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Solution Manual
Solution Manual
Petroleum Refining
Technology and
Economics,
Fifth Edition
by
James H. Gary
by
James H. Gary
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T&F_LOC_C_Master.indd
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Foreword
This manual gives solutions to typical problems in the chapters dealing with processing and each type of
calculation is covered at least once. These should supply sufficient examples for a onesemester
course. Many of the problems give specific values for utility and chemical costs but some do not. The
values used for the solution of those problems for which no values are specified are given below.
Current values can be obtained from Chemical Marketing and the Oil and Gas Journal.
3.1 Using Elk Hills Crude (PC-65-28, p. 417). See curves in Appendix P-A.
3 ____
KW = √ TB__
G
Basis: 100,000 BPCD Louisiana Black Back Bay Crude, USBM #60052
0.19% S, 0.04% N
_ Sulfur Nitrogen
Component Vol% BPD API lb/h/BPD lb/h w% lb/h w% lb/h
Feed:
Crude 100.0 100,000 34.4 12.45 1,245,000 0.19 2,366 0.04 498
Products:
C2- 0.1 100 5.18 518
C3 0.4 400 7.39 2,956
iC4 0.3 300 8.20 2,460
nC4 0.7 700 8.51 5,957
C5-180 F 0.5 500 60.0 10.78 5,390
180-380 F 16.6 16,500 53.5 11.16 184,140 0.024 43
380-520 F 19.5 19,500 43.0 11.83 230,685 0.074 171
520-650 F 19.0 19,000 35.0 12.40 235,600 0.124 292 - 2
650 F+ 43.5 43,500 24.0 13,27 577,294' 0.32 1,860* 0.086 496*
Vacuum Unit:
Feed:
650+ F 100.0 43,500 24.0 13.27 577,294 0.32 1,860 0.086
Products:
650-850 F 57.9 25,200 28.5 12.90 325,080 0.23 748 0.007 23
850-1050 F 29.4 12,800 19.0 13.72 175,616 0.38 667 0.076 134
1050 F+ 12.7 5,504 16.9 13.91 76,598* 0.58 445* 0.44 339*
4.5
4.6
Assume all Conradson Carbon Residue (CCR) is in the 1050° F material. Let: x =
%distilled
C=CCR
Feed:
1050°F+ VRC 100.0 3,000 10.0 14.59 43,770 0.38 166
Products:
8 74 3,825 1.29 49
Coke (w%)
C2 1.5 2.5 28 70
H2S 1.5 34 51
5.3 Feed rate: 7,500 BPSD 3000 BPCD/ 46 t coke/CD = 65 bbl feed/ton coke
Utility requirements:
Amt/unit Total/day
Steam, lb/t coke 700 80,500 lb
Power, kwh/t coke 30 3,450 kWh
Cooling water, gal/bbl feed 70 525,000 gal
Fuel, MMBtu/bbl feed 0.14 1,050 MMBtu
Basis: 100,000 BPCD Elk Hills crude, Kern County, CA, #PC-65-48 1050'F+ VRC: 5.515% on crude
20.5°API CCR = 14.8 w%
Sulfur Nitrogen
Component vol% BPCD °API lb/h/BPD lb/h w% lb/h w% lb/h
Feed:
VRC 100.0 5,515 20.5 13.57 74,884 3.64 2,728 1.92 1,441
Products:
Gas composition:
S free
Component mol % mol/h mol/h MW lb/h lb/h/BPD BPD
5 5 Basis: 10,000 BPSD fresh feed to coker producing 386.2 tons coke/day
25.9 bbl fresh feed/ton coke
Chapter 6
Sulfur
Component Vol BPD °API lb/h/BPD lb/h
% wt % lb/h
Feed:
650-900°F 100.0 10,000 27.0 13.02 130,200 1.2
1,562
Products
Coke, w%
4.57 5,960 6.2 351
C2 & ltr, w% 4.69
6,103 17.3 563
C3 5.14
514 7.61 3,912
C3= 2.08
208 7.42 1,521
C4 6.28
628 8.76 5,501
iC4 4.85 485 8.22 3,987
nC4
1.53 153 8.51 1,302
C5+ naphtha 50.25
5,025 57.8 10.90 54,769 0.15 86
TGO
35.0 3,500 21.8 13.47 *
47,145 1.2 `562
LGO
26.3 * 2,630 26.8 13.04 * 34,286
HCO
8.7 870 8.3 14.78 12,859
Total
10,513 130,200 1,532
*
By difference
Total yield increased from 5,025 BPCD to 6,743 BPCD or 34.2 v%.
