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PS3000: Refinery Operations Simulator REFINERY OPERATIONS SIMULATOR The PS3000 is a simulation software package is

PS3000: Refinery Operations Simulator

REFINERY OPERATIONS SIMULATOR

The PS3000 is a simulation software package is rigorous and detailed simulation models of Refinery process plants.

The package consists of the following modules:

PS-3001 PS-3002 Atmospheric Distillation Unit Vacuum Distillation Unit PS-3003 Fluid Catalytic Cracking Unit PS-3004
PS-3001
PS-3002
Atmospheric Distillation Unit
Vacuum Distillation Unit
PS-3003
Fluid Catalytic Cracking Unit
PS-3004
Hydrogen Generation Unit
PS-3005
Hydrodeslphurization Unit
PS-3006
Catalytic Reforming Unit
PS-3007
Continuous Catalytic Regeneration Unit
PS-3008
Hydrocracking Unit
PS-3009
PS-3010
Sulphur Recovery Unit
Amine Treating Unit

Plant familiarization: Simulator offers the best platform for learning process plant configuration, instrumentation, control system, critical parameters and their design values and normal plant operations.

Ensure Smooth Start Ups: Plant Simulator allows operators to become familiar with operation while they increase their familiarity with the controls and graphical scenes. Continued training ensures increasingly smooth start-ups in the future.

Reduce Incidents and Downtime: Training personnel in a non-destructive environment enable you to validate emergency controls before actual use. Testing modifications to compressor controls can avoid damage from surges. One can purposely trigger malfunctions (such as a trip) to test operator reactions and improve response reactions.

Maximize Performance: The Simulators are based on rigorous first-principles models and actual controls, allowing you to troubleshoot actual process and

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator control problems. They unlock the fundamental understanding required to modify,

PS3000: Refinery Operations Simulator control problems. They unlock the fundamental understanding required to modify, test, and improve processes and maximize plant performance.

Benefits to Academic Institutions: The Dynamic Simulator helps to teach the students the fundamentals as well as complex process operations. It provides opportunity for the chemical / instrumentation engineering students to know what is happening in the industry. Simulator trained students will have edge over their counterparts in the competitive scenario with respect to their knowledge in Instrumentation & Control and Process operations.

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3001: ATMOSPHERIC DISTILLATION UNIT PROCESS DESCRIPTION In Preheat I section,

PS3000: Refinery Operations Simulator

PS3001: ATMOSPHERIC DISTILLATION UNIT

PROCESS DESCRIPTION

In Preheat I section, crude is heated by a series of heat exchangers with kerosene,

Diesel and Pump around as a heating medium In Desalter, the impurities such as salt and other contaminants are removed from crude by the desalting process. In Preheat

II section, the desalted crude is again heated by a series of heat exchangers with

kerosene, Diesel, Pump Around and reduced crude oil as heating medium.

In Crude Heater, the natural draft furnace heats the crude oil to a high temperature

enough to permit separation of components in distillation column. In Crude Column, the tower contains 49 trays, which facilitates the contact between vapor and liquid and through fractionation the crude oil components are separated into desired materials for further processing.

In Product Stripper, the products like Naphtha, Kerosene and Diesel are separated

according to their boiling range. Three pump around systems namely, Top, Middle and Bottom Pump around are employed to maintain the desired temperature gradient in the tower.

The stabilizer unit is designed to stabilize the naphtha from the feed coming from the overhead accumulator of a crude distillation unit. Stabilized naphtha and LPG are the products from the stabilizer.

