SOLUTIONS MANUAL FOR

Petroleum Refining
Technology and
Economics,
Fifth Edition

by
James H. Gary

48171.indd 1 5/29/07 11:34:30 AM

48171.indd 2 5/29/07 11:34:30 AM
 SOLUTIONS MANUAL FOR
Petroleum Refining
Technology and
Economics,
Fifth Edition

by
James H. Gary

48171.indd 3 5/29/07 11:34:30 AM

 CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2007 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business

No claim to original U.S. Government works

Printed in the United States of America on acid-free paper
10 9 8 7 6 5 4 3 2 1

International Standard Book Number-13: 978-1-4200-4817-1 (Softcover)

This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are
indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the
publisher cannot assume responsibility for the validity of all materials or for the consequences of their use.

No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission
from the publishers.

For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact
the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides
licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment
has been arranged.

Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation with-
out intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com

T&F_LOC_C_Master.indd
48171.indd 4 1 5/29/07 11:34:31
11:27:00 AM
 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.

Utility and chemical costs:

Power, electric, $/kWh 0.08

Fuel gas, $/MMBtu 3.50
Fuel oil, $/bbl 60.00
Water, make-up, $/Mgal 0.45
Cooling Water (CW), circ, $/Mgal 0.07
Steam, $/Mlb 3.15
Hydrogen, $/Mscf 3.75
Demulsifier chemical, $/lb 2.40
HF acid, $/lb 1.10
Amine solution, $/lb 2.30
Caustic, $/lb 1.05
Polymerization catalyst, $/ib 2.25
Incl. disposal, $/lb 4.50

Crude and product values ($/bbl):

Crude, $/bbl at refinery 49.00
LPG 40.60
UL Reg (87 PON) 57.00
UL Prem. (91 PON) 61.00
Jet (Turbine) 63.00
#2 Diesel 63.00
#2 Heating Oil (HO) 61.00
 Chapter 3

3.1 Using Elk Hills Crude (PC-65-28, p. 417). See curves in Appendix P-A.

3.2 TB = 550 ºF = 1010 ºR

Gravity = 26.5 ºAPI = 0.896 See Appendix B in textbook

3 ____
KW = √ TB__
G

KW = 11.21 for 550 ºF fraction

TB = 750 ºF = 1210 ºR Gravity = 17 ºF = 0.953

KW = 11.18 for 750 ºF fraction

KW550 – KW750 = 11.21 – 11.18 = 0.03

KW < 11.8, gravity < 35 ºAPI, KWdiff <0.15

This crude should make a good asphalt

3.3 482-527 ºF frac (250-275 ºC) = 31.0 ºAPI

527-572 ºF frac (275-300 ºC) = 19.4 ºAPI

This is a naphthenic crude

 Chapter 4

4.1, 4.2, 4.3

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*

Total 100.5 100,000 1,245,000 2,366 498

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*

* by difference Notes: C4 & ltr set equal to vol % loss

Sulfur from Fig. 4.4a Nitrogen from Fig. 4.3

4.4 Utility requirements

Atm Dist Unit Vac Dist Unit

/bbl feed /day /bbl feed /day
Steam (300 psig), M lb 0.010 1,000 0.010 1,000
Power, Mkwh 0.0009 90 0.0003 13
CW circ, M gal 0.150 15,000 0.150 6,526
Fuel, MM Btu 0.05 5,000 0.03 1,305

4.5

Stream Avg BP, ° F Sp Gr KW CI

C5-180 F 115 0.739 11.38 40.5
180-380 F 280 0.764 11.84 22.5
380-520 F 450 0.811 11.95 23.6
520-650 F 585 0.850 11.94 29.6
650-850 F 750 0.884 12.05 34.4
850-1050 F 950 0.940 11.93 50.6

4.6
Assume all Conradson Carbon Residue (CCR) is in the 1050° F material. Let: x =
%distilled
C=CCR

For crude: 1.2 = a + b (0) a = 1.2

For 24.5% residue: 4.6 = 1.2 + 75.5b b = 0.045

For 5.5% residue: C = 1.2 + 94.5(0.045)

