Sei sulla pagina 1di 15

MAY 2014 JULY 2014, Vol. 4, No. 3; 1851-1865.

E- ISSN: 2249 1929

Journal of Chemical, Biological and Physical Sciences


An International Peer Review E-3 Journal of Sciences
Available online atwww.jcbsc.org

Section A: Chemical Sciences

CODEN (USA): JCBPAT Research Article

Enhance C5+ Recovery Predicting and Maximizing The


Reformate Production in Naphtha Stabilizer Using HYSYS

Ahmed Raheem Hashim* and Alaa Abdulrazaq Jassim

* 1, 2Department of Chemical Engineering, Basra University, Basrah, Iraq

Received: 19 April 2014; Revised: 28 April 2014; Accepted: 05 May 2014

Abstract: The naphtha stabilizer in Al-Basrah Refinery was subjected to simulation and
optimization to find the optimum operating conditions by using Aspen HYSYS V7.1. A
steady state simulation model is utilized to study the behaviour of multi-component non-
ideal mixture in the naphtha stabilizer distillation. Optimization results showed that, its
possible to increase the recovery of C5+ in the reformate from 97 % in actual unit to
99.6 %, also the reformate production increases about (2.383%) from the actual reformate
production by changing the design variables and operating conditions. A sensitivity
analysis has been used to determine which variable can be used in the optimization tool.
Keywords: Refinery, Stabilizer, Optimization, HYSYS, Sensitivity Analysis.

INTRODUCTION

Naphtha is a generic term applied to refined, partly refined or unrefined petroleum products and liquid
products of natural gas which distill below1 240oC. Naphtha contains varying amounts of its constituents
paraffins, naphthenes, aromatics and olefins in different proportions in addition to potential isomers of
paraffin that exist in naphtha boiling range. Naphtha is used as automotive fuel, engine fuel, and jet-B
(naphtha type). Broadly, naphtha is classified as Light Naphtha and Heavy Naphtha. Light naphtha is used
as rubber solvent, lacquer diluent, while heavy naphtha finds its application as varnish solvent, dyers
naphtha, and cleaners naphtha2. Naphtha is transformed into reformate by catalytic reforming. This
process involves the reconstruction of low-octane hydrocarbons in the naphtha into more valuable high-

1851 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

octane gasoline components without changing the boiling point range. Naphtha and reformate are
complex mixtures of paraffins, naphthenes, and aromatics in the C5-C12 range. In the refineries the crude
oil feedstock is a complex multi-component mixture which has to be separated into groups of compounds.
The complexities of feeds and products made the development of simulating such processes are
important. Simulation is a key step in distillation column optimization problems. Accuracy, speed and
convergence properties are three important factors in selection of proper simulation method. Accuracy
depends mainly on the distillation column modeling assumptions followed by the termination criteria in
simulation steps. Simulation of the chemical processes and unit operations such as distillation column are
an integral part of optimization. As plant problems to be simulated increased in complexity, like safety
problems, feed fluctuations in composition and flow rates temperature fluctuation according to the heat
exchanger load and so on, thats led to further focus on the simulation programs. One example of these
simulators is HYSYS software, which is simulation software developed at Hyprotech Ltd which is being
used to compare the result with simulation program and the actual data for the distillation column. The
simulation program will be the core of the optimization program; it shall be used to simulate the actual
distillation column.
In 2000, Vaughan .M3 simulated a steady state multicomponent multistage distillation column by using
HYSYS software. The thermodynamic properties calculated using Soave-Redlich-Kwong equation of
state. A good working knowledge of HYSYS was concluded and its operation was realized. An
understanding of the benefits, as well as, the idiosyncrasies of HYSYS was also obtained through a lot of
trial and error and reading the help menus and manuals. In 2003, Okeke and Akofe4 optimized gasoline
production in crude oil distillation and naphtha stabilizer unit, where maximizing the yield of gasoline and
its intermediates will directly impact positively on total pool gasoline production. Steady state simulation
of the fractionator and the stabilizer was done by using HYSYS. The operating conditions were depended
for optimizing the fractionator and the stabilizer. The optimization was done by using Hysys software
with using Sequential Quadratic Programming. The effect of the gasoline yield was studied with respect
to the return temperature of the reboiler, where found that decreasing reboiler return temperature lead to
increase the gasoline yield.
In 2005, Vasconcelos et al.5 simulated the debutanizer column of a fluid catalytic cracking unit by using
Hysys software, where the feed was naphtha mixture. The results and the top and bottom temperatures
were analyzed to maintain the appropriate values of the LPG and the gasoline Reid Vapor Pressure. The
reboiler duty and the reflux flow rate were used as manipulated variables. The multi-variable steady state
HYSYS optimizer was used in the optimization, which the net profit is used as the objective function. It
was used the SQP optimization method and the RVP of gasoline as the constraint. In 2009,
Saghatoleslami et al.6 simulated the distillation column of 31 trays with a condenser, two side strippers
and a reboiler in HYSYS software by using Modified Hysim Inside Out method . The distillation was
optimized using Hysys software. To obtain this objective, a nonlinear SQP (Sequential Quadratic
Program) model has been adopted for the optimization purposes. The objective function was chosen in a
way that it would maximize the annual income. In 2010, Begum et al.7 studied the quality of three
products of a fractionation column considering different design conditions of the column using natural gas
condensate as column feed. The whole simulation study and analysis was done on ASPEN HYSYS V7.1.
Design basis for simulation used are: fluid package Peng-Robinson, method of simulation pseudo-
component, generation and plate by plate calculation, solver HYSIM Inside-Out, properties generation
HYSYS properties. In 2010, Moghadassi et al.8 carried out the simulation of the atmospheric distillation
unit of an existing petroleum refinery by using Hysys software. Optimization was performed on the