MAJOR EQUIPMENT

Feed pump and preheat exchangers Desalter Pre heat exchangers Crude heater Atmospheric Distillation Tower Pump around systems Products strippers Product coolers Overhead condenser and reflux drum Stabilizer

TRAINING EXERCISES

Crude feed pump failure Booster pump failure RCO Pump failure Reflux pump failure Stabilizer Reflux Pump failure Steam failure Power failure Instrument Air failure Fin Fan failure Atomizing Steam Indication failure

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

TRAINING BENEFITS PS3000: Refinery Operations Simulator This dynamic simulator helps beginners, experienced operators and

TRAINING BENEFITS

PS3000: Refinery Operations Simulator

This dynamic simulator helps beginners, experienced operators and engineers to achieve the following objectives:

To teach trainees and to recognize, understand the operating fundamentals of a Crude Distillation using dynamic simulation.operators and engineers to achieve the following objectives: To describe about the operation of a Crude

To describe about the operation of a Crude Distillation.of a Crude Distillation using dynamic simulation. To Startup and shutdown of the process using documented

To Startup and shutdown of the process using documented procedures.To describe about the operation of a Crude Distillation. To respond safely and efficiently to disturbances

To respond safely and efficiently to disturbances and malfunctions in the process.and shutdown of the process using documented procedures. SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore,

efficiently to disturbances and malfunctions in the process. SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore,

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3002: VACUUM DISTILLATION UNIT PROCESS DESCRIPTION In the vacuum Distillation Unit

PS3000: Refinery Operations Simulator

PS3002: VACUUM DISTILLATION UNIT

PROCESS DESCRIPTION

In the vacuum Distillation Unit model, the bottom reduced crude oil (RCO) from the atmospheric column is distilled into the following products: Light Vacuum Gas Oil (LVGO), Medium Vacuum Gas Oil (MVGO) and Heavy Vacuum Gas Oil (HVGO). The vacuum bottoms exit the process as vacuum residue. The vacuum Distillation Unit simulator, the entering feed passes through a preheat furnace where partial vaporization occurs before the feed enters the distillation column. Vacuum column operates below atmospheric conditions. The vacuum product cooling section consists of steam generation facilities and tempered water cooling facilities. Vacuum is maintained by a two stage ejector system. The vacuum column overhead vapor flows to the pre-condensers where steam & products are condensed out. The balance vapor passes through the first stage ejector. The discharge from the first stage goes to the inlet condenser and the non-condensed vapors are sent to the second stage. The discharge of the second stage goes to the after condenser and the non-condensable are routed to atmosphere. Condensate is routed to the hot well, from which it is pumped to the desalting water drum by sour water pumps. The condensed steam and the slop oil are let into the Hot well from where it is pumped away.

MAJOR EQUIPMENT

Vacuum Furnace Vacuum Distillation Column Product stripper Product cooling Overhead ejector system Hot well

TRAINING EXERCISES

Feed failure Coil steam failure Heater fuel failure Cooling Water failure Vacuum failure Pump Failures Change in Heater Efficiency Change in Steam Jet Ejector Efficiency Change in Circulating Reflux Change in Internal Reflux

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator TRAINING BENEFITS The Vacuum Distillation Unit simulator helps beginners,

PS3000: Refinery Operations Simulator

TRAINING BENEFITS

The Vacuum Distillation Unit simulator helps beginners, experienced operators and engineers to achieve the following objectives:

To teach trainees and to recognize, understand the operating fundamentals of a Vacuum Distillation unit using dynamic simulation.operators and engineers to achieve the following objectives: To describe about the operation of a Vacuum

To describe about the operation of a Vacuum Distillation unit.of a Vacuum Distillation unit using dynamic simulation. To Startup and shutdown of the process using

To Startup and shutdown of the process using documented procedures.describe about the operation of a Vacuum Distillation unit. To respond safely and efficiently to disturbances

To respond safely and efficiently to disturbances and malfunctions in the process.and shutdown of the process using documented procedures. SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore,

efficiently to disturbances and malfunctions in the process. SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore,

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3003: FLUID CATALYTIC CRACKING UNIT PROCESS DESCRIPTION FCC unit simulator

PS3000: Refinery Operations Simulator

PS3003: FLUID CATALYTIC CRACKING UNIT

PROCESS DESCRIPTION

FCC unit simulator consists of the following major sections:

Feed and pumping sectionFCC unit simulator consists of the following major sections: Reactor and Regenerator section Fractionation section Gas

Reactor and Regenerator sectionof the following major sections: Feed and pumping section Fractionation section Gas concentration section The

