information from the CSV file: • •
•
List of components. Three critical physical properties: molecular weight, centroid boiling point, and specific gravity. The rest of the physical properties are calculated based on the three critical properties. All petroleum properties.
A-43
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A-44
Petroleum Assay XML Files
A.5 Petroleum Assay XML Files The following figure displays the structure of an XML file containing petroleum assay data. Figure A.2
The XML file can contain the exact same information as the CSV file. The XML file contains the name of the petroleum assay, description, created date, last modified date, a list of components available, and the molecular weight, normal boiling point, specific gravity, and petroleum properties of each component. Aspen HYSYS Petroleum Refining imports the following information from the XML file: •
List of components.
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Petroleum Methods & Correlations A-45
•
•
Three critical physical properties: molecular weight, centroid boiling point, and specific gravity. The rest of the physical properties are calculated based on the three critical properties. All petroleum properties.
If the petroleum assay data file contains petroleum properties outside Aspen HYSYS Petroleum Refining petroleum property list, Aspen HYSYS Petroleum Refining imports the data from the non-default petroleum properties and designate the non-default petroleum properties as UserProp-n, where n is an integer value. If the petroleum assay data file does not have values for a petroleum property, Aspen HYSYS Petroleum Refining leaves the petroleum property blank.
The difference is the data provided by the XML file is stored into branches of a tree browser. There are four levels or branches in a typical petroleum assay XML file. • • • •
File version File type Crude and component information Individual component properties
The information in the XML file is presented in three colors: • Blue indicates the code used by the XML. • Red indicates the displayed variables. • Black indicates the value that can be modified.
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A-46
Petroleum Assay XML Files
A.5.1 File Versions The first level branch of the petroleum assay XML file displays the file version, as shown in the figure below. Figure A.3
You have to click the Plus icon to expand the Version branch to view the second level branch.
A.5.2 File Types The second level branch of the petroleum assay XML file displays the file type, that indicates whether the file was created, exported, imported, and so on. Figure A.4
You have to click the Plus icon view the third level branch.
to expand the Type branch to
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Petroleum Methods & Correlations A-47
A.5.3 Crude and Component Information The third level branch of the petroleum assay XML file displays the following: • • • • •
Name of the petroleum assay Description of the petroleum assay Date of when the petroleum assay was created Date of when the petroleum assay was last modified List of components in the petroleum assay
Figure A.5
You have to click the Plus icon to expand the Crude and Component branch to view the information in each branch. In the Component branch, each individual component has a Y or N value for the active state.
• •
The Y indicates the component is being used in the petroleum assay. The N indicates the component is not being used in the petroleum assay.
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A-48
Petroleum Assay XML Files
In the Component branch, the list of components are split into two types: •
•
Library components. These are the standard and default components provided by Aspen HYSYS Petroleum Refining. Each library component branch contains the name of the component and indicator on active state. Hypothetical components. These are the non-standard crude oil components. Each hypothetical component branch contains the name of the component, indicator on active state, indicator on the component type (in other words, is it a hypocomponent? Yes or No), final boiling point temperature (in Kelvin), and initial boiling point temperature.
A.5.4 Individual Component Information The forth level branch displays all the physical and petroleum properties of each individual component. Figure A.6
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Petroleum Methods & Correlations A-49
You have to click the Plus icon to expand the Individual Component branch to view the property information in each branch. Each Property branch contains the name of the property and the property may or may not have a value. You can specify or modify the value of a property by clicking in between the two quotation marks and typing in the new value.
A.6 PET Files The HYSYS petroleum assay file (*.pet) contains the same information as the CSV or XML file, in addition the *.pet file also contains information about the fluid packages, reactions, and component maps associated to the petroleum assay. In other words, the .pet file contains all the information located in the Simulation Basis Manager view. Figure A.7
Aspen HYSYS Petroleum Refining imports all the following information from the PET file: • •
List of components. Three critical physical properties: molecular weight, centroid boiling point, and specific gravity. The rest of the physical properties are calculated based on the three critical properties. A-49
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A-50
PET Files
•
All petroleum properties.
