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Article1379670771 - Doust Et Al
Article1379670771 - Doust Et Al
Steady-state and dynamic simulation play important roles in investigation of refinery units. Therefore,
simulation can help this investigation and behavior assessment. In this paper, simulation was done by
commercial software. In fact, because of solving many state equations simultaneously and using
control theory, dynamic simulation has more significant impact than steady-state simulation. Flow,
pressure, temperature and level (FPTL) were controlled by Proportional-Integral-Derivative (PID)
controllers in the unit. The case study is Kermanshah Refinery. The behavior of the FPTL controllers in
dynamic regime were observed after the changing of the crude oil feed flow rate by 3% for 5 h. ASTM
D86 boiling points (compositions) of two simulations were compared with experimental data. Finally,
system sensitivity to inputs variables was investigated in the MATLAB/SimulinkTM by transferring the
dynamic results. Transient responses to changes such as feed temperature, feed flow rates, steam flow
rates and the duties of the reboilers of columns in Gasoline unit were plotted. Among of all
disturbances, the system is more sensitive to changes in the feed temperature, the duties of the
reboilers of columns in gasoline unit and simultaneous combination of above changes.
Key words: Steady-state, dynamic, PID controller, ASTM D86, Sensitivity, MATLAB simulink, transition
responses.
INTRODUCTION
Today, distillation of crude oil is an important process in
almost all of the refineries. Simulation of the process and
analysis of the resulting data in both steady-state and
dynamic conditions are fundamental steps in decreasing
of the energy costs and controlling the quality of the oil
products. The dynamic simulation when adding some
Proportional-Integral-Derivative (PID) controllers and
setting them to have desired responses, has more
significant impacts and challenges than steady-state
simulation in crude oil distillation units. A PID controller is
a controller that includes three elements (Araki, 2002).
PID control systems have exactly the same structure as
depicted in Figure 1, where the PID controller is used as
jsadeghi@hamoon.usb.ac.ir.
1
C(s) = KP 1 + + D s
I s
(1)
I and D are
100
Dynamic files
model
of
the
distillation
Doust et al.
101
(4)
0 = Ln +1 + Vn 1 + Fn Ln Vn S n
(5)
d(Mn xn, j )
dt
(7)
Energy balance
Dynamic general energy balance of stage n:
X n +1 = X n
f (Xn)
f
'
(Xn )
(2)
d(Mh
n n)
=Ln+1hn+1 +Vn1Hn1 +Fh
n f Lh
n n VH
n n Sh
n n +QM Qs Qloss
dt
(8)
The changes in the specific enthalpy of the liquid phase
are generally very small compared to the total enthalpy of
the stage. This means that, normally, the energy balance
can be reduced to an algebraic equation which is used as
the basis to calculate the flow of vapor from the stage
which is made a steady-state space. Finally, the energy
balance is as follows (Lee et al., 1975):
Mass balance
The following is a representative sketch of any of these
stages (Figure 2):
Vapor-liquid equilibrium
Vapor-liquid equilibrium of component j for theoretical
stage n:
dM
dt
= L n + 1 + V n 1 + F n L n V n S n (3)
n ,j
n ,j
P n s, aj t
Pn
n, j
xn,
(10)
102
Product
Naphtha
Blending naphtha
Kerosene
Atmosphere gas oil
Atmospheric residue
Steady-state simulation
Product
To fuel
To LPG unit
Bottom product
Product
To flare
To LSRG Merox
HSRG to platforming
n, j
y n , j Pn = x n , j Pnsa, jt
(11)
Pressure
Dynamic simulation
Pn = Pn + 1 + P
V
P = 0
K
(12)
(13)
Doust et al.
Figure 3. Steady-state simulation scheme of distillation unit; (a) preheating; (b) atmospheric distillation
column; (c) Gasoline unit (light and heavy).
103
104
Doust et al.
Figure 4. Dynamic simulation scheme of distillation unit; (a) preheating; (b) Atmospheric
distillation column; (c) Gasoline unit (light and heavy).
105
106
350
280
Experimental
Steady-state
Dynamic
240
220
200
180
160
140
120
100
Experimental
Steady-state
Dynamic
300
Distillation temperature ASTM D86(F)
260
250
200
150
100
0
20
40
60
Amount distillated(%)
80
100
50
20
40
60
Amount distillated(%)
80
100
440
300
280
260
240
220
200
180
Experimental
Steady-state
Dynamic
420
Distillation temperature ASTM D86(F)
320
20
40
60
Amount distillated(%)
80
100
TM
400
380
360
340
320
300
280
260
20
40
60
Amount distillated(%)
80
100
ACKNOWLEDGMENT
The financial support provided by the Kermanshah Oil
Refining Company is gratefully acknowledged.