1852 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

prepared simulation through the use of a sequential quadratic programming approach (SQP) by using
Hysys optimizer. The objective function consisted of energy minimization and production level
maximization. The results obtained from optimization were implemented on the real process and it was
demonstrated that the suggested changes increased overhead production levels and maintained product
quality. In 2010, Nawaz and Jobson9 simulated a demethanizer by using HYSYS 2006.5 software to
determine the process power requirement and its sensitivity to selected variables. The process separates
ethane and heavier components, from natural gas (NG). The optimization problem solved by the SQP
algorithm is carried out in MATLAB using the function fmincon. The objective function is to minimize
the total power requirement for the process. The results after optimization were the operating pressure is
36 bar and the reflux ratio is 0.6. In 2011, Sharifzadeh and Thornhill10 simulated and optimized a
sequence of three distillation towers that separate C5, C6, C7+ and heavy-ends products. The first column,
depentanizer, has three products. The required computational effort of simulating the process is relatively
high because the pyrolysis gasoline must be estimated by 34 components. The modified Peng- Robinson
equation of state is applied for thermodynamic calculation. The simulation is performed using Aspen-
HYSYS V7.1 and the optimization algorithm is GA toolbox of MATLAB which is linked to Aspen
HYSYS. In 2012, Jibril et al.11 simulated an atmospheric crude distillation tower by using HYSYS
software, the column consist of 29 trays plus a partial condenser. The simulation results showed that the
column needed to be optimized in order to convert more of the atmospheric residue into other premium
products like diesel, kerosene and naphtha.
In 2012, Moghadam et al.12 investigated condensate stabilization using two methods of multistage flash
vaporization and distillation (fractionation) by using HYSYS simulation software, where a distillation
column with a reboiler and without any condenser (non-refluxed column) was used. The scope of this
process is to separate very light hydrocarbon gases, methane and ethane in particular, from the heavier
hydrocarbon components (C3+). Peng Robinson equation of state was applied for thermodynamic
calculations of both gas and liquid phases. It was found that heat duty in multistage flashing is much
higher than distillation while liquid recovery is less than the stabilization unit. The results showed that
depending on the properties of feed to be stabilized, the fractionation method is preferred over the
multistage flashing. In 2012, Raji et al.13 modeled and simulated a single stage distillation which used as
main fractionators for vapor effluents from fluid catalytic cracking (FCC) unit and separation into end
products recovery such as the flue gases, gasoline (C5+) and bottom oil.
A computer based model was Presented that can simulate and optimize the performance of an existing
industrial (FCC) unit in steady state. Computer simulation was carried out using Hysys V3.2, where Peng
Robinson was used as equation of state in the modeling. The simulation studies to optimize the unit was
performed by manipulating various process variables such as the molar flow rate of recycle bottom oil
and reflux ratio, which were subject to constraint Reid Vapor Pressure (RVP) of gasoline. The objective
function was to maximize net profit of the desired products. The effect of the reflux ratio was studied on
the objective function which is the net profit, where found that as the reflux ratio decreases from 6.76 to 4
the gasoline product flow decreases as well but the net profit percentage showed the net profit change of
0.0027 and 0.0047 respectively. In 2013, Binous and Bellagi14 investigated the fractionation of various
industrially relevant hydrocarbon mixtures, where the mixture is light hydrocarbons (ethane, propane,
butane, pentane, hexane and heptanes. The overhead product of this column is propane rich and is
condensed in the condenser. The simulation has been done by using Mathematica software. Simulation
results were compared to those obtained using Aspen-HYSYS software. In calculations with Mathematica
and Aspen HYSYS, the Peng-Robinson equation of state has been used.