4.7 Stream disposition:

C2 - Fuel gas or feed to hydrogen unit
C3 & C4 LPG (C4 may go to gasoline blending)
LSR naphtha Gasoline blending (or to isomerization)
HSR naphtha
Kerosine Catalytic reforming
AGO (Lt gas oil) Jet fuel blending
LVGO
HVGO Diesel fuel & #2 heating oil blending
VRC FCC or hydrocracker feed
 Chapter 5

5.1 Graphically estimate Conradson Carbon Residue = 5.46%

5.2 Material balance around delayed coker

Basis: Crude #53016, Hastings field, Brazoria County, Texas

1050 ºF+ VRC is 3.0 v% Of crude, CCR = 5.46 w%
10,000 BPCD crude rate to refinery
Vol Sulfur
Component % BPCD ºAPI lb/h/bpd lb/h
wt% lb/h

Feed:
1050°F+ VRC 100.0 3,000 10.0 14.59 43,770 0.38 166

Products:

C4- (w%) 8.59 3,760 51

Naphtha 17.10 513 52.3 11.23 5,760 0.14 8

Gas Oil 75.32 2,260 21.9 13.46 30,425 0.19 58

8 74 3,825 1.29 49
Coke (w%)

Total 2,773 43,770 166

Yields: Coke = 1.6(5.46) = 8.74 w%

Gas (C4-) = 7.8 + 0.144 (5.46) = 8.59 w%
Naphtha = 11.29 + 0.343(5.46) = 13.16 w%
Gas Oil = 100 - 30.09 = 69.51 w%

Naphtha = (186.5/(131.5 + 12))(13.16) = 17.10 v% Gas

Oil = (155.5/(131.5 + 12)(69.51) = 75.32 v%
Coke produced = 46 t/D 65 bbl fresh feed/ton of coke.

Coker gas balance:

Total gas = 3,760 lb/h
Sulfur in gas = 51 lb/h
Sulfur-free gas = 3,709 lb/h = 3,709/22.12 = 167.7 lb-mol/h

Component mol% mol/h MW lb/h lb/h/BPD BPD

C, 51.4 86.2 16 1,381

C2 1.5 2.5 28 70

C2 15.9 26.7 30 801

C3 3.1 5.2 42 218 7.61 29

C3 8.2 13.8 44 605 7.42 82

C4 2.4 J 4.0 56 225 8.76 26

iC4 1.0 1.7 58 97 8.22 12

nC4 2.6 4.4 58 254 8.51 30

H2 13.7 21.5 (23.0) 2 43(46)

CO2 0.2 0.3 44 15

H2S 1.5 34 51

Total 100.0 210.1 3,760 179

Total liquid products = 2,773 + 179 = 2,952 BPCD ( ) H2 value before H2S reaction

5.3 Feed rate: 7,500 BPSD 3000 BPCD/ 46 t coke/CD = 65 bbl feed/ton coke

2006 capital cost:

10 bbl/t = $68,000,000
30 bbl/t = 89,000,000
 :. 65 bbl/t = $39,000,000

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

5.4 Coker material balance

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:

C4-, w% 9.9 7,437 11.01 818

Lt naphtha 7.1 389 ? 65.0 10.51 4,088 0.67 27

Hv naphtha 13.0 719 50.1 11.36 8,168 1.34 109 0.18 14
LCGO 33.2 1,833 30.0 12.78 23,422 1.79 420 0.12 29
HCGO 18.0 991 14.3 14.16 14,037 3.81 535 2.26 317
Coke, w% 23.7 17,732 4.62 818 6.10 1,081