HYSYS User Property Aliases for Aspen HYSYS Petroleum Refining When you import a HYSYS assay into Aspen HYSYS Petroleum Refining, the user properties defined in the HYSYS oil environment should be transferred to their corresponding Aspen HYSYS Petroleum Refining properties. However, because HYSYS names are limited to 12 characters, they will frequently not match their corresponding Aspen HYSYS Petroleum Refining names, which may be longer. As a workaround for this, Aspen HYSYS Petroleum Refining is set up to recognize certain under-12 character property names from HYSYS, and to pass their values to the correct Aspen HYSYS Petroleum Refining property names. After the HYSYS assay import, you should rename the HYSYS user properties using the aliases shown below, so their values will be applied to their associated Aspen HYSYS Petroleum Refining properties. The table lists the Aspen HYSYS Petroleum Refining user property names on the left, and the associated aliases on the right. When the HYSYS user property is renamed using the alias, and the assay is recalculated, the imported HYSYS properties are applied to the correct Aspen HYSYS Petroleum Refining property names. Target Aspen HYSYS Petroleum Refining Property
Use this HYSYS Alias
Acidity
Acidity W
Aniline Point
Aniline Pt
Assay - Aromatics Vol Pct
Aromatics V
Assay - Aromatics Wt Pct
Aromatics W
Asphaltene Content
Asphaltene
Basic Nitrogen Content
Basic N2
C to H Ratio
C/H Ratio
Cloud Point
Cloud Pt
A-50
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Petroleum Methods & Correlations A-51
Target Aspen HYSYS Petroleum Refining Property
Use this HYSYS Alias
Conradson Carbon Content
Conradson C
Copper Content
Copper
Cetane Number
Cetane No
Flash Point
Flash Pt
Freeze Point
Freeze Pt
MON (Clear)
MON-Clear
MON (Leaded)
MON-Leaded
Assay - Naphthenes Vol Pct
Naphthene V
Assay - Naphthenes Wt Pct
Naphthene W
Nickel Content
Nickel
Nitrogen Content
Nitrogen
Assay - Olefins Vol Pct
Olefins V
Assay - Olefins Wt Pct
Olefins W
Assay - Paraffins Vol Pct
Paraffins V
Assay - Paraffins Wt Pct
Paraffins W
Pour Point
Pour Pt
Refractive Index
Ref Idx
Reid Vapour Pressure
RVP
RON (Clear)
RON-Clear
RON (Leaded)
RON-Leaded
Smoke Point
Smoke Point
Sulfur Content
Sulfur
Mercaptan Sulfur Content
Mercaptan S
Sodium Content
Na
True Vapour Pressure
TVP
Vanadium Content
Vanadium
Iron Content
Iron
Luminometer Number
Lumino No
C5 Mass
C5 W
C5 Vol
C5 V
Viscosity @ 38C
Visc @ 38C
Viscosity @ 50C
Visc @ 50C
Viscosity @ 60C
Visc @ 60C
Viscosity @ 100C
Visc @ 100C
Wax Content
Wax
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A-52
Spiral Files
A.7 Spiral Files The Spiral file contains the exact same information as the CSV and XML file. The only difference is that the format and layout of the information is structured so the information can be read by the Crude Manager software. Refer to the Crude Manager help system for more information. Aspen HYSYS Petroleum Refining imports the following information from the Spiral file: • •
•
List of components. Three critical physical properties: molecular weight, centroid boiling point, and specific gravity. The rest of the physical properties are calculated based on the three critical properties. All petroleum properties.
A.8 References 1
“31.0 API Iranian Heavy Crude Oil”, Chevron Oil Trading Company, 1971.
2
Albahri, T.A., Riazi, M.R., and Algattan, A.A., 2003, “Analysis of Quality of Petroleum Fuels”, Energy & Fuels, Vol. 17, No. 3, pp. 689-693.
3
Aspen Physical Property System 12.1 Physical Property Data, AspenTech Support, Aspen Technology Inc., viewed: 21 April 2006, http://support.aspentech.com/CustomerSupport/Documents/ Engineering/AES%2012.1%20Product%20Documentation/ AprSystem%2012.1/ APRSYS%20121%20Physical%20Property%20Data.pdf
4
Auckland, M.H.T., and Charnock, D.J., “The Development of Linear Blending Indices for Petroleum Properties”, J. Institute Petroleum, Vol. 55, No. 545 (September 1969), pp. 322-329.
5
Baird, Cud Thomas IV, 1989, Guide to Petroleum Product Blending, HPI Consultants Inc., Texas.
6
Crude Name: Sample Assay PTI Assay IF: SMP.01.2002, 2003, Specializing In Crude Assay Information, PetroTech intel, viewed: 21 April 2006, http://www.petrotechintel.com/pti.data/ components/std_assay.pdf
A-52
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Petroleum Methods & Correlations A-53
7
DIADEM 2004, version 2.3.0, DIPPR Information and Data Evaluation Manager for the Design Institute for Physical Properties, BYU DIPPR Lab, e-mail: [email protected].
