HT Reformer

Straigh Run: Kerosene, Diesel

ADU

HT Cat.
Cracker

VDU
Coker

Above is my simplified version of a refinery that illustrates the bare-bones version

that Im using for the trial calculations. There are formulas and equations for more
complex refinery set-ups, but this seemed the easiest to generalize. Specific cases
can be put through the more rigorous numbers if necessary.

Outline of some simplifications/assumptions that are occurring in this assessment:

1. Gasoline blending is not taking into consideration. Because of this paraffins,
aromatics and naphthenes from the reforming process are not separated into
different percentages. Rather, they are all considered gasoline. Additionally,
RON is assumed to be 94 for all calculations (this is on the high side and will
give an estimate on the low side of gasoline output).
2. Numerous advanced processes are being ignored, most noteably, alkylation
and catalytic hydrocracking. The consequence of ignoring alkylation puts the
gasoline production estimate on the low side. Catalytic hydrocracking can
produce both gasoline and distillates (jet fuel, diesel). There are formulas to
determine the percentage of output, but requires additional linear logic to
decide what portion of the initial feed goes to the hydrocracker. This
information was not included in the initial set-up. It has the potential to be
considered later. The calculations are more complicated because the
hydrocracker has the capability of being set up to provide more gasoline,
diesel or jet fuel based on the needs of the refinery.
3. The calculations are done on broad specifications. Exact refinery production
calculations are considered as proprietary information.
 4. Distillates are isolated as a single category, but contain both diesel and jet
fuel. There is no exact amount to separate the two. Diesel comprises the
majority.
5. Another important assumption is that the streams can only flow in a straight
line. For example, once fractions are sent to the vacuum distillation unit,
they can only be sent to the coker or produce what they will from the vacuum
distillation unit (VDU). This is going to give low estimates, as certain
fractions of VDU can be sent to catalytic crackers and reformers as well, but
this starts to get outside the scope of the simple programing we wanted.
6. Corrections for sulfur content are also being ignored. This would cause a
slight over-estimate in product, especially for samples that are high in sulfur
content. This calculation can be done on a case by case basis, but was too
complicated for this simple first generation model.

Step 1: Initial Distillation: CDU output.

1. CDU unit (initial distillation): Important fractions to be considered for

calculation data:
a) 190-380 F: Naptha fraction proceeds to a hydrotreater to remove
sulfur and other impurities and onto the catalytic reformer to
produce gasoline.
b) 380-580 F: These cuts are assumed to be used as straight run,
with minimal purification in a hydrotreater, but can be taken as a
percentage of the initial input.
c) 580-650 F: This gas oil fraction goes through the hydrotreater, on
to the catalytic cracker. The catalytic cracker is assumed to
operate at 75% efficiency to produce gases, gasoline, gasoil
(distillates?) and coke.
d) 650-1050 F: This fraction comprises light, medium and heavy gas
oils. The lighter hydrocarbons in this fraction can be used in
marine diesel, while 800+ heads to the vacuum distillation unit
(VDU) is isolated via the vacuum distillation unit and produces
vacuum gas oil (light, medium and heavy) along with vacuum
residue. The residue heads to the coker.
e) 1050+ F: This is the residue fraction and after the VDU, it will
head to the coker, where it will produce gasoline, distillate, gases
and coke.

Further calculations will be performed on the coker, catalytic cracker and reformer
(although the reformer calculations will only be necessary if gasoline blending is
considered).