1853 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

Simulation of Naphtha Stabilizer: In this simulation, the unstabilized naphtha feed stream containing
hydrogen, methane, ethane, Propene, Propane through n-Tetradecane is processed in a distillation column
to remove Hydrogen and the lighter hydrocarbons. A vapor (off gas) and liquid (LPG) draw are taken off
the overhead receiver, while the reformate off from the bottom yielding a liquid product with a high
octane number. A flow sheet for this process is shown below in Figure 1.

Figure 1: Process flow sheet for naphtha stabilizer.

The molar flow rate of the feed stream was set at 390.34 kgmol/hr, with a temperature of 176 oC and
pressure of 14 kg/cm2. The distillation column was set up with 30 trays and the feed stream entering at
tray 16. In the simulation of naphtha stabilizer the Peng-Robinson Package was selected. The main reason
behind this, it is widely used for refinery simulation as it can handle the hypothetical pseudo-components.
From properties generation, two databases can be used for ASPEN HYSYS 7.1 HYSYS properties and
ASPEN properties.
Sensitivity Analysis: The objective of this process is to evaluate the influence of main variables on the
recovery of C5+ in order to decide which variables should be optimized. The sensitivity analysis is done
using Aspen HYSYS as a tool to evaluate different variables over the reformate production, as well as the
condenser and reboiler duty in the distillation column. The variables listed below are the ones tested.
1. Number of Stages (NS)
2. Reflux Mole Ratio (RR)
3. Reboiler heating duty
4. Condenser heating duty
5. Feed Stage (FS)
6. Feed Temperature (TF)
7. Feed flow rate (F)

1854 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

As can be seen in Figure 2. The number of stages and the reflux ratio were analyzed, where more reflux
ratio gives the highest C5+ recovery. Moreover, columns with the number of stages greater than 32, give
the same C5+ recovery in the reformate, for all the cases studied. This means that increasing the number
of stages above 32 would not affect the separation.

Recovery of C5+ in the Reformate RR 0.5


1
RR 1
0.98
RR 1.5
0.96
C5+ recovery

0.94 RR 2

0.92 RR 2.5
0.9
RR 3
0.88
RR 3.5
0.86
N=26 N=28 N=30 N=32 N=34 N=36 RR 4
Number of Stages

Figure 2: Influence of the number of stages and reflux ratio in


the C5+ recovery in the reformate.

Condenser Duty
2000
RR 0.5
1800
RR 1
Condenser Duty in KW

1600
1400 RR 1.5
1200 RR 2
1000
RR 2.5
800
600 RR 3
400 RR 3.5
200
RR 4
0
26 28 30 32 34 36
Number Of Stages

Figure 3: Influence of the number of stages and reflux ratio on the


condenser duty.

1855 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

Reboiler Duty RR 0.5


3000
RR 1

Reboiler Duty in KW
2500
RR 1.5
2000
RR 2
1500
RR 2.5
1000
RR 3
500
RR 3.5
0 RR 4
26 28 30 32 34 36
Number of Stages

Figure 4: Influence of the number of stages and reflux ratio


on the reboiler duty.

On Figures 3 and 4 the energy (condenser and reboiler) duty is analyzed using the same variables. As can
be seen the condenser and reboiler duty do not have changes on the recovery of C5+ for different stage
number column, while more reflex ratio require more energy consumption, where at higher reflux ratios,
greater condenser and reboiler duty needed. In Figures 5 to 7 the feed stage location influence is studied.
A similar behavior with the number of stages is observed: columns with more than 30 stages show similar
curves.

