2023p4

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University of British Columbia *

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476

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Chemistry

Date

Dec 6, 2023

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pdf

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4

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1 Assignment 4 Due: Thursday, 30 November 2023, 23:59 pm Use Hysys to simulate a vacuum crude column in oil refinery. Stream Vacuum Feed is the bottom stream from an Atmospheric Crude Column (not part of this simulation). It is pumped by the pump P-101 and heated in a fired furnace FH-100. To account for the formation of the cracking gas and liquid in the furnace, as well as air leaks to the column, calculations of the flow rates of cracking gas, liquids, and leaks is performed in the block Feed Cracking. Stream S-4 is fed to the vacuum column (Figure 1). This column has the following products: VC-Ovhd, LVGO (Light Vacuum Gas Oil), HVGO (Heavy Vacuum Gas Oil), and VC Resid. Figure 1. Part of the oil refinery with vacuum furnace and vacuum crude column. Specifications Vacuum Feed Assay (adjusted to 1atm) TBP Distillation Assay Liq Vol % T ( ° F) 1 540.4 2 580.8 5 642.8 10 697.0 30 831.8 50 935.7 70 1097.8 90 1298.0 98 1485.4 Cut the assay into individual components using AutoCut. Define a blend and install the stream Vacuum Feed. Vacuum Feed: F = 41,560 bbld (std id liq vol flow), T = 630 F, P = 31 psia. P-101: Centrifugal Pump. Outlet pressure 140 psia, Adiabatic efficiency 75%. CHBE 476 Modeling and Optimization in Chemical Engineering Department of Chemical and Biological Engineering The University of British Columbia Tutorial 1 Monday, 9 September 2019, 4–5:45 pm Bulk Properties Bulk density 18 API_60 Molecular Weight 460
2 Furnace FH-100: Use fired heater. Radiant Zone Inlet: S-1. Radiant Zone Outlet: S-3. Fuel Streams: Natural Gas. Air Feed in SS Mode: Air. Combustion Product: S-2. Model Selection. Steady State Model: Simple Fired Heater. Efficiency = 70%. Natural Gas: T = 100 F, P = 70 psia, initial flow rate = 3,000 lb/hr. Composition: methane 90 mol%, ethane 10 mol%. Once the simulation converges, adjust the flow rate of this stream such that the temperature of the stream S-3 = 745 F. Report the flow rate of Natural Gas required to achieve this temperature. Air: T = 100 F, P = 70 psia, initial flow rate = 70,000 lb/hr. Composition: nitrogen 79 mol%, oxygen 21 mol%. Once the simulation converges, adjust the flow rate of this stream so that the mole fraction of O2 in S-2 = 0.04. Report the air flow rate needed to achieve this. The preheated feed composition (stream S-3) is adjusted for cracking in the furnace. Cracking Corrections and Leaks flow rate: These calculations are performed in the calculation block Feed Cracking using the following heuristics: Cracking gas flow rate: ࠵? !"#$%&’( *#+ (lb/hr) = ࠵? ,#$--. /001 (barrel/hr) 24 (hr/day) ∙ 0.6 Cracking gas composition (mol/mol): C2 = 0.75, C3 = 0.25 Cracking liquid flow rate: ࠵? !"#$%&’( 2&3-&1 (lb/hr) = ࠵? ,#$--. /001 (barrel/hr) 1000 ∙ 30 Cracking liquid composition (mol/mol): assume n-C11 = 0.5, n-C12 = 0.5 for simplicity. Leaks flow rate – to account for air leaks to the vacuum column the following formula is used: ࠵? 20#%+ (lb/hr) = 6 7 ࠵? ,#$--. /001 (barrel/hr) 1000 For simplicity, use the Leaks composition (mol/mol) as N2 = 1. Perform the calculation of the leaks flow rate in the block Feed Cracking, which is also used for the cracking corrections. Note : The mass balance must be preserved—the mass flow rates of streams S-3 and S-4 should be the same (as well as their temperatures). To account for the pressure drop in the furnace, specify the pressure of the stream S-4 = 4 psia. Vacuum Column Absorber (no condenser, no reboiler). Number of stages = 8. Pressures: P top = 0.155 psia, P bottom = 0.425 psia.
3 There are three pumparounds. Positions of feed and product streams, and pumparounds are shown in Figure 2. Figure 2. Vacuum crude column details Vacuum Column Specifications (a) Stage 1 temperature: 135 F. (b) LVGO-PA rate: 30,000 bbld. (c) LVGO overflow: 0.1 lbmole/hr. (Add: Column Liquid Flow. Name: LVGO overflow. Stage 2. Flow Basis: Molar. Spec Value: 0.1 lbmole/hr.) (d) HVGO-PA rate: 50,000 bbld. (e) HVGO draw T: 520 F. (f) Overflow to flash zone: 0.1 lbmole/hr. (Add: Column Liquid Flow. Name: Overflow to flash zone. Stage: 6. Flow Basis: Molar. Spec Value: 0.1 lbmole/hr.) (g) Vac-Resid PA rate: 5,000 bbld (h) Stage 8 temperature: 675 F. Report (90% quantitative + 10% qualitative) (a) (20%) (i) Report the mass flow rates (lb/hr) of Air, Natural Gas and S-3 stream Explain how you adjusted the Air and Natural Gas flowrates to achieve 0.04 O2 in S- 2 and T = 745 F in S-3. (ii) Provide a snapshot of the Feed Cracking subflowsheet of the pfd and explain the procedure you used to include the cracking corrections to obtain stream S-4. (b) (10%) Report the D86 T5, T50, and T95 temperatures for all product streams. (c) (10%) There are no sidestrippers in the vacuum column. Why?
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4 (d) (20%) Set the temperature out of the furnace (stream S-3) to 745 (original value) 750, and 755 F and calculate the ratio of the sum of the LVGO and HVGO mass flow rates and the mass flow rate of the fresh feed. If the goal is to increase this ratio (since the VGOs are much more valuable than resid), what is your suggestion for the temperature at which to run the furnace? Are there any counterarguments? (e) (30%) Optimize the Air and Natural Gas flowrate to maximize the LVGO and HVGO product streams. Explain your choice of the objective function, variables, ranges, and constraints (if any). What is the optimized LVGO and HVGO mass flowrates? Upload your simulation files to the CHBE 476 Canvas page, before the posted due date and time. Provide a separate Hysys (.hsc) file as required for each Report section (a)- (e). Provide a pdf file of your report. The report should 3-5 pages long and briefly specify the problem statement, questions, and your complete answers (including the appropriate number of significant digits). Cleary present your numerical answer with appropriate units and three significant digits for each section, where appropriate.