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Simulation Model Increases VBU Conversion
Simulation Model Increases VBU Conversion
visbreaker conversion
Introduction of advanced analytical monitoring, chemical treatment
and process optimisation has raised the profitability of a visbreaker unit
I
n today’s refining climate, control becomes more and more A second step for increasing
the economics of a visbreak- important to prevent drastic unit profitability was based on
ing unit are mainly related negative outcomes. a new development using a
to the conversion levels Severity is a function of oper- proprietary simulation model
achieved. Conversion is limited ating temperatures and velocity of flow regimes and liquid-
by the impact of cracking reac- steam. This article presents a phase velocities across the
tions on the progressive case of optimisation of these visbreaker heater coils as a
destabilisation of the two variables at the Repsol function of flow rates, operat-
asphaltenes present in the unit Tarragona visbreaker, resulting ing temperatures and velocity
feed. This destabilisation causes in major improvements to steam.
fouling phenomena, due to visbreaker conversion. The results of the model were
precipitation of the asphaltenes validated in the unit by Repsol
and conversion of some of the Repsol Tarragona process and operation engi-
asphaltenes to generate coke The Repsol Tarragona refinery neers with Baker Hughes
particles at cracking tempera- is a state-of-the-art 200 000 b/d service engineers and its tech-
tures above 400°C (752°F), and refinery that has broad experi- nical service group. Operational
these phenomena limit unit run ence processing opportunity changes were implemented
lengths. On the other hand, crudes and feeding different based on the results from the
destabilised asphaltenes can residues to the visbreaker unit. simulation work, while the
easily aggregate over time and, The first step of this project impact on fouling and sedi-
since produced visbreaker resid was the implementation of ments formation, which could
is often a base stock for the Baker Hughes’ advanced potentially affect produced fuel
production of heavy fuel oils, analytical VisTec technologies oil quality, was continuously
this can lead to problems with for the rapid and reliable monitored. At the same time,
hot filtration test (HFT) results. assessment of visbreaker tar furnace skin temperature trends
Visbreaker severity is moni- (vistar) and heavy fuel oil were continuously tracked and
tored to maximise conversion, stability, and to evaluate foul- normalised to achieve targeted
taking into account excessive ing tendencies in the unit. This unit run length.
coke generation and the step enabled the refinery to run The implementation of all the
tendency of asphaltenes to the unit close to its operating steps described in this article
precipitate, either inside process limits and maximise conver- resulted in further valuable
equipment or as sediments in sion, while rapidly adapting increases in conversion without
the heavy fuel oil produced. As process conditions to changes negative effects on unit run
fouling increases exponentially in processed feed quality or length and fuel oil
at higher conversions, process flow rate. specifications.
2 Q1 2011 www.digitalrefining.com/article/1000425
Optimal visbreaker operating
limits Pure vapour
In the first phase of the
programme’s implementation Mist (drop) flow Mist evaporation
at Repsol Tarragona, limits for
vistar stability and coke genera-
tion control parameters were
optimised. These parameters Annular flow
0.0% steam
0.1% steam
enon: a rapid increase in skin
0.2% steam
0.3% steam temperatures in one particular
0.5% steam location at a relatively cold
1.0% steam portion of the radiant section.
While several parameters can
affect tube skin temperatures,
including the distribution of
heat or flame patterns in the
Increasing flow rate, ton/h radiant section that can create
higher temperatures on coil
Figure 2 Simulation results of liquid-phase velocities at critical radiant sections skin locally, the simulation
4 Q1 2011 www.digitalrefining.com/article/1000425
revealed that at this location an
annular-type flow regime was
&URNACE OUTLET TEMPERATURE ²#
likely to develop above moder-
6ELOCITY STEAMFEED RATE
ate steam levels of 0.20–0.30
wt%, and this flow regime
would contribute to faster
heater coking. This determina-
tion is interesting, as it
demonstrates how poor flow
regimes can be developed even
at moderate steam injection
rates in the case of vertical
furnace tubes.