8
Fasullo, P.A., “Rvp Reductions Would Harm U.S. Gas-Processing Industry”, Oil Gas Journal, Vol. 86, No. 5 (February 1, 1988), pp. 51-56.
9
Healy, W.C., Maassen, C.W., and Peterson, R.T., “A New Approach to Blending Octanes”. API Midyear Meeting, Division of Refining, New York (May 27, 1959).
10
Hu, J., and Burns, A.B., “New Method Predicts Cloud, Pour, Flash Points of Distillate Blends”, Hydrocarbon Processing, Vol. 49, No. 11 (November 1970), pp. 213-216.
11Regulation
of Fuels and Fuel Additives, 2001 CFR Title 29, Volume 8, National Archives and Records Administration, Code of Federal Regulations,viewed: 21 April 2006, http://www.access.gpo.gov/ nara/cfr/waisidx_01/40cfr80_o1.html
12
Riazi, M.R., Nasimi, N., and Roomi, Y.A., 1999, “Estimation of Sulfur Content of Petroleum Products and Crude Oils”, Ind. Eng. Chem. Res., Vol. 38, no. 11, pp. 4507-4512
13Riazi,
Mohammad R., and Roomi, Yousef A., 2001, “Use of Refractive Index in the Estimation of Thermophysical Properties of Hydrocarbons and Petroleum Mixtures:, Ind. Eng. Chem. Res., Vol. 40, No. 8, pp. 1975-1984
14Stewart,
W.E., “More About Figuring RVP of Blends”, Petroleum Refiner, Vol. 40, No. 10 (October 1960), p. 109.
15
Stewart, W. E., “Predict RVP of Blends Accurately”, Petroleum Refiner, Vol. 38, No. 6 (June 1959), p. 231.
16
Strategic Petroleum Reserve Crude Oil Assay Manual, 2nd ed., Strategic Petroleum Reserve Crude Oil Assays, U.S. Department of Energy, Assistant Secretary for Fossil Energy Strategic Petroleum Reserve Headquarters, viewed: 21 April 2006, http:// www.spr.doe.gov/reports/docs/crudeoilassaymanual.pdf
17
Technical Data Book: Petroleum Refining, American Petroleum Institute, Vol 1 - III, May 1985.
18
R.O.Wickey, D.H. Chittenden, Hydrocarbon Processing, 42, 6, 1963, 157-158.
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A-54
References
A-54
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Index A assay curves 6-47 Assay Manipulator 3-2 add 3-3 assay tab 3-6 change props page 3-7 composition page 3-9 connections page 3-4 create 3-3 design tab 3-4 notes page 3-5 options page 3-6 parameters page 3-5 property view 3-3 shift props page 3-8 user variables page 3-5 worksheet tab 3-10 B Blend centroid boiling point A-3 heat of formation A-4 liquid density A-4 molecular weight A-3 physical properties A-2 specific gravity A-4 Blending Macros 2-18 Blending Rules 2-6 user define 2-17 Blends Healy method A-8 mass A-6 mole A-6 MON A-8 RON A-8 volume A-7 C Calibration advanced options 4-102 catalyst 4-98 catalyst results 4-118 catalyst weight 4-104 coke laydown 4-104 configure reactor 4-92 control variables 4-107 data set 4-87 design reactor 4-91
feed blend results 4-115 feed condition 4-96 feed data 4-94 feed properties 4-95 feed type 4-94 heater temperatures 4-106 initial parameter value 4-107 manage data set 4-87, 4-91 objective function 4-108 operation measurement 4-103 operation variables 4-95 overall results 4-121 parameter 4-107 pinning percent 4-104 product property results 4-110 product yield results 4-116 property view 4-86 reactor control 4-97 reactor geometry 4-93 reactor pressure 4-105 reactor results 4-117 recontactor 4-98 recontactor results 4-119 results 4-109 run 4-87 select data set 4-88 sigma values 4-108 solver commands 4-102 solver console 4-102 solver options 4-101 solver scripts 4-102 summary results 4-120 validation wizard 4-89 Calibration Set Library add set 4-82, 5-64 clone set 4-82, 5-64 delete set 4-82, 5-64 edit set 4-81, 5-63 export set 4-82, 5-64 import set 4-82, 5-64 property view 4-81, 5-63 Catalytic Reformer 4-3 add 4-19 advanced options 4-43 calibration 4-23, 4-86 calibration environment 4-23 calibration factor set 4-81 calibration factors page 4-31 calibration run 4-23, 4-87