0.98 C5+ recovery in reformate


0.979
0.978
0.977 N=26
C5+recovery

0.976 N=28
0.975 N=30
0.974 N=32
0.973
N=34
0.972
0.971
0.97
14 15 16 17 18 19
Feed Stage

Figure 5: Influence of the number of stages and the feed


stage in C5+ recovery in the reformate.

1856 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

Reboiler Heat Duty


2115
2110
N=26
2105
Qr in KW
N=28
2100 N=30
2095 N=32
2090 N=34

2085
14 15 16 17 18 19
Feed Stage

Figure 6: Influence of the number of stages and the feed


stage in the reboiler duty.

Condenser Heat Duty


1395
1390
1385
1380 N=26
Qc in KW

1375 N=28
1370 N=30
1365
N=32
1360
1355 N=34
1350
14 15 16 17 18 19
Feed Stage

Figure 7: Influence of the number of stages and the feed stage in


the condenser duty.

In Figure 5. It is shown that if the feed stage location changed there is no much effect on the C5+
recovery in the reformate. A similar behavior is exposed on Figure 6 and Figure 7, where the influence of
the feed stage and the number of stages is analyzed over the condenser and reboiler duties. In the Figures
8, 9 and 10 below it shows that there are small effect or almost absent for changing the stages from 26 to
34 by changing the feed temperature on the recovery of C5+ in the reformate, while the cooling duty will
increases with increasing the feed temperature and heating duty decreases but still the effect of changing
the number of stages absent for the stages from 26 to 34.

1857 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

C5+ recovery
0.978
0.977
N=26
0.976
0.975 N=28
0.974
N=30
0.973
0.972 N=32
0.971 N=34
0.97
125 135 145 155 165 175 185 195
Feed temperature in oC

Figure 8: Influence of the number of stages and the feed temperature


on C5+ recovery in the reformate.

Reboiler duty in KW
4000
3500 N=2
3000 6
2500 N=2
2000 8
N=3
1500
0
1000
N=3
500
2
0
125 135 145 155 165 175 185 195
Feed temperature in oC

Figure 9: Influence of the number of stages and the feed temperature


on Reboiler duty.

Condenser Duty in KW
1500
1450
N=26
1400
N=28
1350
N=32
1300
N=34
1250
125 135 145 155 165 175 185 195
Feed Temperature in oC

Figure 10: Influence of the number of stages and the feed


temperature on Condenser duty.

1858 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

As shown in the Figures 11to 13 the effect of changing the feed flow by changing the number of stages
on the recovery of C5+ in the reformate is slightly changed and can be ignored while in case change the
feed flow with changing the number of stages the heating flow will increase dramatically.

C5+ recovery in reformate


0.9752
0.975
0.9748
N=26
0.9746 N=28
0.9744 N=30
0.9742 N=32
0.974 N=34
0.9738
0.9736
225 250 275 300 325 350 375 400 425
Feed flow in kmole/h

Figure 11: Influence of the number of stages and the feed flow on
C5+ recovery in the reformate.

Condenser Duty in KW
1600
1400
1200 N=26
1000 N=28
800 N=30
600 N=32
400 N=34
200
0
225 250 275 300 325 350 375 400 425
Feed Flow in Kmole/h

Figure 12: Influence of the number of stages and the feed flow on
Condenser duty.

1859 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

Reboiler Duty in KW
2500

2000 N=26
N=28
1500
N=30
1000
N=32
500 N=34

0
225 250 275 300 325 350 375 400 425
Feed Flow in kmole/h

Figure 13: Influence of the number of stages and the feed


flow on Reboiler duty.