Total 3,932 74,884 2,728 1,441

Gas composition:
 S free
Component mol % mol/h mol/h MW lb/h lb/h/BPD BPD

C1 51.4 153.8 153.8 16 2,461

= 1.5 4.5 4.5 28 126

C2
15.9 47.6 47.6 30 1,427
C2
C3 - 3.1 9.3 9.3 42 390 7.61 51

C3 8.2 24.5 24.5 44 1,080 7.42 145

C4 2.4 7.2 7.2 56 402 8.76 46

iC4 1.0 3.0 3.0 58 174 8.22 21

nC4 2.6 7.8 7.8 58 451 8.51 53

H2 13.7 41.0 15.5 2 31

CO2 0.2 0.6 0.6 44 26

H2S 25.6 34 870

Total 100.0 299.2 299.2 7,436 317

5 5 Basis: 10,000 BPSD fresh feed to coker producing 386.2 tons coke/day
25.9 bbl fresh feed/ton coke

2006 capital cost = $81,000,000

Utility requirements: /unit /day $/day

Steam (300 psig), M lb 0.7 270 189
Power, MkWh 0.03 189
116 313
Cooling water, M gal 0.07 12 215
Fuel, MM Btu/D 0.14 1,400 4,900
Total 5,617

Labor: 4 persons/shift @ 25.50/h/person 21 shifts/week (25.50)(4)(8)(21)/7 = $ 2,448.00 /day

 Total costs = 5,617 + 2,448 = $ 8,065 /day

Chapter 6

6.1 FCC balance

Basis: 10,000 BPCD 27.0°API feed, 650-900°F, S = 1.2 w%. KW =
12.01 Severity = 65 % conversion, zeolite catalyst

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

6.2 Effect of total gas oil recycle.

Feed: BPD v% ºAPI lb/hBPD lb/h
VGO 10,000 74.1 27.0 13.02 130,200
TGO 3,500 25.9 21.8 13.47 47,145

Total 13,500 100.0 25.6 13.14

177,345 Tb VGO = 850°F
Tb TGO = (380 + 950)/2 = 655°F

Tb feed = 0.741(850) + 0.259(655) = 799°F = 1259°R

Kw feed = 11.98

Coke yield = 4.66 w% or 8,264 lb/h versus 5,960

lb/h Increased by 38.7%

Naphtha yield: Kw = 11.98 = 49.95 v%

Kw = 12.01 = 50.36 v% decreased by 0.30 v%/bbl feed

Total yield increased from 5,025 BPCD to 6,743 BPCD or 34.2 v%.

6.3 Direct operating cost.

20,000 BPD feed to FCC

unit. Labor costs:
$900.00/day Power:
$0.08/kWh
Steam: $3.15/Mlb
Fuel: $3.50/MM Btu
Catalyst: $2,000.00/ton
Utilities /bbl feed /day cost/day
Steam, Mlb
-0.03 -600 -1,890.00
Power, MkWh
0.006 120 9,600.00
Cooling water, Mgal
0.5 1,000 450.00
Fuel, MM Btu
0.1 2,000 4,500.00
Catalyst, $
0.25 5,000 5,000.00
Labor
900 900.00

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%

Utilities: /bbl feed /SD /CD $/CD

Steam, Mlb
-0.03 -600 -579 -1,302.00
Power, MkWh 0.006 120 116 6,960.00
CW, Mgal
0.5 10,000 9,650 571.00
Fuel, MM Btu 0.1 2,000 1,930 4,806.00
Catalyst, $
0.25 5,000 4,825 4,825.00

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

(a) Total hydrogen consumption:

(7,500 BPD)(13.30 lb/h/BPD = 99, 750 lb/h feed
(99,750)(0.017)/32.07 = 52.88 lb-atoms S = lb moles hydrogen req'd Hydrogen
req'd for S removal = (52.88)(379)(24)/7,500 = 64 scf/bbl feed

Hydrogen loss (1 lb/bbl feed) = 379/2 = 189.5 scf/bbl feed

Total hydrogen = 64 + 189.5 + 1500 = 1753.5 scf/bbl feed = 2,892 lb/h

(b) Gasoline produced /day:

Fig. 7.3 vol % C5-180ºF = 11.84 v%
Fig. 7.4 vol % 180-400°F = 33.8 v%

Total C5-400ºF naphtha = 45.64 v% = 3,423 BPD

(C) Jet fuel produced:

