Planning for the integrated refinery subsystems

Abstract

In global energy and industrial market, petroleum refining industry accounts for a major share. Through proper planning and the use of adequate mathematical models for the different processing units, many profit improving opportunities can be realized. The increasing crude oil price has also made refining of crude oil blends to be a common practice. This thesis aims to provide useful insight for planning of the integrated refinery subsystems. The main subsystems referred to are (1) The crude oil unloading subsystem (2) The production and product blending subsystem and (3) The product distribution subsystem. Aspen HYSYS® was first used to develop a rigorous model for crude distillation unit (CDU) and vacuum distillation unit (VDU). The rigorous model was validated with pilot plant data from literature. The information obtained from the rigorous model is further used to develop a model for planning of the CDU and VDU. This was combined with models (obtained from empirical correlations) for fluid catalytic cracker (FCC) and hydrotreater (HDT) units to form a mathematical programming planning model used for refinery production and product blending subsystem planning. Since two different types of crude were considered, the optimum volumetric mixing ratio, the sulphur content at that mixing ratio and the CDU flow rate were determined. The yields fraction obtained from the rigorous model were then used to generate regression model using least square method. The sulphur composition of the crude oil was used as independent variable in the regression model. The generated regression models were then used to replace the regular fixed yield approach in a refinery planning model and the results compared. From the results obtained, the proposed method provided an alternative and convenient means for estimating yields from CDU and VDU than the regular fixed yield approach. The proposed aggregate model for the production and products blending subsystem was integrated with the modified scheduling model for the crude unloading subsystem developed by Lee et al. (1996) and products distribution model developed by Alabi and Castro (2009) for refinery planning. It was found that the regression model could be integrated in a refinery planning model and that the CDU flow rate was maximised as compared to the non- integrated system.