Improve Crude Distillation Unit Operations

With Advanced Capabilities in Aspen HYSYS®

Ajay Lakshmanan, Product Management
Ankita Mangal, Product Management
Sandeep Mohan, Product Marketing
June 27, 2017
Today’s Presenters

Ajay Lakshmanan, Product Management

Ankita Mangal, Product Management

Sandeep Mohan, Product Marketing

2 © 2017 Aspen Technology, Inc. All rights reserved.

 Agenda

• Refining Business Objectives

• Challenges in CDU Operations
• How Aspen HYSYS Helps Improve CDU Operations
• Application Demonstration
• Conclusion
• Next Steps
• Q&A

3 © 2017 Aspen Technology, Inc. All rights reserved.

Refining Business Objectives

‒ Know your operational

Maximize Asset Utilization limits
‒ Flexibility to process
broad range of crudes

Maximize Refinery ‒ Predict potential

Maximize Uptime operational problems
Profit Margins
‒ Quick troubleshoot of
operational issues

‒ Tracking and analysis

Minimize Energy Costs of key equipment
performance

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 Challenges in CDU Operations
Critical, Complex Operation
‒ Primary separation governing downstream
processing

High Energy Consumption

‒ Heat integration and energy saving is critical

Identification of Bottlenecks and Solutions

Frequent Feedstock Changes Causing

Operational Issues
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 How Aspen HYSYS Helps Improve CDU Operations

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Increase Capacity & Reduce OPEX

Change the Feedstock Or

Troubleshoot problems

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2017 Aspen Technology, Inc. All rights reserved.
 FIRST STEP: Understand your columns operation

How does it function?

Heat and material balances?

Increase Capacity & Reduce OPEX

Thermodynamic and equilibrium limits?

Change the Feedstock Or

Troubleshoot problems
What are the hydraulic constraints?
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2017 Aspen Technology, Inc. All rights reserved.
Columns are Complex

Separation Efficiency

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Columns are Complex

Separation Efficiency

Image From:
Sulzer.com

Trays and Packing

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Columns are Complex

Weeping

• Limited capacity
Excessive
Flood Pressure Drop • High energy use

• Product quality issues

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Column Analysis: Concurrent Thermal and Hydraulic
Analysis
Visual Upgrade External
design tools

Vendor creates design

Design against base case, confirm
proposal
hydraulic operability for off-design cases
collaboratively
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Results- Interactive Hydraulic Plots

Trays Packing

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Validated Workflows to Save Time
Tested by Engineers in Operations and Design at Top Companies

Examples of added functionality:

Templates Autosizing Multiple Monitors Guidance

Abide by company Start off with suggested View inputs and results Use built-in and defined
standards, rules of sizing, overwrite as interactively constraints
thumb needed

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 CASE STUDY: Tupras
Control of Column Performance by Aspen HYSYS Tools

Business Challenge & Objective Results & Benefits

• Naphtha splitter column was unable to meet the

• Successful troubleshoot and revamp of the naphtha splitter column
required product spec
unit resulting in an expected
• Revamp project with the objective of – 40% increase in column capacity
– Maximizing capacity – 15% reduction in utility consumption (~ savings of $500,000 per year)
– Ensure products meet specification – On spec Products
– Improve energy recovery – Pay back in less than one year

Solution Overview
• Rigorously simulated naphtha splitter column and heat
exchangers in Aspen HYSYS
– Column Analysis showed why the column was
underperforming and how to rectify
– Rigorous heat exchanger models using Aspen EDR
HSRN
predicted operational issues and remedy
NAPTHA SPLITTER COLUMN LSRN
– Using ‘pipe segment’ in Aspen HYSYS conducted
velocity and pressure drop check for the units piping
Ref: Presentation from Tupras titled “Control of Column Performance by Aspen HYSYS Tools” By Asli Reyhan at Aspen Technology User Conference OPTIMIZE-17 hosted at Houston Texas (April-25 & 26, 2017)

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Software Demo

1 2
Analyze Analyze Heat
Column Exchanger
(CDU) (Preheat
Train)

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Software Demo

1 2
Analyze Analyze Heat
Column Exchanger
(CDU) (Preheat
Train)

Integrated CDU + Preheat

3 Train Analysis
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Process Optimization and Fast Data Reconciliation
with equation oriented modeling

Aspen HYSYS offers

‘Equation Oriented’ Solver for
Crude Distillation Unit Models

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Crude Distillation Unit in Sequential Modular Simulation

Recycle Blocks for Nested Loops

Adjust Blocks for Calibration

Optimization is a Challenge

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Crude Distillation Unit in Sequential Modular Simulation

Setup is Straightforward

Solution Time can be prohibitive for

large data reconciliation models

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Crude Distillation Unit in Equation Oriented Simulation

Nested Loops Solve Simultaneously

One Model for Calibration & Optimization

Optimization is Feasible

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Crude Distillation Unit in Equation Oriented Simulation

Solution Time is in Seconds

Significant Expertise to Setup

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Crude Distillation Unit in Equation Oriented Simulation

Solution Time is in Seconds

Significant
Objective:Expertise
Make Setupto Easy
Setup

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Software Demo

Fully Integrated Process

Optimization and Data
Reconciliation

Integrated CDU + Preheat Train

Analysis
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 Crude Distillation Unit Calibration using Data Reconciliation
180
130
80
30
0 50 100

280
260
240
220
20 Measured Qualities
200 5 Point D86 Distillation
0 50 100 for Naphtha, Kerosene,
350 Diesel, AGO
300

250
0 50 100

420

370
Calibrate 4 Column Efficiencies 320
Main Tower, Diesel, Kerosene, AGO Side Strippers 0 50 100
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 Crude Distillation Unit with Pre-Heat Train Optimization

Naphtha Pump around streams

Kerosene

Optimize
Pump Around Flows
Kerosene Reboiler &
Preheater Duty

AGO
Diesel
Residue
Maximize Profit
Product Price – Feed cost – (Steam & Fuel cost)
26 © 2017 Aspen Technology, Inc. All rights reserved.
Webinar Summary
• Aspen HYSYS enables rigorous simulation of
columns, heat exchangers as well as the
integrated CDU complex.

• Refineries stand to gain considerable benefits

from improved operations using
– an integrated CDU & preheat train simulation
solution.
– individual unit monitoring solutions for distillation
columns and heat exchanger networks

• We have training materials available in Aspen

Technology customer support site that can help
you develop simulation models for your CDU.

27 © 2017 Aspen Technology, Inc. All rights reserved.

Next Steps….
Click on the below links for step by step guidelines on
How do I do this myself ?
1. How to Build a CDU Model in Aspen HYSYS
2. How to Evaluate Effects of Crude Change on CDU

How do I learn about

Watch short video on Aspen HYSYS EO
Aspen HYSYS EO?

Need Help to Setup CDU Contact your Aspen Technology representative.

Models for your refinery? Additional contacts:
Ajay.Lakshmanan@aspentech.com
Ankita.Mangal@aspentech.com
Sandeep.Mohan@aspentech.com
28 © 2017 Aspen Technology, Inc. All rights reserved.
Q&A

Ajay Lakshmanan
Ajay.Lakshmanan@aspentech.com

Ankita Mangal
Ankita.Mangal@aspentech.com

Sandeep Mohan

Sandeep.Mohan@aspentech.com

29 © 2017 Aspen Technology, Inc. All rights reserved.

Thank You