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    Refining Process Simulation HYSYS V10 (Hydrocracking, Visbreaking, Delayed Coking)

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    Borisvc8
    This document provides an overview of refining processes simulation in HYSYS V10, including hydrocracking, thermal cracking processes like visbreaking and delayed coking. It describes the feed for the simulation, hydrocracking to break carbon bonds and remove contaminants using hydrogen and a catalyst, and the differences between visbreaking which uses mild heating and delayed coking which uses moderate heating and results in coke byproduct.

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    Refining Process Simulation HYSYS V10 (Hydrocracking, Visbreaking, Delayed Coking)

    Uploaded by

    Borisvc8
    315 views11 pages
    This document provides an overview of refining processes simulation in HYSYS V10, including hydrocracking, thermal cracking processes like visbreaking and delayed coking. It describes the feed for the simulation, hydrocracking to break carbon bonds and remove contaminants using hydrogen and a catalyst, and the differences between visbreaking which uses mild heating and delayed coking which uses moderate heating and results in coke byproduct.

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    Refining Process Simulation HYSYS V10 (Hydrocracking,visbreaking,delayed coking)

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    Refining Process Simulation HYSYS V10 (Hydrocracking,visbreaking,delayed coking)

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    This document provides an overview of refining processes simulation in HYSYS V10, including hydrocracking, thermal cracking processes like visbreaking and delayed coking. It describes the feed for the simulation, hydrocracking to break carbon bonds and remove contaminants using hydrogen and a catalyst, and the differences between visbreaking which uses mild heating and delayed coking which uses moderate heating and results in coke byproduct.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    315 views11 pages

    Refining Process Simulation HYSYS V10 (Hydrocracking, Visbreaking, Delayed Coking)

    Uploaded by

    Borisvc8
    This document provides an overview of refining processes simulation in HYSYS V10, including hydrocracking, thermal cracking processes like visbreaking and delayed coking. It describes the feed for the simulation, hydrocracking to break carbon bonds and remove contaminants using hydrogen and a catalyst, and the differences between visbreaking which uses mild heating and delayed coking which uses moderate heating and results in coke byproduct.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The key takeaways are that the document discusses refining processes like hydrocracking, thermal cracking processes including visbreaking and delayed coking.

    Visbreaking involves milder cracking conditions than delayed coking. Visbreaking produces mainly fuel oil while delayed coking produces more valuable light products and coke as a byproduct. Delayed coking involves a continuous filling and emptying of drums.

    A typical delayed coking unit consists of a furnace to preheat the feed, coking drums where cracking and fractionation occur, and a fractionation column to separate products with recycled streams.

    REFINING PROCESS SIMULATION (HYSYS V10) - PART 2

    FEED
    The feed for this simulation is a vacuum residue from a North American Crude
    (California) with an APIº=19.
    Following we can see the distillation curve (TBP), cut yields and initial conditions:
    HYDROCRACKING
    Hydrocracking is a refining process for conversion of heavy gas oils and heavy diesels
    or similar boiling-range heavy distillates into light distillates (naphtha, kerosene, diesel,
    etc.) or base stocks for lubricating oil manufacture. The main propose of this process is
    to break carbon-carbon bonds of large aromatic compounds and remove contaminants.
    The process consists of causing feed to react with hydrogen in the presence of a catalyst
    under specified operating conditions: temperature, pressure, and space velocity.
    Some of these streams would be hard to process in other cracking processes (FCC)
    because of the high contaminants content and the higher carbon residue (S, N, O), which
    quickly deactivates the catalyst, in the hydrocracking process the presence of hydrogen
    minimize these effects.
    Hydrocracking catalysts consist of active metals on solid, acidic supports and have a
    dual function, specifically a cracking function and a hydrogenation function. The cracking
    function is provided by the acid catalyst support (hydrodealkylation, hydrodecyclization,
    hydrocracking, and hydroisomerization) and the hydrogenation function is provided by
    the metals (desulfurization and denitrification—hydrogenation of polyaromatics and
    monoaromatics).
    a) Paraffin Dehydrocyclization
    (Hexane) C6H14 + 4H2