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catalyst 4-36 catalyst activity model 4-13 catalyst results 4-54 catalytic reformer environment 4-21 coke make model 4-11 components 4-6 configure reactor 4-59 connections page 4-30 create 4-19 deactivate catalyst 4-9 delete 4-20 design 4-30 environments 4-16 export calibration factors to file 4-111 factor set 4-82 feed 4-33 feed blend results 4-48 feed characterization 4-4 feed type library 4-56 feed type property view 4-80 fractionator 4-44 fractionator specs 4-45 main environment 4-17 modify calibration factor set 4-112 notes page 4-32 product property results 4-52 product yield results 4-49 property view 4-29 push calibration factors to simulation 4111 reaction expressions 4-9 reaction paths 4-7 reactor control 4-34 reactor design 4-59 reactor feed 4-61 reactor feed condition 4-65 reactor feed properties 4-63 reactor feed type 4-62 reactor geometry 4-60 reactor operation 4-64 reactor results 4-53 reactor section 4-33, 4-58 reactor temperature control 4-15 recontactor 4-38 recontactor results 4-54 reformer configuration wizard 4-24 results 4-47 solve commands 4-42 solver console 4-42
solver options 4-40 solver scripts 4-42 summary results 4-47 system pressure control 4-14 template 4-18 theory 4-6 zone pressure 4-45 Characterized GC Data Results property view 2-40 Comma Separated Value File See CSV File component level Aniline Point A-9 aromatics A-9 asphaltene A-9 basic nitrogen A-9 C to H ratio A-9 Cloud Point A-10 Conradson carbon A-10 copper A-10 Cu/Fe A-10 Flash Point A-11 Freeze Point A-11 molecular weight A-11 MON Clear A-12 naphthenes A-12 Ni A-12 Nitrogen A-12 olefins A-12 paraffins A-12–A-13 Pour Point A-13 refractive index A-13 Reid Vapor Pressure A-14 RON Clear A-14 RON Leaded A-14 rvp A-14 sg A-15 Smoke Point A-15 specific gravity A-15 sulfur A-15 vanadium A-15 viscosity A-15 wax content A-16 CSV File A-41 format A-41 layout A-41 property units A-43 D Data Control
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property view 6-48 Data Set Manager add data set 4-91 clone data set 4-91 delete data set 4-91 property view 4-87, 4-91 rename data set 4-91 Delta Base Utility 10-3 add 10-3 create 10-3 data layout in HYSYS format 10-11 data layout in PIMS format 10-6 delete 10-4 dependent variables 10-10, 10-15 derivative analysis tab 10-6 derivative equations 10-22 derivative values 10-20 edit 10-4 export derivatives 10-23 independent variables 10-8, 10-12 property view 10-5 proxy variables 10-9, 10-13 scope objects 10-19 select variable 10-16 target objects 10-18 variables tab 10-11 E Edit Bulk Properties property view 2-23 Edit Property Distribution Parameters property view 2-39 Editing Properties property view 2-24 F Factor Set fractionator page 5-66 property view 4-82, 5-64 reactor page 5-66 Flowsheet Menu notes manager 1-9 H HCR Configuration Wizard 5-23 calibration factors 5-27 configuration 5-24 geometry 5-26 HCR Reactor Section
catalyst deactivation page 5-55 configuration page 5-49 design tab 5-49 feed blend page 5-59 feed data tab 5-51 feeds page 5-54 geometry page 5-50 hydrogen balance page 5-62 hydrogen system page 5-61 library page 5-51 notes page 5-50 operation tab 5-53 product properties page 5-60 product yields page 5-60 properties page 5-52 property view 5-48 reactor page 5-61 recycle gas loop page 5-55 results tab 5-59 solver console page 5-58 solver options page 5-56 specifications page 5-54 Hydrocracker 5-3 add 5-19 calibration factor set 5-22 Calibration Set Library 5-63 catalyst deactivation page 5-35 components 5-6 connections page 5-29 create 5-19 deactivation of catalyst 5-16 delete 5-20 design tab 5-29 environments 5-17 Factor Set 5-64 feed blend page 5-41 feed characterization 5-3 feed page 5-32 feed type library 5-46 fractionator page 5-45 fractionator tab 5-39 HCR configuration wizard 5-23 HCR environment 5-21 HCR reactor section 5-48 hydrogen balance page 5-46 hydrogen system page 5-44 main environment 5-18 notes page 5-31 product properties page 5-43