Doust et al.
600
Experimental
Steady-State
Dynamic
D
istillationtem
peratureASTMD
86(F)
550
500
450
400
350
300
250
20
40
60
Amount distillated(%)
80
100
DistillationtemperatureASTMD86(F)
700
650
600
550
500
450
400
20
40
60
Amount distillated(%)
80
100
Figure 11. Scheme of Distillation unit in the MATLAB simulink with inputs and outputs.
107
BNaphtha
Stream("46")
Kerosene
193.794
6928
5279.22
5279.2
6927
5279.18
6926
193.793
193.7925
193.792
193.7935
5279.16
5279.14
5279.12
5279.1
6925
6924
6923
193.7915
6922
5279.08
193.791
0
10
15
20
Time(h)
25
30
35
5279.06
40
10
15
20
Time(h)
25
30
35
6921
0
40
10
15
20
Time(h)
25
30
35
AGO
4737.9
4
Stream("52-1")
1.4403
1767.5
4737.75
4737.7
1.4401
1766.5
4737.8
1766
1765.5
1765
1764.5
4737.65
10
15
20
Time(h)
25
30
35
1764
40
10
15
Stream("56-1")
1.4399
1.4398
1.4397
20
Time(h)
25
30
35
40
1.4395
Stream("47-1")
1969
1160
1968
1159
1161
1966
1965
1964
1963
1962
1.44
1.4396
1970
1967
1158
1157
1156
1155
1154
10
15
20
Time(h)
25
30
35
40
Stream("39")
x 10
1.4402
1767
Stream("52-1") Flow (bbl/day)
4737.85
108
1153
10
15
20
Time(h)
25
30
35
40
Figure 12. Steady-state curves of stream: 46, B_Naphtha, Kerosene, AGO, (39-1), (52-1), (56-1) and (47-1).
10
15
20
Time(h)
25
30
35
40
40
Doust et al.
Stream("46")
Kerosene
6935
AGO
5281
4739.8
4739.6
6930
5280.5
4739.4
6920
6915
6910
4739.2
AGO Flow(bbl/day)
6925
5280
5279.5
4739
4738.8
4738.6
4738.4
6905
4738.2
5279
6900
6895
4738
10
15
20
Time(h)
25
30
35
5278.5
40
4737.8
BNaphtha
193.83
1.446
x 10
10
15
20
Time(h)
25
30
35
40
10
15
20
Time(h)
25
30
35
40
Stream("52-1")
Stream("39")
1780
193.825
1775
1.444
193.815
193.81
193.805
193.8
Stream("39") Flow(bbl/day)
193.82
1.442
1.44
1.438
193.795
10
15
20
Time(h)
25
30
35
1765
1760
1755
1.436
193.79
1770
40
1.434
1750
0
10
15
Stream("56-1")
20
Time(h)
25
30
35
40
10
15
20
Time(h)
25
Stream("47-1")
2000
1180
1990
Stream("56-1")Flow (bbl/day)
1170
1980
1970
1960
1950
1150
1140
1130
1940
1930
1160
10
15
20
Time(h)
25
30
35
40
1120
10
15
20
Time(h)
25
30
35
40
Figure 13. Curves of stream with change of feed temperature (+ 10C): 46, B_Naphtha, Kerosene, AGO, (39-1), (52-1), (56-1) and (47-1).
30
35
40
109
BNaphtha
Stream("46")
Kerosene
193.8
6935
5279.9
193.799
5279.8
6930
6920
6915
6910
6905
10
15
20
Time(h)
25
30
35
193.796
193.795
193.794
5279.1
4737.9
4737.8
AGO Flow (bbl/day)
10
15
20
Time(h)
1.446
4737.7
4737.6
4737.5
4737.4
25
30
35
5279
40
10
15
20
Time(h)
25
30
35
10
15
20
Time(h)
25
30
1790
1.444
1780
1.443
1.442
1.441
1770
1760
1750
1740
1730
10
15
20
Time(h)
25
30
35
40
1720
10
15
20
Time(h)
25
Stream("47-1")
1200
2040
1150
2020
2000
1980
1960
1940
1920
1100
1050
1000
950
900
1900
850
1880
1860
10
15
20
Time(h)
25
30
35
40
40
Stream("52-1")
Stream("56-1")
2060
35
1800
1.445
1.439
40
Stream("39")
x 10
1.44
5279.3
5279.2
AGO
5279.4
193.792
4738
4737.3
5279.5
193.793
193.791
40
5279.6
6900
5279.7
193.797
6925
BNaphtha Flow(bbl/day)
193.798
110
800
10
15
20
Time(h)
25
30
35
40
Figure 14. Curves of stream with change of Reboilesduty,V-106-DE (+ 3%): 46, B_Naphtha, Kerosene, AGO, 39, (52-1), (56-1) and (47-1).