Feed = 99,750 lb/h + 2,892 lb/h = 102,642 lb/h
Products:
C 3 & ltr = 1.0 + 0.09(11.84) = 2.066 w% _ 2,060 lb/h
iC4 = (0.377)(11.84)(7,500)(4.686)(42)/24 = 2,747 lb/h
nC4 = (0.186)(11.84)(4.223)(42)/24 = 1,219 lb/h
KW = 11.73 (sulfur-free basis)
H2S produced = 1,802 lb/h
C5-180ºF = (0. 1184)(7,500)(9.73) _ 8,640 lb/h
180-400°F = (0.338)(7,500)(11.25) _ 28,518 lb/h
Total 44,987 lb/h
r
Jet fuel = 102,642 - 44,987 = 57,655 lb/h
KW = 11.63 sp gr = 0.836 lb/h/BPD = 12.20

Jet fuel = 4,726 BPD

7,2 Feed: 23.7°API KW = 12.02

From Fig. 7.3: C5-180°F yield = 17.87 v%
iC4 yield = 6.74 v%
Alkylate production = 3,500 BPD
iC4 requirement = 0.65(3,500) = 2,275 BPD (Table 11.5) :.
Hydrocracker feed rate = (2,275)/0.0674 = 33,753 BPD
 7.3 Characterization factors of gasoline and jet fuel in Prob. 7.1.

From 7.1: Feed Kw = 12.02

MABP of C,-400'F = 240'F
MABP of jet fuel = 460 ° F

for C5-180'F naphtha Kw = 12.01 (Fig. 7.6) jet fuel Kw =

11.73

7.4 Overall material balance.

Basis: 10,000 BPSD fresh feed Kw = 12.1 S = 0.7% N = 0.3%

Severity = 2,000 scf/bbl of hydrogen for hydrocracking. 0=0.15%

Component V% BPSD °API lb/h/ 1b/h w% lb/h S w% N lb/h N w% 0 lb/h O Kw

BPD S

Feed:

Gas oil 100.0 10,000 26.5 13.07 130,800 0.7 916 0.3 392 0.15 196 12.1

H2, scf/B 4,400

Total 10,000 135,200 916 392 196

Products:

220 196
H2O
970 916
H2S
480 392

C3&ltr,w% 4.3 5.620

13.8 1,380 8.22 11,340

iC4
6.8 680 8.51 5,790
nC 4
C,-180'F 365 36,500 83.0 9.62 35,110 12.72

180-400°F 68.5 68,500 55.4 1 05 75,670 11.95

400-520'F 0.0

Total 135,200 916 392 196

7.4 (cont'd
Hydrogen balance: lb/h w% H2 lb/h H2

Out: H20 220 11.1 24

H2S 970 5.9 57

480 17.6 84
NH3

C3 & ltr 5,620 19.8 1,113

C4 17,130 17.2 2,946

C5-180°F 35,110 16.3 * 5,723

180-400°F J 75,100 14.1 * 10,589

in sol'n (1 lb/B) 416

Total out 20,952

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

7.5 Direct operating costs (excluding labor)

Item: /bbl feed unit cost $/bbl feed

1,780 $3.00/Mscf 5.34

Hydrogen, scf
69.5 2.25/Mb 0.16
Steam, lb
0.054/kWh 0.64
Power, kWh 11.9
417 0.0522/Mgal 0.02
Cool. water circ., gal
Fuel, MM Btu 0.178 1.80/MM Btu 0.32

0.089 0.089/bbl 0.089

Catalyst consum., $
0.20/bbl 0.20
Royalty, running, $ 0.20

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.

Hydrogen to remove S, N, & 0: (10,000 BPSD = 130,270 lb/h feed)

0.45% S = 596 lb/h = 18.31 lb-moles/h H2S, requires 18.31 lb-moles/h H2
0.18% N = 234 lb/h = 8.34 lb-moles/h NH3, requires 25.07 lb-moles/h H2
0.11% 0 = 143 lb/h = 4.47 lb-moles/h H20, requires 4.47 lb-moles/h H2
Total hydrogen for removal = 47.85 lb-moles/h

Total hydrogen consumption = (2,100)(10,000/24) + (47.85)(379) = 893,135 scf/h = 21,435,244 scf/D- or

2,144 scf/B feed.
 Chapter 9

9.1 Basis: 48.5° API naphtha, 0.62 w% S, 0.15 w% N, & 0.09 w% 0.

(70 scf/bbl)(0.62) + (320 scf/bbl)(1500-15)/10000 + (180 scf/bbl)(0.09) = 108 scf/bbl

Total hydrogen should include loss to light gases. This is approximately 1 lb/bbl feed .