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product yields page 5-42 property view 5-20, 5-28 reaction kinetic expression 5-14 reaction kinetics 5-6 reaction paths 5-11 reactor page 5-44 reactor section tab 5-31 reactor temperature control 5-16 recycle gas loop page 5-34 Results 5-67 results tab 5-41 solver console page 5-38 solver options page 5-36 specification page 5-34 specs page 5-39 system pressure control 5-16 template 5-18 tuning factors page 5-30 zone pressures page 5-39 I Input Experts 6-13 connections page 6-13 side stripper page 6-14 specs page 6-19 zone page 6-18 Input Stream Base Yield property view 8-11 N Notes add 1-8 Notes Manager 1-9 add 1-9 edit 1-9 search 1-10 view 1-9 Notes page 1-7 Notes tab 1-7 O Optimization Object property view 9-26 P PET file A-50 Petroelum Assay Composition property view 2-26
Petroleum Assay add 2-7 analysis tab 2-41 blending rules 2-17 centroid point 2-4 composition 2-26 copy 2-8 create 2-7 delete 2-8 edit 2-7 edit properties 2-24 estimation tab 2-42 export 2-15 gas chromatography 2-34 GC data results 2-40 gc data tab 2-34 import 2-9 Haverly H/CAMS 2-13 PIMS 2-11 import HYSYS assays 2-27 information tab 2-22 notes tab 2-44 plots tab 2-44 PONA tree diagram 2-36 property view 2-20 remove 2-8 summary information 2-22 view 2-7 Petroleum Assay Manager property view 2-5 Petroleum Assay Utility 10-23 add 10-24 boiling curves page 10-28 connections page 10-26 create 10-24 delete 10-25 design tab 10-25 dynamics tab 10-30 edit 10-25 plots page 10-29 properties page 10-29 results tab 10-28 Petroleum Assays 2-2 csv file 2-10, 2-16 PET file 2-9 pet file 2-16 Spiral file 2-16 xml file 2-10, 2-16 Petroleum Assays Utility
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notes page 10-27 Petroleum Column 6-2 add 6-12 auto reset 6-36 calibration tab 6-53 column profiles page 6-39 condenser handling 6-7 configuration 6-22 connections page 6-22 conventions 6-3 convergence 6-21 convergence results 6-37 create 6-12 cumulative plots 6-51 design tab 6-22 energy balance page 6-41 energy page 6-56 equilibrium error 6-33 equilibrium tolerance 6-33 feed page 6-54 feed-propducts page 6-40 heat and spec error 6-34 heat tolerance 6-33 incremental plots 6-52 initialize ideal K 6-35 installation 6-12 maximum iteration 6-33 notes page 6-37 performance tab 6-37 plots 6-42 plots page 6-42 plotted results page 6-58 products page 6-55 property view 6-20 run / reset buttons 6-21 save for initial estimate 6-34 side draws page 6-29 side stripper page 6-26 solver options 6-32 solveropts page 6-32 spec tolerance 6-33 specifications 6-30 specs page 6-30 stage-by-stage method 6-8 stream detail 6-40 stream summary 6-38 summary page 6-38 super critical handling model 6-34 tabular results page 6-57
tbp cut points 6-9 theory 6-4 trace level 6-35 two liquids check 6-36 volume interchange curve 6-50 water handling 6-7 water tolerance 6-36 worksheet tab 6-37 zone page 6-24 zone-by-zone method 6-4 Petroleum Distillation Column 6-2 property view 6-20 Petroleum Feeder 7-2 add 7-2 connections page 7-4 connections tab 7-4 notes page 7-4 parameters page 7-5 parameters tab 7-5 property view 7-2 user variables tab 7-6 worksheet tab 7-6 Petroleum Properties A-5 component level A-5, A-9 Healy method A-8 mass blend A-6 mole blend A-6 MON blend A-8 RON blend A-8 stream level A-5, A-16 volume blend A-7 Petroleum Yield Shift Reactor 8-2 assay properties page 8-13 base shift page 8-12, 8-14 base yield page 8-9 conditions page 8-9 connections page 8-5 design tab 8-4 indep variables page 8-7 notes page 8-8 product flow tab 8-8 product properties tab 8-13 properties page 8-15 property view 8-3 reactor params page 8-6 tbp curves page 8-16 theory 8-2 user variables page 8-8 worksheet tab 8-17