From above study the more variables that can effect on the recovery of C5+ and the reformate production
are the reflux ratio, the cooling and the heating duties.
Optimization of A Distillation Column: Distillation is the most common means for separation of
chemical components and lies at the heart of petroleum refining; it has no moving parts and scales easily
and economical to all production levels. However, distillation is highly energy intensive and can consume
a lot of the total energy in a typical chemical or petrochemical process. As a result, optimization of
distillation columns is essential for the productivity and profitability of these processes. Moreover,
because distillation feeds, product demands and even ambient conditions change over time, optimization
in response to these changes is also a key contributor to successful operation.
Optimization in the chemical and petroleum industry is gaining increased interest because of its
importance in maintaining product quality and enhancing production levels while improving profit
margins. The optimization of the distillation is different from one process to another, due to the difference
in the objective function of the distillation column. The objective function was chosen in the present study
in a way that it would maximize the productivity of the reformate by considering the variables that have
been studied in the sensitivity analysis. Hysys contains a multi-variable steady-state optimizer. Once the
flowsheet has been built and a converged solution has been obtained, the optimizer could be utilized to
find the operating conditions which minimize (or maximize) an objective function.
The following terminology is used in describing the HYSYS optimizer:
Primary variables which are imported from the flowsheet whose values are manipulated in order
to minimize (or maximize) the objective function.
Objective function is the function which should be minimized or maximized.
Constraint functions are defined in three ways. Inequality and equality constraint functions
which may be defined in the optimizer spreadsheet.

1860 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

In order to maximize the productivity and the recovery of C5+ to the maximum , the objective function
should be a function of the top, bottom temperature and reflux ratio parameters. To obtain this objective,
it was essential to manipulate the variables and allow some of the variables to be adjusted in way such as
to achieve the necessary limits. Furthermore, to enhance the results and to accomplish the required limits
for a particular variable, it was essential to apply some constraints on the objective function. The
constraints of the manipulated variables used for the optimizations are as shown in Table 1.

Table-1: The constraints of the manipulated variables of the process.

Parameter Low bound High bound


Reflux ratio 1 4
Condenser temperature (oC) 35 55
Reboiler temperature (oC) 220 230

RESULTS AND DISCUSSION

The naphtha stabilizer distillation column used in the production of reformate has been simulated using
Aspen HYSYS 7.1 simulator. There are many variables should be determined first before the simulation
of this process such as feed temperature and flow rate , condenser temperature, reboiler temperature,
column pressure and molar reflux. HYSYS V7.1 optimizer was used to choose the optimum manipulated
variables (reflux ratio, reboiler temperature and condenser temperature).
In Figure 14a. The temperature profile shows how the temperature changes in the column. In the first
stage where the temperature is about 45 C, where the lowest temperature of the condenser is the
temperature where the vapors are partially condensed and that temperature is the bubble point
temperature. There is a temperature augmentation on the second stage, because of the reflux introduction
to the column. The temperatures continue increasing as the stages go down till the feed stage where the
feed is entering in high temperature in 176 C. Near to the reboiler the temperature increases dramatically
because of the reboilers heat duty where high temperature needed to vaporize all the components in the
reboiler and that temperature is the dew point temperature.

Temperature profile Molar Flow Profile


250 a 700 b
Molar Flow kmol/h

600
Temperature in oC

200
500
150 400
300
100 Temperatu Liquid
re profile 200
50 100 Vapor
0
0 1 4 7 10 13 16 19 22 25 28 31
1 4 7 10 13 16 19 22 25 28 31 Stage number
Stage Number

Figure 14: Distillation Column Temperature and Flow rate Profiles.

1861 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

In Figure 14b. The molar liquid and vapour flows are exposed. As feed is introduced in the liquid phase,
there is an increase on the liquid molar flow on stage 16; a decrease of the flow rate is noticed due to the
high temperature which reigns at the bottom of columns. The vapour flow tends to be constant in the
column, except on stages 2 and 16, this may happen because the reflux temperature is low and
condensates some of heavy components in the vapor phase, while in the stage 16 the feed temperature is
very high and vaporizes some of the heavy components and traces of light gases in the liquid phase. For
trays( >17) the vapour slowly increases that is due to the more volatile components that are existed in the
feed as well as the amount of the vapor which result in evaporating the liquid that comes down to the
reboiler.
Optimization Results: The initial focus of the optimization work was to arrive at operational changes
that could be implemented without significant plant interruptions or modification. Many different
variables were methodically tested to see the effects on throughput. A theoretical approach to optimization
was also adopted, to find ways to increase throughput without sacrificing product quality. The HYSYS
software was employed to see if the changes resulted in improvements. A large number of solutions were
found at the end of this process.
Optimization of the naphtha stabilizer distillation column was achieved by using the manipulated
variables (temperature of condenser, temperature of reboiler and the reflux ratio) , while the objective
function was the maximization of the production of the reformate in the bottom product of the column.
The key for good and reliable optimization is the simulating model, and specifications on the variables
and the objective function. Aspen HYSYS provide multi-objectives in the same optimization runs. In
Aspen HYSYS optimization the decision variables must be defined and the step change in each
manipulated variables. At each iteration Aspen HYSYS assumed a value for the decision variables
(temperature of condenser, temperature of reboiler and the reflux ratio) and send the assumption to the
simulating model in the HYSYS to calculate Off gas rate, LPG rate and the reformate production. The
estimated result from simulating model will be used in optimization to calculate and evaluate the
reformate production rate.