Total hydrogen consumption = 108 + (379/2) = 295 scf/bbl feed.

9.2 Hydrogen required for hydrotreating.

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

RSH + H2 - H2S + RH mol H2/mol S = 1.0

R2S + 2H2 - H2S + 2 RH mol H2/mol S = 2.0

Req'd mol/h H2= 1.2((1.73)(1) + (1.73)(2)) = 6.228

H2 from 100 gal reformer feed:

C6H12 - C6H6 + 3H2 20 gal benzene 90% conversion

H2 produced = 0.9(20/13.1)(3) = 4.12 lb-moles

C7H14 – C7H8 + 3H2 10 gal C7H14 90% conversion

H2 produced = 0.9(10/15.4)(3) = 1.75 lb-moles

C8H16 - C8H10 + 3H2 10 gal C8H16 90% conversion

H2 produced = 0.9(10/18.3)(3) = 1.48 lb-moles

Total moles H2 produced/100 gal reformer feed = 4.12 + 1.75 + 1.48 = 7.35 lb-moles

Reformer feed required = (6.228/7.35)(100)(1.2) = 101.7 gal/h = 58.1 BPD

 Chapter 10

10.1 Effect of reactor pressure.

10,000 scf H2 = 26.35 lb-moles 1 bbl methylcyclopentane (MCP) = 3.13 lb-moles

∆G = ∆F = RT1nK -15,110 = -(1977)(755)(2.303 logK) K = 26,980

at equilibrium: C6H12 → C6H6 + 3H2

(3.13-x) x (26.35+3x) where: benzene= x moles
MCP = 3.13 - x moles

Total moles = 29.48 + 3x hydrogen = 26.35 + 3x moles

K = (Pbenzene)(Phydrogen)3/(Pmethglcyclopentane )

At 600 psig (40.82 atm):

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)

x = 1.093 lb-moles benzene = 0.275 bbl benzene from 1 bbl MCP

At 300 psig (20.41 atm):

x = 2.50 lb-moles benzene = 0.631 bbl benzene from 1 bbl MCP

10.2

4,500 BPD HSR naphtha feed, KW = 11.9, severity = 92RON

Yields: C5+ reformate = 85.2 v% (Fig. 10.4)

Butanes = 5.4 v%
n-butane = 58.5 v% of total butanes = 3.16% of feed

C5+ reformate = 3,834 BPD n-butane = 142 BPD

10.3 10,000 BPD 180-380ºF HSR naphtha feed. 50.2° API, MABP = 275ºF.
Severity = 96 RON. KW = 11.58

Component Vol % BPD °API lb/h/BPD lb/h

Feed:
180-3800 HSR 100.0 10,000 50.2 11.36 113,600

Products:

H2, w% 1.74 1,977

C1 + C2, w% 1.1 1,250

C3, w% 1.88 288 7.42 2,136

iC4 2.07 207 8.22 1,702

2.91 291 8.51 2,476

nC4
C5+ reformate 86.0 8,600 39.2 12.10 104,059

Total 9,386 113.600

10.4 Isomerization unit, once-thru (∆RON = 13), 6,200 BPSD. Labor = $17.37 /h/operator

2006 installed cost= $27,000,000 (Fig. 10.10)

Utility Amt/bbl feed $/unit $/bbl feed

Power, kWh 1.0 0.054 /kWh 0.054
CW circ, gal 750 0.0522 /Mgal 0.039
Fuel, MM Btu 0.02 1.80 / MM Btu 0.36
Catalyst repl, $ 0.05 0.05
Hydrogen, scf 40 2.50 /Mscf 0.01

