Refining Technology in the Petroleum, Metals and Bioprocesses Industries

Transcription

1 Refining Technology in the Petroleum, Metals and Bioprocesses Industries Brenno C. Menezes Postdoc, University of São Paulo São Paulo, SP, BR Lecture 2 São Paulo, Mar 01 st, 2018 Galo Carrillo Le Roux Professor of Chemical Engineering University of São Paulo São Paulo, SP, BR 1

2 Lecture 2 22-Feb Introduction 1 22-Feb Energy and Material balances: World and Brazil 1-Mar Introduction/Project Reserves, Production and Consumption 2 1-Mar Flowsheet Structures, Ref Tech Comparison and Fundaments OpenIMPL, Types of Projects, Main Papers 8-Mar Petroleum 3 8-Mar Caracterization of Petroleum and derivatives 15-Mar Petroleum Distillation and other separation processes 22-Mar Petroleum 4 15-Mar OpenIMPL Tutorial 29-Mar No Class Blending and distillation problems 5-Apr Petroleum 5 22-Mar Catalytic, Thermal Cracking, Solvent Deasphalting 12-Apr Petroleum PETRO-SIM Tutorial: CDU and VDU 19-Apr Petroleum 29-Mar No Class Metals 17% Bioprocesses 17% Ref Tech Introduction 16% Petroleum 50% 6 5-Apr Hydrotreating and Hydrocracking Reforming, Isomerization and Alkylation 7 12-Apr Supporting Processes and Natural Gas Processing Petrochemicals 8 19-Apr OpenIMPL Tutorial: Alkylation process (scalar-based) OpenIMPL Tutorial: Refinery-wide problems (structural-based) 26-Apr Exam Apr Exam: Introduction and Petroleum TYPE OF ASSESSMENT: M = 70% Test + 30% Project 3-May Metals 10 3-May Minerals and metallic derivatives. Physical Metallurgy 10-May Metals Metal processing: smelting, conversion, others May Electrochemical processes: deposit of metals and alloys Other metallurgic processes 17-May Bioprocesses May Main routes, biomasses and biological platforms. Biorefineries: 24-May Bioprocesses conventional and advanced May Biorefinery concepts in comparison with the petroleum and minerals refining. Bioportfolio in industry 31-May Exam May Exam: Introduction, Petroleum, Metals and Bioprocesses Refining Technology in the Petroleum, Metals and Bioprocesses Industries Tests = (2.5*Test *Test2)/7 Project = 1.0 Writing (in English: extra point) 1.0 Scope + Complexity 1.0 Tools handled in the group Project deadline: 31-May

3 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

4 Outline 1) Flowsheet Superstructures 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

5 How do we represent the flowsheet? Perimeters Supply/Demand Points or Sources/Sinks Pools Inventory or Holdup Batch-Processes Variable-Size & Fixed-Time (VSFT) or Fixed-Size & Variable-Time (FSVT) Continuous-Processes Blenders, Splitters, Separators, Reactors, Fractionators & Black-Boxes Dimensional-Processes Geometry Transforms (Reels, Rolls, Sheets, Ingots, Logs, etc.) Parcels Moveable/Transportable Inventory or Holdup with Round-Trip Travel-Time Pipelines Moveable/Transportable Inventory as FIFO (First-In-First-Out) UOPSS = STN x RTN Pilelines Stackable Inventory as LIFO (Last-In-First-Out) Port-In Flows into a Unit (similar to a nozzle). Port-Out Flows out of a Unit

6 How do we formulate the variables and constraints? Models Quantity (quantity) Logistics (quantity & logic) Quality (quantity & quality) Quantity details: Flows, holdups, yields, etc. Logic details: Setups, startups, switchovers, shutdowns and sequence-dependent switchovers, etc. Quality details: Densities, components, properties, conditions and coefficients i.e., catalyst activity, enthalpy, etc.

7 Continuous versus batch operations Batch-processes -> accumulated over time Batch-Processes Variable-Size & Fixed-Time (VSFT) or Fixed-Size & Variable-Time (FSVT) Example: a batch distillation operation consists of an initial quantity of feed material being batched into a piece of equipment and during its operation, one or more product materials can be continuously or semi-continuously drawn out (Henley and Seader 1981; Phismister and Seider 2001). Continuous-processes -> there is a negligible rate of accumulation Continuous-Processes Blenders, Splitters, Separators, Reactors, Fractionators & Black-Boxes In a continuous process none of the feeds or products remains inside the unit such that the mass of material charged equals the mass of material discharged for any time interval, window or period during its operation Batch process is usually characterized by its quantity-size or batch-size whereas a continuous process is described by its quantity-size per time or charge-rate. Batch processes have inventory or holdup whereas continuous processes have zero inventory or holdup.

8 Oil & Gas Upstream to Midstream (Well Scheduling) Schedule the startup of wells in oil & gas field reservoirs over a multi-decade timehorizon with year or month time-periods subject to resource constraints such as rig and water availability, plant capacity, etc. Novelty is to represent each well as a batch-process with relative time-varying yields (i.e., declining curve profile). Rig to Position Well Head Upstream Reservoirs Midstream Plant Kelly, J.D., Menezes, B.C., Grossmann, Decision Automation for Oil and Gas Well Startup Scheduling Using MILP, ESCAPE 27, October, 2017.