Total
$18,560.00
6.6 Operating cost per barrel of gasoline boiling-range product.
Labor costs: $ 1,150.00 /D
Power: 0.06 /kWh
Steam: 2.25 /Mlb
Fuel: 2.49 /MM Btu
Catalyst: 900.00 /t amorphous
3,000.00 /T zeolyte
Depreciation: $ 625,000.00 /yr
On-stream factor: 96.5%
Gasoline yield: 58 v%
Labor, $
1,150 1,150.00
Depreciation, $
1,712 1,712.00
Royalty, $0.10/bbl 2,000 1,930 1,930.00
Total
20,652.00
20,000 BPSD feed (0.58)(0.965) = 11,600 BPCD naphtha Cost = $1.78/bbl naphtha
Chapter 7
Chapter 7
7.1 Feed rate: 7,500 BPD Hydrogen hydrocracking consumption: 1,500 scf/bbl =
2,474 lb/h
Feed:
Gas oil 100.0 10,000 26.5 13.07 130,800 0.7 916 0.3 392 0.15 196 12.1
Products:
220 196
H2O
970 916
H2S
480 392
400-520'F 0.0
480 17.6 84
NH3
In:
130,380 13.4 * 17,558
Gas oil
Hydrogen 100.0 4,400
Total in 21,958
1,006
Excess hydrogen
* From Fig. 7.6
Total 6.77
7.6 Calculate hydrogen consumption for maximum naphtha (gasoline) yield.
Basis:10,000 BPSD, 24.0° API feed, 617-950'F boiling range, 0.45% S, 0.18% N, 0.11% 0. KW =
12.14 (S, 0, & N free basis)
From Figures 7.4 and 7.3, hydrocracking hydrogen consumption is - 2,100 scf/B.
Total hydrogen should include loss to light gases. This is approximately 1 lb/bbl feed .
Amount of sulfur:
1000 bbl @ 55° API = 11,070 lb/h
RSH sulfur = 55.35 lb/h = 1.73 mol/h
R2S sulfur = 55.35 lb/h = 1.73 mol/h
Total moles H2 produced/100 gal reformer feed = 4.12 + 1.75 + 1.48 = 7.35 lb-moles
K = (Pbenzene)(Phydrogen)3/(Pmethglcyclopentane )
26,980 = ((x/(29.48+3x))(40.82))(((26.35+3x)/((29.48+3x))(40.82))3/((3.13-
x)/(29.48+3x))(40.82)
10.2
Feed:
180-3800 HSR 100.0 10,000 50.2 11.36 113,600
Products:
10.4 Isomerization unit, once-thru (∆RON = 13), 6,200 BPSD. Labor = $17.37 /h/operator
Operating cost /bbl reformate @ 96 RON = ($1.08/0.86) = $1.26 Operating cost /bbl
Products:
Pentane 119 Pentane 111
Alkylate 2,644 Alkylate 2,471
Total alkylate 2,763 2,582
Total iC4 req’d = 4,580 BPD Total C5+ alkylateproduced=5,345BPD
Feed:
Feed:
Products:
Product source:
Alkylate Bottoms Tar
Feed Pentane
BPD lb/h BPD lb/h BPD lb/h
C3= 111 2,471 25,074 195 2,144 26 354
11.13
Feed: BPCD lb/h
C5 159 1,445
Butane requirement for a 10 psi RVP gasoline: (6505)(4.98) + M(52.0) = (6505 + M)(9.0)
43M = 26150
M = 608 moles nC4 req'd = 173 bbl
Total 6,415
* Table 12.4 (book)
Flash point of blend = 55 ° F
12.5 Calculation of pour point of mixture.
Reference Table 12.7.
Component Bbl ASTM Pour point, PPBI vol frac pPPBI
50% temp °F
A 5,200 575 10 8 0.290 2.32
B 3,000 425 50 0.167
61 10.19
C 6,500 500 65 98 0.362 35.48
D 3,250 550 45 40 0.181 7.24
Total 17,950 1.00 55.23
ASTM 50% point = 518.3°F
At 500°F 50% point: Pour point= (1.23/(66-54))(5°) + 50° =50.5°F
At 525°F 50% point: Pour point = (3.23/(63-52)(5°) + 50° =51.5°F
.'. at 518'F 50% point, pour point = 51'F
12.11 Calculate n-butane requirement for 12.0 psi RVP and PON of blend.
Component BPSD RVP, psi VPBI pRVP
n-butane w 51.6 138.0 138W
LSR naphtha 4,200 11.1 20.3 85,260
Lt hydrocrackate 1,800 12.9 24.4 43,920
1. A oil refinery feeds two different crude oils. Crude Oil 1 costs $45.00/bbl and Crude
Oil 2 costs $41.00/bbl. The refinery produces gasoline, diesel oil and fuel oil. Gasoline
sells for $65.00/bbl, diesel oil sells for $60.00/bbl, and fuel oil sells for $50.00/bbl. The
yields for each crude oil are shown in the following table:
The maximum sales volume for Gasoline is 30,000B/D, and the maximum sales
volume for Fuel Oil is 100,000B/D. Formulate this as a linear program application
Solution:
Solution:
Yield
Vector
Feedstock
Propylene -1.0000
Isobutane -1.6000
Product
Propane 0.298
Pentane 0.0717
Alkylate 1.594
Alky Bottoms 0.126
Tar 0.017
Utilities
Steam, l b 6.91
Power, kwh 2.32
Cooling water, m gal 2.33
Fuel, MMBtu 0.65
Solution:
4. Calculate the crude oil breakeven value for Crude Oil D using the information shown
below:
CASE 1 CASE 2
Amount
Crude A 50,000B/D 40,000B/D
Crude B 40,000 40,000
Crude C 20,000 20,000
Reference Crude ($50/B) 10,000
Crude Oil D($40/B) 10,000
Solution:
Solution
ISBN 1-420-04817-1