Labor cost/bbl = (2)(8)(3)(17.37)/6200 = 0.134

Total direct cost = 0.647

10.5 Reformer operating cost. 8,400 BPSD, 50.2° API HSR naphtha. KW = 11.6
Severity = 96 RON

Utility Amt/bbl feed $/unit $/bbl feed

Steam, lb 30 2.25 /Mb 0.0675
Power, kWh 3 0.054 /kWh 0.162
CW circ, gal 600 0.0522 /Mgal 0.031
Fuel, MM Btu 0.3 1.80 /MMBtu 0.54
Catalyst repl, $ 0.10 0.10
Royalty, $ 0.075 0.075

Labor/bbl feed = (2)(8)(3)(17.37)/(8,400) = 0 10

Total direct operating costs 1.08
10.6 Cost/bbl reformate as function of severity.
C5+ reformate yield at 96 RON = 86.0 v% at 90 RON = 90.2 v% (Fig. 10.4)

Operating cost /bbl reformate @ 96 RON = ($1.08/0.86) = $1.26 Operating cost /bbl

reformate @ 90 RON = ($1.08/0.902) = $1.20

10.7 Single largest component of direct operating cost is fuel cost.

50.2% of DOC including royalty & 54.0% of DOC excluding royalty.

 Chapter 11
11.1 Feed: 2,700 BPD C4= and 2,350 BPD iC4.
From Table 11.5, 1.2 bbl iC4 required /bbl C4 :. iC4 is limiting reactant and only 1,958 bbl C4 can
react.
Product: BPCD
C4= 742
nC4 249
133 1
C5
Alkylate 2,959 J Total alkylate = 3,092 BPD
J
Btms. 233
Tar 19

11.2 Feed to alkylation unit:

Butylene 1,750 BPD Propylene 1,550 BPD
iC4 req’d 2,100 iC4 req’d 2,480

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

11.3 Alkylation unit material balance.

Component BPD lb/h/BPD lb/h iC4 req’d, BPD

Feed:

C3= 1,710 7.61 13,013 2,736

C4= 3,320 8.76 29,083 3,984

C5= 1,550 9.45 14,648 2,170

iC4 9,570 8.22 78,665

Total 16,150 135,409 8,890

Products: BPD lb/h/BPD lb/h

C3 510 7.42 3,784

680 8.22 5,590
iC4
nC4 422 8.51 3,591

C5 1,050 9.18 9,639

Alkylate 10,000 10.22 102,216
Btms 833 9,309
Tar, 20°API 94 13.62 1,280
J
Total 1,977 135,409
Feed Pentane Alkylate Btms Tar
123 2,726 215 29
C3=
226 5,017 395 32
C4=
C5= 701 2,257 223 33
Total 1,050 10,000 833 94

11.4 Construction costs and chemical & utility requirements.

Total C5+ alkylate production= 11,050 BPSD Construction cost= $50,000,000
(Fig11.6)
HF H2SO4 Utility and
Item Chemical
Costs
Amt $/bbl* Amt $/bbl*

Steam, lb/B 200 0.45 200 0.45 2.25 /Mlb

Power, kWh/B 3.7 0.20 4.6 0.25 0.054/kWh
CW, gal/B 3,700 0.19 3,300 0.17 0.0522/Mgal
Acid, lb/B 0.3 0.14 30 0.90 BF= 0.46/lb
Caustic, lb/B 0.2 0.06 0.06 H2SO4 0.03/lb
0.2
Caustic=0.29/lb
Royalty, $B 0.03 0.03 0.04 0.04
Total 1.07 1.87
* $/bbl TA
 11.11 Overall material balance.