30
35
40
Doust et al.
BNaphtha
Stream("46")
193.794
6928
Kerosene
5279.22
193.7935
6925
6924
6923
5279.2
5279.18
193.793
Kerosene Flow(bbl/day)
6926
6927
193.7925
193.792
5279.16
5279.14
5279.12
5279.1
193.7915
6922
5279.08
6921
0
10
15
20
Time(h)
25
30
35
193.791
0
40
10
15
AGO
25
30
35
5279.06
40
10
15
20
Time(h)
25
30
35
Stream("52-1")
Stream("39")
x 10
1.4403
4737.9
20
Time(h)
1800
1750
1.4402
4737.85
AGO Flow(bbl/day)
1.4401
4737.8
4737.75
1.44
1.4399
1.4398
1.4397
1700
1650
1600
1550
4737.7
1500
1.4396
4737.65
10
15
20
Time(h)
25
30
35
1.4395
40
1450
0
10
15
20
Time(h)
25
30
35
40
10
15
20
Time(h)
25
30
35
40
Stream("56-1")
Stream("47-1")
2300
2250
1160
2200
1159
Stream("47-1") Flow(bbl/day)
1161
2150
2100
2050
2000
1950
1158
1157
1156
1155
1154
10
15
20
Time(h)
25
30
35
40
1153
10
15
20
Time(h)
25
30
35
40
Figure 15. Curves of stream with change of Reboilesduty,V-108-SP (+ 3%): 46, B_Naphtha, Kerosene, AGO, 39 , (52-1), (56-1) and (47-1).
40
111
BNaphtha
Stream("46")
6928
193.83
6926
193.825
Kerosene
5281.5
6924
5281
6920
6918
6916
6914
Kerosene Flow(bbl/day)
6922
193.82
193.815
193.81
193.805
5280.5
5280
193.8
6912
5279.5
193.795
6910
6908
10
15
20
Time(h)
25
30
35
193.79
40
1.444
AGO
x 10
10
15
20
Time(h)
25
30
35
5279
40
10
Stream("39")
15
20
Time(h)
25
30
35
Stream("52-1")
1800
4740
1.4435
4739
4738.5
AGO Flow(bbl/day)
1750
1.443
4739.5
1.4425
1.442
1.4415
1.441
1.4405
10
15
20
Time(h)
25
30
35
1.439
40
10
Stream("56-1")
1600
1550
1500
15
20
Time(h)
25
30
35
40
1400
10
15
20
Time(h)
25
30
Stream("47-1")
1200
2300
1150
2250
1100
2350
2200
2150
2100
2050
1050
1000
950
900
850
2000
1950
1650
1450
1.4395
4737.5
1700
1.44
4738
Stream("56-1") Flow(bbl/day)
112
10
15
20
Time(h)
25
30
35
40
800
10
15
20
Time(h)
25
30
35
40
Figure 16. Curves of stream with simultaneous combination of above changes: 46, B_Naphtha, Kerosene, AGO, 39, (52-1), (56-1) and (47-1).
35
40
40
Doust et al.
Nomenclature
AD , n
hn
: Temperature on stage n [ C ]
U: Manipulated value
x n + 1, j
y n 1 , j
yn, j
hf
hT , n
hD , n
zn, j
]
]
L ,n
K P : controller gain
Ln +1 : the molar liquid that overflows onto stage n from
stage n+1 [
: pressure on stage n
QM : heat of mixing [
]
r: desired value
R&D: Research and Development
holdup on stage n) [
]
P(s): process transfer function
xn, j
hn +1
AT , n
113
REFERENCES
Almudena RF (2001). Dynamic Modelling and Simulation with Ecosimpr
of an Ethanol Distillation Column in the Sugar Industry, Madrid, 1:
150-200.
Araki M (2002). Control systems, Robotics and Automation. Kyoto
University, Japan, 1: 235-376.
Aspen Physical Property System (2009). Physical property methods
and models. Aspen Technol. 1: 356-739.
Juma H, Tom P (2009). Steady-State and Dynamic Simulation of
Crude Oil Distillation Using Aspen Plus and Aspen Dynamics. Pet.
Coal. J. 51(2): 100-109.
Kermanshah Refinery (2009). Operating data of Distillation unit.
Lee BI, Kesler MG (1975). A generalized thermodynamic correlation
based on three Parameter corresponding states. AIChE. J. 21(3):
510-527.
Luyben WL (2006). Distillation Design and Control Using Aspen
Simulation. John Wiley & Sons. New York, 1: 10-283.