Calculations for CDU:

TBP-true boiling point (correction for the simpler technique used to determine
atmospheric distillation values in the lab): There are a couple methods of calculation
TBP (R)= {(2.2ln(100/(100-LV%)))^2.7 +1}490
TBP=a(ASSAYBP)^b (%=% of sample distilled) reported as T% (i.e. T10= TBP at
10%)
% a B
0 0.9167 1.0019
10 0.5277 1.0900
30 0.7429 1.0425
50 0.8920 1.0176
70 0.8705 1.0226
90 0.9490 1.0110
95 0.8000 1.0355

Additional values that may be of importance for subsequent calculations:

VABP=volume average boiling point=(T10+T30+T50+T70+T90)/5
MeABP=mean average boiling point=VABP-
=-0.94402-0.00865(VABP-32)^0.667+2.99791(SL)^0.335 SL=(T90-T10)/(90-10)
Watson Characterization Factor (K): Unit used to distinguish a crude feed, used in
multiple further calculations: K=(Tb)^1/3/SG or K=(MeABP)^1/3/SG
API= -0.0004(LV%)^3 +0.05(LV%)^2-2.4(LV%)+800use mid. point volume for
each fraction. Can also calculate the
LV%=percent of accumulated liquid volume (this is total based on what boiling
point the fractions are collected at. The higher boiling point fractions will have
higher numbers.
IBP=initial boiling point
EBP=end boiling point
SG=specific gravity (usually provided in the assay, API=(141.5/SG)-131.5)
M=average molecular weight of the fraction=42.965[exp(2.097X10^-4Tb-
7.78712SG+2.08476X10^-3TbSG]Tb^1.26007SG^4.98308
Wt%S can be determined if not given in the assay, but requires 3 other calculations.
Tb=(((IBP+EBP)/2)-32)/1.8 (Can add 273 to get the temperature in Kelvin if
necessarywhich it is to calculate K value)

Cut Volume %: This can be determined from the initial percentages in the crude
assay: %vol at EBP-%vol and IBP.
Cut Volume=% in decimal form(BPD feed)this gives a BPD value. If the product is a
straight run product, this value can be used as the output value of that fraction.

Calculations: Naptha Hydrotreater and Catalytic Reformer

BPD: This value will have been calculated in the CDU phase.
SCFB (standard cubic feet per barrel)
Sf=%wt of sulfur for fractioncan be calculated, but hopefully is given.
From the hydrotreater, need to calculate the paraffin (P), napthene (N) and aromatic
(A)volumes to get a C5+ vol% which is the amount of gasoline produced.
Subscript p=product, subscript f=feed, Kf=Watson characterization factor of the feed
Vol%P=12.8Kf^2-259.5Kf+1330
Vol%N=-78.5Kf^2+1776.6Kf-9993.7
Vol%A=38.4Kf^2-894.3Kf+5219.4

Hydrotreater:
SCFB H2 =191Sf-30.7
APIp=0.01(SCFB H2) +0.036(APIf)-2.69
APIp=APIf+ APIp

C5+ vol%=142.7914-0.77033 X RON +0.219122 X (N+2A)F The RON number is

based on the blend of gasoline desired. For the purpose of this set up, assume that
RON=94. This number will be a percentage that will be multiplied by the BPD feed
to give the BPD of gasoline produced by this process.

Calculations: Middle Distillate Hydrotreater and Catalytic Cracker:

Hydrotreater:
SCFB H2 =110.8Sf+10.2(100)-659 (assumes 100% severity of hydrotreater)
APIp=0.00297(SCFB H2) -0.11205(APIf)+5.5419
APIp=APIf+ APIp
Catalytic Cracker: Assumption 75% conversion (CONV)
Coke wt%=0.05356XCONV-0.18598XAPI+5.966975
Light cycle oil (distillates) LV%=0.0047XCONV^2-0.8564XCONV+53.576
Gases wt%=0.0552XCONV+0.597
Gasoline LV%=0.7754XCONV-0.7778

Calculations: Coker
CCR-Conradson carbon residue: This is a physical property of the crude, should be
provided in the assay data. If it isnt, give a range between 10-25%
Gas(C4-)wt%=7.8+0.144X(wt%CCR)
Naptha wt%=11.29+0.343X(wt%CCR)
Coke wt%=1.6 X(wt%CCR)
Gas Oil wt%=100-wt% of other three
Gas oil and naptha can be broken down further if necessary, but wont do that in
first generation example.