Component BPCD °API lb/h/BPD lb/h bbl iC4 req'd

Feed:

C3= 1,550 7.61 11,796 2,480

C4= 3,520 8.76 30,835 4,224

C5= 1,800 9.45 17,010 2,520

iC4 9,510 8.22 78,172

Total 16,380 137,813 9,224

Products:

C3 462 7.42 3,428

iC4 286 8.22 2,351

nC4 447 8.51 3,804

C5 1,164 9.18 10,685

Alkylate 10,411 70.4 10.23 106,453
Btms 873 53.5 11.16 9,765

Tar 98 21.0 13.54 1,327

Total 13,741 137,813

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

C4= 239 5,319 54,442 419 4,631 34 463

C5= 814 2,621 26,568 259 2,990 38 510

Total 1,164 10,411 106,084 873 9,765 98 1,327

 11-12 Construction cost and annual chemical and utility requirements. 97.2% on-stream
factor. 9,000 BPCD = 9,260 BPSD.
2005 construction cost, U.S. Gulf Coast = $48,000,000

Annual utility and chemical requirements:

HF alkylation unit
/bbl TA /CD Annual
Steam, lb 11 99 x 103 36,135 x 103
Cooling water, gal circ 3,700 33.3 x 106 12,154 x 106
Acid, lb 0.3 2,700 986 x 103
Caustic, lb 0.2 1,800 657 x 103
Sulfuric acid unit

Steam, lb 200 1.8 x 106 657 x 106

Cooling water, gal circ 3,300 29.7 x 106 10,841 x 106
Acid, lb 30 270 x 103 98,550 x 103
Caustic, lb 0.2 1,800 657 x 103

11.13
Feed: BPCD lb/h

C4= 2,500 21,875

iC4 2,800 22,981

Total 5,300 44,856

Products:

C4= 167 1 458

nC4 297 2,532

C5 159 1,445

C5+ alkylate 3,525 36,048

Bottoms 278 3,067
Tar, 20° API 22 306
Total 4,448 44,856
 Chapter 12

12.1 Amount n-butane to give desired RVP.

Item Bbl °API MABP lb/bbl lb MW Moles Mol% RVP PRVP

LSR 750 78.6 140°F 236.1 177075 84 2108 32.4 11.1 3.60
HSR 1250 48.2 280 275.7 344625 120 2872 44.2 1.0 0.44
620 57.0 235 263.1
C5 + T 163122 107* 1525 23.4 4.0 0.94
Total 2620 J
6505 100.0 4.98
Maxwell, J.B., "Data Book on Hydrocarbons", D. Van Nostrand, New York, 1950.

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

nC4 MW= 58 RVP = 52.0

12.2 PON of blend in 12.1 if 10% MTBE was added:

Component Bbl v% RON pRON* MON pMON*

n-butane 170 5.5 93.0 5.14 92.0 5.06
LSR naphtha 750 24.2 66.4 16.06 61.6 14.91
HSR naphtha 1,250 40.3 62.3 25.12 58.7 23.66
TCC naphtha 620 20.0 85.5 17.10 76.6 15.32
MTBE 310 10.0 119 11.9 101 10.1
Total 3,100 100.0 75.3 69.1
PON = (75.3 + 69.1)/2 = 72.2
 12.3 Blending gasoline

Component Bbl RVP VPBI Bbl x VPBI

nC4 W 52.0 138 138W

LSR naphtha 2,730 11.1 20.3 55,419

94 RON reformate 2.490 2.8 3.62 9,014

Hvy hydrocrackate 6,100 1.1 1.12 6,832

C5+ FCC naphtha 3,600 4.4 6.37 22,932

Total 14,920 + W 138W + 94,197

For 12.5 psi, VPBI = 23.5 23.5(14,920 + W) = 138W + 94,197

W = 2,240 bbl nC4 to give 12.5 psi RVP

Component Bbl Vol % RON vol fract x RON

nC4 2,240 13.1 93.0 12.2

LSR naphtha 2,730 15.9 66.4 10.6
94 RON reformate 2,490 14.5 94.0 13.6
Hvy hydrocrackate 6,100 35.5 67.6 24.0

FCC C5+ naphtha 3,600 21.0 19.4

Total 17,160 100.0 79.8

(79.8)(1-x) + 118x = 90 x = 0.267

26.7 v% ethanol to get a 90 RON for blend. regulations.