Table-2: Aspen HYSYS optimizer iterations results.

Iter.NO Reflux Ratio TC (C) TR (C) Objective function


1 2.5 45 223 325.36
2 2.5 46 220 331.20
3 2.5 46 220 331.20
4 3.05 45.44 220 332.15
5 3.05 45.44 220 332.15
6 3.05 45.44 220 332.15
7 3.03 46.79 220 332.11
8 3.93 46.78 220 332.70
9* 4 46.77 220 332.71

1862 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

Table-3: Aspen HYSYS optimization results.

Off gas LPG Reformate Qc Qr


Iter.NO Recovery of C5+
(kmole/h) (kmole/h) (kmole/h) (KW) (KW)
1 31.99 33.00 325.36 1189.89 1914.56 0.97346
2 37.43 21.71 331.20 981.07 1705.82 0.98567
3 37.43 21.71 331.20 981.07 1705.82 0.98567
4 39.27 18.93 332.15 1093.93 1836.68 0.99188
5 39.27 18.93 332.15 1093.93 1836.68 0.99188
6 39.27 18.93 332.15 1093.93 1836.68 0.99188
7 40.65 17.57 332.11 1079.38 1829.84 0.99166
8 42.56 15.09 332.70 1306.59 2071.93 0.99557
9* 42.61 15.01 332.71 1326.34 2092.11 0.99569

As Table 2 shows the objective function is increasing at each iteration and the maximum reformate
production was found at iteration (9) at which the production rate equal to (332.71) kmole/h. The
percentage increasing in the production based on the production at actual operating conditions
(324.78kmole/h) is equal to (2.388%). The local optimums for the naphtha stabilizer from Table 3 are:

The maximum recovery of C5+ in the reformate regarding for other decision variables can be
found at iteration (9), where the percentage of the increasing from the normal operation (0.9747)
is (2.09%).

The maximum reformate production regarding for other decision variables can be found at
iteration (9), the reformate production increases about (2.383%) from the actual reformate
production (324.78) kmole/h.
The Off gas production from iteration (9) was increased (26.8%) from the actual off gas
production which is (31.19) kmole/h.
The LPG production from iteration (9) was decreased (56.32%) from the actual LPG production
which is (34.37) kmole/h.
The energy consumption for the condenser that can be found from iteration (9) is (1326.34KW),
the percent of increasing in the energy consumption was (21.23%) from the actual energy
consumption (1044.77 KW).
The energy consumption for the reboiler that can be found from iteration (9) is (2092.11) KW, the
percent of increasing in the energy consumption at iteration (8) is (15.9%) from the actual energy
consumption (1759.19 KW).
The relation between the numbers of iterations with the reformate production is shown in Figure 15. The
reformate rate increases and decreases in different iteration.

1863 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

334.00

Reformate production (kgmole/h)


332.00
330.00 optimum
328.00
326.00
324.00
322.00
320.00
1 2 3 4 5 6 7 8 9
Iteration number

Figure 15: Reformate production with the Iteration Number.

So, the previous results show, the maximum reformate production can be compared with normal
production at different operation conditions as listed in the Table 4.

Table-4: Comparison between operating and optimum values.

S/N Operation condition Normal operation Optimum values


1 Reflux ratio 2.05 4
2 Condenser temperature (C) 45 46.77
3 Reboiler temperature (C) 223 220
4 Reformate production(kmole/h) 324.78 332.71