Calculations at 90 t/h (198
416 lb/h) flow rate show the
different transitions in this Figure 3 Test run: steps in steam percentage and heater outlet temperatures
tube, with the development of
annular flow regimes (see unit feed rate can be deter- Test run for velocity and heater
Table 1). mined. The simulation has been outlet temperatures optimal
Most of the modelling effort extended to other operating range
was directed to the hottest part heater outlet temperatures. Based on the simulation results,
of the radiant section. This is The simulation results a detailed programme for the
the most critical part of the revealed the relationship test run was designed by the
furnace in terms of unit run between flow regime and refinery’s process and opera-
length because it is where the liquid-phase velocity at tions engineers, with
rates of skin temperature decreasing steam ratios. Based programmed step-down of
increase are highest. on these results, a test run was velocity steam at a constant
Calculations were performed at programmed at the Repsol flow rate and resid feed qual-
different flow rates and temper- Tarragona refinery. The effect ity. Repsol’s technical staff, in
atures. Table 2 shows the of process changes on the foul- co-operation with Baker
example output at 120 t/h (264 ing tendency of the visbreaker Hughes, provided support for
554 lb/h) and 450°C (842°F) heater and main fractionator definition of the targets and for
heater outlet temperatures. column, as well as existing or its achievement within a test
The ideal flow regime was potential sediments in the run of the Tarragona
identified as a zone between produced heavy fuel oil (fluxed visbreaker. The temperature
bubble type and annular/slug vistar), was monitored using was changed during the test
flow. Optimal steam injection VisTec analytical techniques. run according to the
ratios at 120 t/h (264 554 lb/h)
are then in the range between
0.10 wt% and 0.25–0.30 wt%. Hottest tube in radiant section: simulation results
Under these conditions, flow
regime and liquid-phase veloci-
Steam, Velocity mixed Reynolds Flow regime Flow regime Velocity liquid
ties were in the ideal range. wt% phase, mt/sec, no •105 tube inlet tube outlet phase, mt/sec
Graphs have been created for tube outlet
different simulations. Figure 2 0.00 1.89 5.68 Bubble Bubble 1.72
0.10 2.37 6.87 Intermittent Intermittent 2.23
shows simulation results for
0.20 2.78 7.83 Intermittent Intermittent 2.50
liquid-phase velocity at 450°C 0.30 3.15 8.68 Intermittent Intermittent 2.67
(842°F) heater outlet tempera- 0.50 3.84 1.02 Annular Annular 2.97
ture as a function of flow rate 1.00 5.38 1.50 Annular Annular 3.66
1.25 6.10 1.64 Annular Annular 3.80
and steam injection ratios.
From this graph, optimal
levels of steam as a function of Table 2
0% 0% 0% 0% 0% 00% 0% 0% 0%
Furnace outlet temperature, °C
.0
controlled in the normal range,
22 24 26
0 Isoconversion
9. 9.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
.0
0
.0
0
. 0 8. 0 0.
Then, keeping a constant
2
0
1
an initial decrease of velocity
0
12 14 16
steam was performed, setting it
0
.0
down to 0.40 wt%. Finally, the
0
.0
temperature was set back to the
0
.0
10
00
3/8 4/8 4/8 5/8 5/8 6/8 6/8 7/8 7/8 8/8 the test, 440°C (824°F), while
steam was cut to 0.25 wt%.
Figure 4 Isoconversion and heater outlet temperature during test run Changes in steam percentage
and heater outlet temperatures
are shown in Figure 3.
A marked decrease in steam
resulted in a higher residence
time with a very positive effect
on conversion. The conversion
of resid feed to distillates is
reported as isoconversion, as is
typically used by the refinery
to monitor the visbreaking
unit’s performance, instead of
6ELOCITY STEAMFEED RATE raw conversion. Isoconversion
)SOCONVERSION
takes into account the amount
of distillates within the
produced vistar, whose distilla-
Figure 5 Isoconversion and velocity steam percentage during test run tion would yield a resid with
the same viscosity as the
programme. VisTec monitoring In the first phase, the heater visbreaker feed, and represents
techniques were used to meas- outlet temperature was set the real conversion achieved in
ure the fouling and stability close to the normal limit of VSI the process. Isoconversion is
limits of the vistar and fluxed stability to 442ºC (828°F), start- shown in Figures 4 and 5 as a
vistar (heavy fuel oil) and coke ing from a lower than usual function of changes in tempera-
particle concentrations. operating heater outlet tures and steam ratios.
The reduction in the steam-
to-feed ratio clearly has a
400 1.20 positive impact on severity.
350 Particles (VCI) Steam dilution VSI vistar 1.00
The decrease in steam ratio
Steam, kg/h per pass
300
0.80
from 0.85–0.25 wt% at 440°C
250
VCI/vistar
200 0.60
150 ture resulted in a very marked
0.40
100 increase in isoconversion, from
0.20
50
20% to about 22%. Even when
0
4/8/09 4/8/09 5/8/09 5/8/09 5/8/09 5/8/09 5/8/09 5/8/09 6/8/09 6/8/09 6/8/09 6/8/09
0.00
the temperature was decreased
5.00 17.45 8.30 10.00 11.00 12.00 13.00 16.45 11.15 13.00 17.15 18.30
to 440°C (824°F), the corre-
sponding cut from 0.40–0.25
Figure 6 Velocity steam reduction vs VSI and VCI wt% of steam resulted in a
6 Q1 2011 www.digitalrefining.com/article/1000425
further increase of 1% in
isoconversion. These data
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