12.4 Flash point calculation.

Component Bbl Vol Frac Flash pt., ° F FPBI8 (vol frac)(BI)
A 2,500 0.222 120 331 74

B 3,750 0.333 35 18,900 6,294

C 5,000 0.444 150 108 48

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

12.6 Viscosity of blend.

Reference Table 12.3.
Component Bbl Vol Frac Viscosity, cSt Viscosity BI (vol frac)(BI)
A 2,000 0.2 75.5 0.419 0.0983
B 3,000 0.3 225 0.5725 0.1718
C 5,000 0.5 6,500 0.730 0.365
Total
0.6351
.•. Viscosity of blend = 700 cSt @ 130'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

C5+ alkylate 4,500 4.6 6.73 30,285

Hvy hydrocrackate 9,150 1.1 1.12 10,248
94 RON reformate 11,500 2.8 3.62 41,630

C5+ FCC naphtha 15,600 4.4 6.37 99,372

Total 46,750 + W 310,715 + 138W
12.11 (cont'd)

For 12.0 psi RVP, VPBI = 22.3

22.3(46,750 + W) = 310,715 + 138 W
W = 6,325 BPSD

Component BPSD Vol frac RON pRON MON pMON

n-butane 6,325 0.119 93.0 11.07 92.0 10.95

LSR naphtha 4,200 0.079 66.4 5.25 61.6 4.87

Lt hydrocrackate 1,800 J 0.034 82.8 2.82 82.4 2.80

C5+ alkylate 4,500 0.085 97.3 8.27 95.9 8.15

Hvy hydrocrackate 9,150 0.172 67.6 11.63 67.3 11.58

94 RON reformate 11,500 0.217 94.0 20.40 84.4 18.31

C5+ FCC naphtha 15,600 0.294 92.3 27.14 76.8 22.58

Total 53,075 1.000 86.6 79.2
PON = (86.6 + 79.2)/2 = 82.9
14.1 PROBLEMS

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:

Crude Oil 1 Crude Oil 2

Gasoline 0.15 0.25

Diesel Oil 0.25 0.25
Fuel Oil 0.6 0.50

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:

Gasoline Material Balance 0.15X1 + 0.25X2 = X3

Diesel Oil Material Balance 0.25X1 + 0.25X2 = X4
Fuel Oil Material Balance 0.6X1 + 0.5X2 = X5
Gasoline Sales Constraint X3 < 30,000
Fuel Oil Sales Constraint X5 < 100,000

Objective Function: Maximize -45X1 + -41X2 + 65X3 + 60X4 + 50X5

Where, X1 = Crude Oil 1 flow

X2 = Crude Oil 2
X3 = Total Gasoline
X4 = Total Diesel Oil
X5 = Total Fuel Oil
2. Develop a vector based Alkylation model feeding Propylene feedstock using the yield
data shown in the Alkylation and Polymerization Chapter.

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

Utility consumption based on HF Alkylation.

3. Develop a delta base process model for a delayed coking unit using the data in the
Coking and Thermal Processing Chapter. It is only necessary to describe the coke and
gasoline yields.

Solution:

Feed Base Delta Delta

Yield API Con
(Assumed) Carbon

Feed 1.0 -1.0

GASOLINE 24.4 -0.8 0.4

GAS OIL 43.0 -0.6 -4.5

API -12 10.0 2.0

CON CARBON -22 20.0 2.0

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

Gross Margin($1,000/D) 165 150

Solution:

Breakeven Value $40.00 – 15/10 = $38.50

5. The sales department has an opportunity to sell an additional 10,000 BPD gasoline at
$55.00/Bbl. Using the data from the refinery LP shown below determine if this sell is
profitable.

BASE CASE CASE 1

Regular Gasoline ($60/B) 50,000 50,000

Premium Gasoline ($65/B) 50,000 50,000
Jet Fuel ($50/B) 20,000 20,000
Alternate Reg Gasoline ($55/B) 0 10,000

Gross Margin ($1,000/D) 100.00 102.00

Solution

Breakeven Value 55 - (102-100)/10 = $53.00

 48171

ISBN 1-420-04817-1

00 AM 48171.indd 5 5/29/07 11:34:42 AM