9 From Distillates to Diesel (Diesel Scheduling) Distillates rundown to hydrotreaters, etc. and then are blended into various grades of diesel to meet the sales demands. Capture spot market opportunities when possible. Spot v. Contract Orders Kelly, J.D., Menezes, B.C., Grossmann, Logistics Optimization for Dispositions and Depooling of distillates in Oil-Refineries, ESCAPE 28, June, 2018.

10 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

11 Blending operations with recipes (Kelly and Zyngier, 2017) xift: in-flow variables at each time-period with i = {1,2,3} yipt: individual stream property variables where p may also be a set or list of properties for multi-property blenders. out-flow and out-property are labeled xft and yptrespectively. The overall or total flow and flow-property balances in open-equation or implicit-form can be seen in the following equations: (NT corresponds to the number of time-periods) The blend recipes ridenote the fraction, intensity or transfer coefficient of a feed stream i flow with respect to or divided by the product stream flow as below:

12 Splitting operations with ratios (Kelly and Zyngier, 2017) xjft: out-flow variables at each time-period with j = {1,2,3} The total flow balance is identical to the blender operation where all of the out-properties are simply set equal to the in-property as : The split ratios rj denote the fraction of a product stream j flow with respect to or divided by the feed stream flow as below:

13 Separating operations with recoveries (Kelly and Zyngier, 2017) yckt: individual stream component variables at each time-period with k = {1,2} Usually a separator is primarily designed to be simplifications of more rigorous vapor liquid separation processes such as equilibrium flash, distillation, fractionation and evaporation although they can also be used to model solid solid separations of fines and lumps in mining and minerals processing (i.e., crushing beneficiation). The overall or total flow is the same as both blender and splitter. And, similar to the blender for properties, there are individual bilinear flow-component balances for each component as: In addition, for each outlet stream we also require that the sum of the components in each stream must equal unity as follows which provides the necessary stream component normalization. The recover of j=2 and c=2:

14 Reacting operations with reactions (Kelly and Zyngier, 2017) The component balances for each reactant and product species which states that each component or species must conserve at the molecular or atomic level as follows: (g is the chemical reaction index, k is the component index, xg,t is the extent-of-reaction and rg,c is the component s stoichiometric coefficient involved in each reaction.) The second set of equations to complete the reactor operation is to ensure that the component fractions or compositions within the outlet stream are normalized identical to the separator operation:

15 Fractionating operations with renderings (Kelly and Zyngier, 2017) components c1 and c2 in are distributed or cut into five cuts denoted as the overall cut set {h1,h2,h3,h4,h5} The set of bilinear equations to formulate how the flow on each outlet stream is a function of the inlet flow, inlet composition and the renderings of each cut per component per outlet stream, where rj,k,h is the rendering for each outlet stream, each inlet composition and each cut respectively. The set of equations to model the composition of each new outlet component c3 and c4 on the three outlet streams is given by the bilinear component flow balance equation below: (wck,h,kk is the new component kk composition amount for each inlet component and cut respectively.)

16 Black-box operations with relationships (Kelly and Zyngier, 2017) Conditions (z1t, z2t and z3t) can either be independent variables or they can be dependent on other variables in the system if needed by specifying other relationships. Yields (y1t, y2t, y3t, y4t and y5t) are identical to recipes, ratios, recoveries, reaction stoich. and renderings, except that when modeling a unit-operation (both convergent and divergent), it requires a characteristic charge-size if it is a continuous-unit or a batch-size if it is a batch-unit we declare as xt. The set of equations relating a stream flow to its yield and its unitoperation s size is as follows: Each yield may be an arbitrary nonlinear function or formula of the conditions (or any other variable) and a stream property may also be any general relationship of the conditions such as: (ryn() and rynp() are the relationships relating the operating conditions to the stream yields and properties respectively for stream n)

17 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

18 Petroleum Refinery (Khor and Varvarezos, 2017)

19 Petroleum Refinery

20 Petroleum Refinery

21 Bio Refinery Thermochemical = yellow squares Mechanical processes = white squares Chemical/Biochemical = blue squares

22 (Jong and Jungmeier, 2015) Bio Refinery

23 (Jong and Jungmeier, 2015)

24 (Jong and Jungmeier, 2015)

25 Metals Refinery (Spitz and Trudinger, 2009)

26 Metals Refinery

27 Copper Refinery

28 Copper Refinery

29 Copper Refinery

30 Iron Refinery

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32 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

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34 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

35 Simulation Optimization (Khor and Varvarezos, 2017)

36 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

37 Conclusions Impact in Industry to replace energy and material by bio-of-things (BoT) : Biorefinery prices is still expensive in comparison with petroleum. Needs of technological frontier with the research, development and deployment (RD&D) of more advanced biorefineries to produce more complex bioproducts for energy and material. Demands of: advances inbiomass processing; biotechnology involvement inside the supply chain and market of the other refining technologies coproduction of bioproducts together with materials, chemicals, food, feed, etc., adding the necessary value to the bioportfolio. AICHE-17, Nov 2 nd,

38 Outline 1) Flowsheet Superstructures and Elements 2) Refining Technology Comparison and Fundaments 3) Open IMPL 4) Types of Projects 5) Conclusions 6) Homework Refining Technology in the Petroleum, Rodrigues Metals and et al. Bioprocesses (2016) Industries

39 Obligatory

40 Obligatory

41 Advised

42 Advised