Fractionation sectionFeed and pumping section Reactor and Regenerator section Gas concentration section The Fluidized Catalyst Cracking

Gas concentration sectionReactor and Regenerator section Fractionation section The Fluidized Catalyst Cracking Unit (FCCU) upgrades

The Fluidized Catalyst Cracking Unit (FCCU) upgrades relatively heavy hydrocarbon to high grade lighter products via fluidized catalytic cracking and fractionation. The heavy hydrocarbon oil makes contact with hot powdered catalyst under selected conditions of time, temperature and pressure. The unit cracks the heavy hydrocarbon oil into fuel gas, LPG, Gasoline, TCO and CLO. In Preheater section, feed is preheated through heat exchanger with the help of slurry from fractionator bottom.

In Reactor/Stripper section, the oil feed enters the base of the reactor risers in a liquid or partially vaporized state, and is then completely vaporized by contact with the hot regenerated catalyst dropping from the regenerator standpipes into the riser lines. In Regenerator section, the coke deposits accumulated on the catalyst in the reactor are burned off at high temperature in the presence of air In Fractionator section, it separates the reactor vapor effluent into a wide range of cracked hydrocarbons as product streams.

In Gas concentration section, Dry gas, LPG and Stabilized gasoline are separated from wet gas and unstabilized gasoline. The gas concentration section mainly consists of Wet Gas Compressor (WGC), Primary Absorber, Sponge Absorber, C2 Stripper and Debutanizer.

UNITS SIMULATED

TRAINING EXERCISES

Feed Surge drum and preheat exchangers Riser, Reactor, stripper Regenerator Flue gas waste recovery Air Blower Fractionator Furnace Main Fractionator Slurry Steam generators Product Strippers Wet Gas Compressor

Feed failure Air blower failure WGC failure Cooling water failure Power failure Instrument air failure Fail stack slide valve Fail spent catalyst slide valve Fail regenerator standpipe slide valve Pump Failures

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator High Pressure Separator Primary Absorber Sponge Absorber C2 Stripper Debutanizer

PS3000: Refinery Operations Simulator

High Pressure Separator Primary Absorber Sponge Absorber C2 Stripper Debutanizer

Valves failures Change in catalyst activity Water in feed Change in feed CONCARBON Number Heat exchanger / cooler / reboiler fouling Passing of FG in DFAH Passing of torch oil to regenerator Passing of BFW in regenerator

TRAINING BENEFITS

The Fluid Catalytic Cracking Unit simulator helps beginners, experienced operators and engineers to achieve the following objectives:

operators and engineers to achieve the following objectives: To teach trainees and to recognize, understand the

To teach trainees and to recognize, understand the operating fundamentals of a Fluidised Catalytic Cracking using dynamic Simulation.

To identify the main equipment and operations associated with Fluidised Catalytic Cracking of a Fluidised Catalytic Cracking using dynamic Simulation. To Startup and shutdown of the process using
To identify the main equipment and operations associated with Fluidised Catalytic Cracking

To Startup and shutdown of the process using documented procedures and operations associated with Fluidised Catalytic Cracking To respond safely and efficiently to disturbances and

To respond safely and efficiently to disturbances and malfunctions in the process.

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SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3004: HYDROGEN GENERATION UNIT PROCESS DESCRIPTION The Hydrogen unit is designed

PS3000: Refinery Operations Simulator

PS3004: HYDROGEN GENERATION UNIT

PROCESS DESCRIPTION

The Hydrogen unit is designed for a capacity of 4754 kg/hr of Hydrogen. The feed to the unit is Naphtha. The Hydrogen unit is divided into five main sections:

DesulphurizationThe Hydrogen unit is divided into five main sections: Reforming CO conversion (shift section) Separation of

Reformingunit is divided into five main sections: Desulphurization CO conversion (shift section) Separation of H2 (excluding

CO conversion (shift section)divided into five main sections: Desulphurization Reforming Separation of H2 (excluding PSA unit) Steam Generation

Separation of H2 (excluding PSA unit)Desulphurization Reforming CO conversion (shift section) Steam Generation Desulphurisation unit consists of three

Steam Generation(shift section) Separation of H2 (excluding PSA unit) Desulphurisation unit consists of three reactors,

Desulphurisation unit consists of three reactors, Hydrogenator R401 followed by two H2S absorbers R402 A/B in series. In reforming section, the hydrocarbon feed is converted into synthesis gas consisting mainly of H2, CO and CO2, besides a minor amount of CH4.