    b) Hydrocracking
    (Heptane) C7H16+ H2 −→ C4H10 + C3H8

    c) HydroDealkylation: Iso-C3H7- C6H5 −→ + C3H6

    d) Paraffin HydroIsomerization

    (Hexane) C6H14
    Hydrocracker units can be operated in the following possible modes: single-stage (once-
    through-mode) operation, single-stage operation with partial or total recycling, and two-
    stage operation. In this case I used the single stage unit with two feeds. One internal
    feed with an APIº=22.22 and an external feed from the visbreaker residue with an
    APIº=8.58 as we see in the following table:
    THERMAL CRACKING
    Thermal cracking is a well-known process used in several refineries all around the world.
    There are many thermal cracking processes as Visbreaking, Delayed coking, Flexy
    coking, UOP Uniflex and Fluid Coking. This time we are going to see visbreaking and
    delayed coking, starting with a brief explanation and the complete HYSYS simulation.
    Before starting the explanation let’s see a comparative table of these two processes:
    VISBREAKING DELAYED COKING
    Mild heating (420ºC – 480ºC) Moderate heating (450ºC – 500ºC)
    2 – 9 Bar 3 – 10 Bar
    Reduction in viscosity Soak drum at 450-480ºC
    Low conversion 10% Processes continues till complete coking
    Liquid phase cracking. Process occurs
    optimized to minimize coke formation Coke remove hydraulically
    -SOKER VISBREAKIG PROCESS (Low Coke 20-40% yield 30%
    temperature and high residence time) High residence time
    -COIL VISKREAKING PROCESS (High
    temperature ad short residence time)

    a) VISBREAKING
    Feed: Atmospheric and Vacuum residues
    Objective: To lower the viscosity of heavy residues under relatively milder cracking
    condition than the conventional cracking processes.
    Visbreaking is essentially a mild thermal cracking operation at mild conditions where in
    long chain molecules in heavy feed stocks are broken into short molecules thereby
    leading to a viscosity reduction of feedstock.
    Two visbreaking processes are commercially available: the soaker visbreaker and
    the coil visbreaker. Now most of the new visbreaker units are of the soaker type. Soaker
    drum utilizes a soaker drum in conjunction with a fired heater to achieve conversion.
    Visbreaking is a non-catalytic thermal process. It reduces the viscosity and pour point of
    heavy petroleum fractions so that product can be sold as fuel oil. It gives 80 - 85% yield
    of fuel oil and balance recovered as light and middle distillates. The unit produces gas,
    naphtha, heavy naphtha, visbreaker gas oil, visbreaker fuel oil (a mixture of visbreaker
    gas oil and vsibreaker recidue). A given conversion in visbreaker can be achieved by
    two ways:
    - High temp., low residence time cracking: Coil Visbreaking.
    - Low temp., high residence time cracking: Soaker visbreaking.
    Reaction in visbreaking:

    CH3-CH2-CH2-CH2-CH2-CH2-CH3 CH3-CH2-CH=CH2 + CH3-CH2-CH3


    (Heptane) (Butene) (Propane)
    b) DELAYED COKING
    Feed: Usually Vacuum Residue
    Objective: Crack heavy oils into more valuable light liquid products with less valuable
    gas and solid coke as byproducts.
    Delayed coking is a type of thermal cracking in which the heat required to complete the
    coking reactions is supplied by a furnace, while coking itself takes place in drums
    operating continuously on a 24 h filling and 24 h emptying cycles
    Delayed coking consists of thermal cracking of heavy residue in empty drum where
    deposition of coke takes place. The product yield and quality depends on the typed
    feedstock processed. Typical delayed coking consists of a furnace to preheat the feed,
    coking drum where the fractionation of the product takes place. The feed is first
    preheated in furnace where the desired cooking temperature is achieved and fed to the
    coking drums normally installed in pairs where the cracking reaction takes place and the
    coke is deposited in the bottom of the reactor. The coke drums overhead vapour flows
    to the fractionating column where they are separated into overhead streams containing
    wet gas LPG and naphtha and two side gas oil streams.
    Recycled stream from the fractionating column combines with the fresh feed in the
    bottom of the column and is further preheated in coke heaters and flows to the coke
    drums. When a coke drum is filled, the heated streams from the coke heated are sent to
    the other drum.
    SIMULATION DIAGRAM (HYSYS V10)

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