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Prediction advanced options 4-102 catalyst 4-98 catalyst weight 4-104 coke laydown 4-104 configure reactor 4-92 design reactor 4-91 feed condition 4-96 feed data 4-94 feed properties 4-95 feed type 4-94 heater temperatures 4-106 operation measurement 4-103 operation variables 4-95 pinning percent 4-104 reactor control 4-97 reactor geometry 4-93 reactor pressure 4-105 recontactor 4-98 solver commands 4-102 solver console 4-102 solver options 4-101 solver scripts 4-102 Product Blender 9-2 add 9-5 automatic pressure assignment 9-9 connections page 9-7 connections tab 9-7 constraints configuration page 9-17 constraints inputs page 9-18 constraints results page 9-20 create 9-5 inlet flow ratios 9-8 notes page 9-7 objectives page 9-22 optimization calculation mode 9-3 optimization tab 9-10 optimizer configuration page 9-23 optimizer results page 9-25 parameters page 9-8 parameters tab 9-8 pressure 9-9 property view 9-5 simulation calculation 9-8 simulation calculation mode 9-3 switching between simulation and optimization 9-4 theory 9-3 user variables tab 9-26
variables configuration page 9-12 variables inputs page 9-13 variables results page 9-15 worksheet tab 9-26 R Reactor Section advanced options 4-72 catalyst 4-67 catalyst results 4-78 configuration 4-59 control 4-66 design 4-59 feed blend 4-74 feed condition 4-65 feed data 4-61 feed properties 4-63 feed type 4-62 geometry 4-60 notes page 4-61 operation 4-64 product properties 4-76 product yields 4-75 property view 4-58 reactor results 4-77 recontactor 4-68 recontactor results 4-78 results 4-73 solver commands 4-71 solver console 4-71 solver options 4-70 solver scripts 4-71 summary results 4-73 Refinery Column Input Experts 6-13 Aspen HYSYS Petroleum Refining common property views 1-5 utilities 10-2 Aspen HYSYS Petroleum Refining Object Palette 1-6 Aspen HYSYS Petroleum Refining Options 1-2 Results feed blend page 5-67 hydrogen balance page 5-70 hydrogen system page 5-70 product properties page 5-69 product yields page 5-68 property view 5-67 reactor page 5-69
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S Select Feed Location property view 5-33 Select Variable property view 10-16 using 10-17 Side Stripper property view 6-27 Spiral file A-52 stream level acetaldehyde toxic emission A-16 Aniline Point A-17 aromatics A-17 asphaltene A-17 basic nitrogen A-17 benzene toxic emission A-19 benzene toxic exhaust emission A-18 butadiene toxic emission A-20 C to H ratio A-21 Cetane Index 4737 A-21 Cetane index 967 A-21 Cetane Number A-22 Cloud Point A-22 Conradson carbon A-23 copper A-23 Cu/Fe A-23 DON(Clear) A-24 Driveability Index A-24 Flash Point A-24 formaldehyde toxic emission A-27 Freeze Point A-26 Hydrogen combustion A-28 Luminometer Number A-28 molecular weight A-28 MON Clear A-28 naphthenes A-29 Ni A-29 nitrogen A-29 NOx emission A-29 olefins A-30–A-31 paraffins A-31 polycyclic toxic emission A-31 Pour Point A-32 refractive index A-33 Reid Vapor Pressure A-34 RON Clear A-35 RON Leaded A-36 rvp A-34
sg A-36 Smoke Point A-36 specific gravity A-36 Standard Liquid Density A-36 sulfur A-37 total toxic emission A-37 vanadium A-37 viscosity A-38 VOC exhaust A-38 VOC total A-40 VOC total non-exhaust A-39 wax content A-41 Swing Cut Utility 10-32 add 10-32 assay table tab 10-37 create 10-32 delete 10-33 edit 10-33 export assay properties 10-33 light ends tab 10-36 pims formate tab 10-39 property calculation 10-38 select assay property 10-38 specification tab 10-34 T Target Objects property view 10-18 scoping 10-19 TBP Cut Points 6-9 Tray Section Details property view 6-24 U User Variable add 1-12 User Variables page 1-10 User Variables tab 1-10 utility delta base 10-3 petroleum assay 10-23 swing cut 10-32 W Worksheet tab 1-6 X XML file A-45
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component A-48 crude A-48 first branch A-47 forth branch A-49 individual component A-49 second branch A-47 third branch A-48 type A-47 version A-47
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