In Shift section, CO is converted to CO2 by reaction with H2O hereby generating H2. At startup and during upsets it is possible to bypass the shift section at the expense of a reduced H2 production. In Separation of H2, the shifted process gas contains H2, CO2 and steam, besides a minor amount of CO and a slip of methane. The produced H2 is separated in the PSA unit (Pressure Swing Adsorption) which also treats HCU off-gas as a feedstock. In Steam generation section, 42 kg/cm2 steam is produced in the H2 generation plant can be used as process steam for heat transfer within the unit and for steam export.

UNITS SIMULATED

Feed drum and preheat exchangers Desulphurization Reactors Pre reformer Tubular reformer Medium Temperature Shift converter Low Temperature Shift converter Recycle compressors Deaerator and BFW pumps BFW preheaters Process Condensate separators

TRAINING EXERCISES

Feed failure Pump failures BFW failure IF, FD fan failures Cooling water failure Power failure Fail Recycle Hydrogen compressor Start-up N2 compressor Reformer trip PSA trip Reforming plugging H2 gas leak Fouling of heat exchangers Sulpur in feed naphtha Feed naphtha temperature Desulphurization reactor catalyst activity

ZnO bed catalyst activity Reformer catalyst activity MTSC / LTSC catalyst activity PSA Efficiency Ambient air temperature Cooling water temperature

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3005: HYDRODESLPHURIZATION UNIT PROCESS DESCRIPTION HydroDesulphurization unit

PS3000: Refinery Operations Simulator

PS3005: HYDRODESLPHURIZATION UNIT

PROCESS DESCRIPTION

HydroDesulphurization unit Simulator is a dynamic simulation model with following sections:

Feed Section – Heavy gas Oil along with the recycle stream enters into the Feed Drum which Heavy gas Oil along with the recycle stream enters into the Feed Drum which is then sent to Preheaters for Preheating.

Preheat Section and Heater – Feed is heated in series of exchangers and in Fired Heater before entering the Feed is heated in series of exchangers and in Fired Heater before entering the Reactor.

Reactor System - The hot Hydrogen charged feedstock stream enters the top of Reactor for Substitution reactions to occur, removing Sulfur from the Hydrocarbon chains and replacing it with Hydrogen.exchangers and in Fired Heater before entering the Reactor. High Pressure Accumulator system - Product Section

High Pressure Accumulator system -from the Hydrocarbon chains and replacing it with Hydrogen. Product Section - The liquid process stream

Product Section - The liquid process stream from the Cold Flash Drum, and Hot Flash Drum are stripped in Product Stripper to strip out remaining Hydrogen sulfide and the other contaminants from the petroleum product.it with Hydrogen. High Pressure Accumulator system - UNITS SIMULATED Feed drum and preheat exchangers Fired

UNITS SIMULATED

Feed drum and preheat exchangers Fired heater Reactor HP Accumulator Medium Temperature Shift converter Low Temperature Shift converter Recycle compressors Deaerator and BFW pumps BFW preheaters Process Condensate separators

TRAINING EXERCISES

Makeup compressor failure Recycle compressor failure Pump failures Reactor feed heater air preheater Fan failures Cooling water failure Power failure Fail reactor feed heater fuel gas flow Fouling of heat exchangers Reactor catalyst activity Maximum DEA supply rate Hydrogen supply pressure Hydrogen supply purity Fresh feed olefin content Fresh feed sulfur content Reactor feed heater tube rupture Reactor no. 1 plugging

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA
PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3006: CATALYTIC REFORMING UNIT PROCESS DESCRIPTION The Catalytic Reforming unit

PS3000: Refinery Operations Simulator

PS3006: CATALYTIC REFORMING UNIT

PROCESS DESCRIPTION

The Catalytic Reforming unit treats sweet naphtha from the naphtha hydrotreating unit to produce high octane reformate, naphtha and hydrogen rich gas. The Catalytic Reforming reactions involve aromatization, dehydrocyclisation of napthenes, isomerisation and hydrocracking to a certain extent. The Catalytic Reforming unit has four sections, namely, Feed preheat section, Reactor section, Product separator section, Debutaniser section.