CONCLUSION

Naphtha stabilizer in Al-Basra refinery is successfully simulated using HYSYS software version 7.1. A
powerful equation of state Peng-Robinson package can be applied to predict the required pure component
properties, such as the fugacity, K-values, compressibility factor and enthalpies for the different phases at
given conditions (temperature, pressure, composition). A sensitivity analysis by using HYSYS was used
to estimate the effect of the process parameters on the reformate product quantity, the recovery of C5+, top
products and energy duties of the naphtha stabilizer. The optimization strategy is incorporated to solve an
optimization problem formulating with an objective function: to maximize the reformate product for a
given decision variable, reboiler temperature, and condenser temperature and reflux ratio. 99.6% purity of
the reformate product can be produced by an optimal reformate production. With changing the operation
condition of reflux ratio of 4, temperature of the reboiler and the condenser of 220 oC and 46.77 oC
respectively. The percentage of the increasing in the production based on the production at actual
operating conditions (324.78kmole/h) is equal to (2.388%). The optimization method is easy and efficient
to implement using HYSYS optimizer tool. The profile for the flow rates and temperature were obtained.
The temperature profile ranged from 45C at the condenser to 223C at the reboiler.

1864 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.
Comprehensive Hashim and Jassim.

REFERENCES

1. G .S. James, Handbook of petroleum product analysisJohn Wiley & Sons Inc,
New Jersey, USA.2002.
2. S.C. Pandey, D.K. Ralli, A.K. Saxena and W.K. Alamkhan. Physicochemical
characterization and applications of naphtha. Journal of Scientific & Industrial
Research. 2004, 63, 03, 276-282.
3. M.R. Vaughan. The Design of a Chemical Plant Using HYSYS Simulation
Program, Msc thesis, University of Tennessee Knoxville. 2000.
4. E.O. Okeke and A.A. Akofe. Optimization of a Refinery Crude Distillation Unit
in the Context of Total Energy Requirement. 2003, APACT03, 28-30.
5. J.G. Vasconcelosa, R.M. Filhoa, R. Spandrib and M.R. Wolf. Dynamic Models
towards Operator and Engineer Training: Virtual Environment, European
Symposium on Computer Aided Process Engineering. 2005, 20,565570.
6. N. Saghatoleslami, F. Shikholeslami, F. Shahrakib and Y. Dadmohamadi. Cost
Estimation and Optimization of the Topping Unit Products at the Steady State
Condition, Proceedings of the 1st Annual Gas Processing Symposium. 2009.
7. D. A. Begum, A. Rahman and K. Kirtania. Condensate Fractionation Column:
Design Variation Study by Simulation. Journal of Chemical Engineering,
IEB.2010, ChE25, 1, 2010.
8. A.R. Moghadassi, S. M. Hosseini, B. Yasini, E. Joudaki, and A. R. Fazlali, An
Optimization Model for the Increment in the Yield of Distillation Columns Based
on Reverse Engineering in the Petroleum Industry, Petroleum Science and
Technology. 2010, 28:10361045.
9. M. Nawaz and M. Jobson. Synthesis and Optimization of Demethanizer Flow
sheets for Low Temperature Separation Processes. Distillation Absorption. 2010.
10. M. Sharifzadeh and F.N. Thornhill. Optimal controlled variable selection using a
nonlinear simulation-optimization framework, 21st European Symposium on
Computer Aided Process Engineering ESCAPE 21, 2011.
11. M. Jibril1, A. D. Folorunsho and A. Manasseh. Simulation of Kaduna Refining
and Petrochemical Company (KRPC) Crude Distillation Unit (CDU I) Using
Hysys. International Journal of Advanced Scientific Research and
Technology.2012, 1, 2.
12. N. Moghadam, M. Samadi and Z.B. Hosseini. Simulation of Gas Condensate
Stabilization Unit Aiming at Selecting the Right Technique and Assessing the
Optimized Operational Parameters. International Conference on Chemical,
Biological and Environmental Engineering.2012, 43.
13. O.Y. Raji, U.A. El-Nafaty, M. Jibril and B.Y. Danjuma. Modelling and
Optimization of Fluid Catalytic Cracking Unit (FCCU) Using Hysys. I. Journal of
Emerging trends in Engineering and Development.2010, 3, 2.
14. H. Binous and A. Bellagi. Simulation of The Separation of Industrially Important
Hydrocarbon Mixtures by Different distillation Techniques Using Mathematica.
Advances in Systems Engineering Research. 2013, 47-78.

* Corresponding author: Ahmed Raheem Hashim; Department of Chemical Engineering,


Basra University, Basrah, Iraq

1865 J. Chem. Bio. Phy. Sci. Sec. A, May 2014 July 2014; Vol.4, No.3; 1851-1865.

Potrebbero piacerti anche