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Optimization of A Refinery Crude Distillation Unit in The Context of Total Energy Requirement
Optimization of A Refinery Crude Distillation Unit in The Context of Total Energy Requirement
INTRODUCTION
The Nigerian National Petroleum Corporation, has 4 refineries, in its downstream operations, The primary goal of this refiner is to achieve and maintain high gasoline production, Hence, the main objective of this study is to optimize gasoline production in all the refineries, The strategy being to first target the CDUs in these refineries. Maximizing the yield of gasoline and its intermediates will directly impact positively on total pool gasoline production,
Phase I began with CDU 1 as a basis to ascertain plant suitability to process different crude oil.
CDU 1 DISTILLATES
The intermediate distillates are as in conventional CDUs, Unstabilized gasoline from the main fractionator is further processed in the stabilizer column, Straight run naphtha and other distillates from the main fractionator are routed further downstream for processing and upgrading, Stabilizer produces an intermediate gasoline as bottoms and LPG as overhead
Main areas are: efficient operation of the CDU, review of configuration of CDU to determine opportunity for further increase in gasoline yield,
Carry out optimization of the CDU Results obtained showed good opportunity.
3.418 0.06
1.00E+02 Design 1.00E-02 Crude LPG Gasoline Kerosene LGO HGO AR HYSYS
1.00E-06
Products
OPTIMIZATION PARAMETERS
The parameters for optimization are derived from process/hardware environments, viz, The main fractionator and the stabilizer are linked together: stabilizer feed comes from the main fractionator, The other gasoline blending stock, SRN, a derivative from the main fractionator is routed for further processing, Four side strippers in the main fractionator, The stabilizer has a condenser and a reboiler
MODELLING PROCEDURE
Stage-wise approach was adopted, viz, Evaluate CDU configuration and steady state simulation data to determine opportunity for optimization, Based on the structure of CDU process and hardware requirements, evolve an optimization algorithm and define boundary conditions to be solved by HYSYS.Plant, Define steady state parameters from HYSYS.Plant simulation as first level data, and referenced as base or design values, Optimize the overall gasoline yield in the context of total energy requirement.
HYSYS OPTMIZER
Primary variables (X1, X2, X3) are manipulated to maximize INB. Primary variables must have upper & lower limits, and these are used to normalize the primary variables, viz,
Xinorm = [(Xi Xilower)/(Xiupper Xilower)]. Where Xi = X1, X2, X3
Objective function as defined by INB, Constraints as defined for RON & RVP,
PROBLEM SOLUTION
Sequential quadratic programming was found to be ideal for solution, Solution was found for all cases studied, General increase in yield of stabilizer feed and SRN from the main column, Gasoline yield was increased by 8 %
STABLIZER Feed, m3/hr Straight Run NAPHTHA product, m3/hr, y1 GASOLINE, m3/hr, y2 Total Gasoline (Straight-run Naphtha+Gasoline)
.5 2
.8 8
.1 5
.4
.4 5
.7 2 44
43
43
44
44
44
Gasoline (m3/hr)
45
.0 2
.5 2
.8 8
.1 5
.4
.4 5
.7 2 44
43
43
44
44
44
Gasoline (m3/hr)
45
.0 2
.5 2
.8 8
.1 5
.4
.4 5
.7 2 44
43
43
44
44
44
Gasoline (m3/hr)
45
.0 2
CONCLUSION
Sequential quadratic programme technique ideal for solution, Solution of the algorithm is reliable, achieving early convergence in the cases studied, Objective of obtaining increased gasoline yield in the context of reduced energy requirement achieved, Since the configuration of the refinery CDUs are similar, this algorithm can be applied to optimize the CDU 2,3,4,5 in the other 3 refineries