In Feed Preheat section, Feed is preheated with the help of heat exchangerssection, Product separator section, Debutaniser section. In Reactor section, it comprises of a reactor and the

In Reactor section, it comprises of a reactor and the interstage heaters where an endothermmic reaction takes place and further it is heated through interstage heaters.section, Feed is preheated with the help of heat exchangers In Product Separator section, the two-phase

In Product Separator section, the two-phase mixture from the condenser flows to the separator. The vapors rich in hydrogen are separated, compressed and recycled back to the CFE.place and further it is heated through interstage heaters. In Debutaniser section, it processes the hydrocarbon

In Debutaniser section, it processes the hydrocarbon liquids which contains the maximum constituents of reformate naphtha and LPG from the separator section.are separated, compressed and recycled back to the CFE. UNITS SIMULATED Feed tank Combined feed exchanger

UNITS SIMULATED

Feed tank Combined feed exchanger Product condenser Charge heater Catalytic reformer 3 stage reactors Inter Heater 2 & 3 Separator Debutaniser

TRAINING EXERCISES

Feed Naphtha supply Pressure Feed Naphtha supply Temperature

Pump failures Cooling water failure Power failure Fuel gas failure Recycle gas compressor failure

Ambient Temperature

Fouling of heat exchangers FO, PG supply pressure

Catalyst Activity

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA
PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3007: CONTINUOUS CATALYST REGENERATION UNIT PROCESS DESCRIPTION The CCR

PS3000: Refinery Operations Simulator

PS3007: CONTINUOUS CATALYST REGENERATION UNIT

PROCESS DESCRIPTION

The CCR regeneration section performs two functions, namely, Catalyst transfer and Catalyst Regeneration

In catalyst Transfer, it is transferred from the Catalytic reforming reactors to the Regenerator and back again to regenerate the catalyst.

In Catalyst regeneration, the coke is burned off at a high temperature and low oxygen concentration and the catalyst passes into the Chlorination Zone where it is oxidized at high temperature and high oxygen concentration (18 to 20 mole %)

The "Logic" is divided into the following:

1. Master Controller

2. Lock Hopper No.1 Controller

3. Lock Hopper No.2 Controller

4. Miscellaneous Logic

Master controller logic contains the logic for the following:

1. Emergency Stop System

2. Regenerator Run-Stop Circuit

3. Catalyst Flow Controller

4. Chemical Selector System

5. Heater Shutdown System

6. Lift Gas Interlock

7. Lock Hopper Selector System

8. Verification

CONTROL SCHEME

TRAINING EXERCISES

Purge gas Flow Controller Lift Gas Flow Controller Hopper Pressure Controller Air Heater Outlet Temperature Controller Regenerator Heater Outlet Temp Controller Air Flow Controller

Lock Hopper failure Pressure Differential Controller failure Chloride Flow failure Downstream failure Regeneration Heater Trip

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator \ SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator \ SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,
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SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3008: HYDROCRACKER UNIT PROCESS DESCRIPTION The Hydrocracking process is a

PS3000: Refinery Operations Simulator

PS3008: HYDROCRACKER UNIT

PROCESS DESCRIPTION

The Hydrocracking process is a versatile process for catalytically hydrocracking heavy petroleum fractions into lighter, more valuable products.

The simulated plant processes a feedstock of vacuum gas oil from the vacuum distillation Column. The feed is converted into lower molecular weight components namely sour gas, heavy naphtha, light naphtha, diesel oil and kerosene. The desired degree of hydrocracking takes place as the feed is processed over a fixed bed of catalyst at elevated hydrogen pressure and temperature. The amount of catalyst required per volume of fresh feed and the pressure level required depend on the nature of the feed and the products desired. When the feed and hydrogen contact the catalyst, nitrogen compounds are converted to ammonia and hydrocarbons, sulfur compounds are converted to hydrogen sulfide and hydrocarbons, and the hydrocarbon feed is hydrocracked into the lower molecular weight products. The effluent from

the reactors is sent to the fractionation section where the products and bottoms are separated. The simulated plant is divided into two major sections to accomplish the hydro cracking process:

A Reactor section, in which the feedstock is processed through two hydrogen-

A

Reactor section, in which the feedstock is processed through two hydrogen-

charged catalytic bed reactors namely lead reactor and main reactor.

A Fractionator section, in which the reaction product is separated into several

A

Fractionator section, in which the reaction product is separated into several

grades of hydrocarbon products, some of which go on to further treatment and some to storage.

MAJOR EQUIPMENT

Feed preheat exchangers and surge drum Lead and Main reactors HP, LP Hot Separators HP, LP Cold Separators H2S absorber Recycle Gas compressor Makeup Hydrogen compressor trains Fractionator furnace Main Fractionator Product strippers

TRAINING EXERCISES

Pump failures Cooling water failure Power failure Fuel gas failure Recycle gas compressor failure MUG compressor failure

Ambient Temperature

Fouling of heat exchangers FO, PG supply pressure

Catalyst Activity for R1, R2

Make-up H2 Purity Heat Exchangers fouling

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3009: SULPHUR RECOVERY UNIT PROCESS DESCRIPTION The process consists of controlled

PS3000: Refinery Operations Simulator

PS3009: SULPHUR RECOVERY UNIT

PROCESS DESCRIPTION

The process consists of controlled combustion of a hydrogen sulfide gas stream, followed by a (catalytic or thermal) reaction between hydrogen sulfide and sulfur dioxide to produce sulfur as a vapor. The vapor is collected and condensed, and the liquid is collected in the sulfur pit. The objectives of the unit operation are not only the production of sulfur, but also the reduction of undesirable gases (such as SO2) being released into the atmosphere. These objectives must be achieved in spite of changes in feedstock properties and upsets to the various operating conditions.

MAJOR EQUIPMENT

Feed gas knockout drums

Combustion chamber Reaction furnace Sulfur condenser 1,2,3, 4 Steam re-heater 1,2,3 Catalytic converter 1,2,3 Sulphur pit

TRAINING EXERCISES

Pump failures Cooling water failure Power failure Fuel gas failure BFW failure

Plugged S Line To Coalescer

Fouling of heat exchangers Feed gas composition

Feed gas temperature

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator PS3010: AMINE TREATING UNIT PROCESS DESCRIPTION In Amine plant, CO2 present

PS3000: Refinery Operations Simulator

PS3010: AMINE TREATING UNIT

PROCESS DESCRIPTION

In Amine plant, CO2 present in the feed synthesis gas is reduced from 54.0% to 0.06% by selective absorption using MEA (Mono Ethanol Amine). Gas handling capacity of the simulated amine plant is 114 TPH of synthesis gas.

Amine plant consists of the following three sections:

Absorber Section

Turbines and Pumps Section

Stripper Section

MAJOR EQUIPMENT

TRAINING EXERCISES

Absorber Column K.O Drum Lean Amine Cooler Lean Amine Heat Exchanger Amine Guard Inhibitor system Lean Solvent Pump A - Motor Driven Lean Solvent Pump B - Turbine Driven Hydraulic Turbine Stripper Column Flash Drum Reflux Drum (D-02) Lean Solvent Exchanger 1 Stripper Overhead Condenser Steam Reboiler Hot Oil Reboiler

Pump failures Power failure Blow absorber relief valve Blow stripper relief valve High CO2 in feed gas Fouling of heat exchanger Cooling water temperature Feed gas temperature Exchanger fouling

Stripper efficiency Absorber efficiency FOAMING IN STRIPPER

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004,

PS3000: Refinery Operations Simulator

PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA
PS3000: Refinery Operations Simulator SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: sales@siminfosystems.com. Website: www.siminfosystems.com