PS3000 Refinery Operations

PS3000: Refinery Operations Simulator

SIM INFOSYSTEMS PVT LTD, 2, D’Silva Road, Mylapore, Chennai 600 004, INDIA Phone: +91-44-24982617, Email: [email protected]. Website: www.siminfosystems.com

REFINERY OPERATIONS SIMULATOR

The PS3000 is a simulation software package is rigorous and detailed

simulation models of Refinery process plants.

The package consists of the following modules:

PS-3001 Atmospheric Distillation Unit

PS-3002 Vacuum Distillation Unit

PS-3003 Fluid Catalytic Cracking Unit

PS-3004 Hydrogen Generation Unit

PS-3005 Hydrodeslphurization Unit

PS-3006 Catalytic Reforming Unit

PS-3007 Continuous Catalytic Regeneration Unit

PS-3008 Hydrocracking Unit

PS-3009 Sulphur Recovery Unit

PS-3010 Amine Treating Unit

Plant familiarization: Simulator offers the best platform for learning process

plant configuration, instrumentation, control system, critical parameters and

their design values and normal plant operations.

Ensure Smooth Start Ups: Plant Simulator allows operators to become

familiar with operation while they increase their familiarity with the controls

and graphical scenes. Continued training ensures increasingly smooth start-ups

in the future.

Reduce Incidents and Downtime: Training personnel in a non-destructive

environment enable you to validate emergency controls before actual use.

Testing modifications to compressor controls can avoid damage from surges.

One can purposely trigger malfunctions (such as a trip) to test operator

reactions and improve response reactions.

Maximize Performance: The Simulators are based on rigorous first-principles

models and actual controls, allowing you to troubleshoot actual process and



control problems. They unlock the fundamental understanding required to

modify, test, and improve processes and maximize plant performance.

Benefits to Academic Institutions: The Dynamic Simulator helps to teach the

students the fundamentals as well as complex process operations. It provides

opportunity for the chemical / instrumentation engineering students to know

what is happening in the industry. Simulator trained students will have edge

over their counterparts in the competitive scenario with respect to their

knowledge in Instrumentation & Control and Process operations.



PS3001: ATMOSPHERIC DISTILLATION UNIT

PROCESS DESCRIPTION In Preheat I section, crude is heated by a series of heat exchangers with kerosene,

Diesel and Pump around as a heating medium In Desalter, the impurities such as salt

and other contaminants are removed from crude by the desalting process. In Preheat

II section, the desalted crude is again heated by a series of heat exchangers with

kerosene, Diesel, Pump Around and reduced crude oil as heating medium.

In Crude Heater, the natural draft furnace heats the crude oil to a high temperature

enough to permit separation of components in distillation column. In Crude Column,

the tower contains 49 trays, which facilitates the contact between vapor and liquid

and through fractionation the crude oil components are separated into desired

materials for further processing.

In Product Stripper, the products like Naphtha, Kerosene and Diesel are separated

according to their boiling range. Three pump around systems namely, Top, Middle and

Bottom Pump around are employed to maintain the desired temperature gradient in

the tower.

The stabilizer unit is designed to stabilize the naphtha from the feed coming from

the overhead accumulator of a crude distillation unit. Stabilized naphtha and LPG are

the products from the stabilizer.

MAJOR EQUIPMENT Feed pump and preheat exchangers Desalter Pre heat exchangers Crude heater Atmospheric Distillation Tower Pump around systems Products strippers Product coolers Overhead condenser and reflux drum Stabilizer

TRAINING EXERCISES Crude feed pump failure Booster pump failure RCO Pump failure Reflux pump failure Stabilizer Reflux Pump failure Steam failure Power failure Instrument Air failure Fin Fan failure Atomizing Steam Indication failure



TRAINING BENEFITS

This dynamic simulator helps beginners, experienced operators and engineers to

achieve the following objectives:

To teach trainees and to recognize, understand the operating fundamentals of

a Crude Distillation using dynamic simulation.

To describe about the operation of a Crude Distillation.

To Startup and shutdown of the process using documented procedures.

To respond safely and efficiently to disturbances and malfunctions in the

process.



PS3002: VACUUM DISTILLATION UNIT

PROCESS DESCRIPTION In the vacuum Distillation Unit model, the bottom reduced crude oil (RCO) from the

atmospheric column is distilled into the following products: Light Vacuum Gas Oil

(LVGO), Medium Vacuum Gas Oil (MVGO) and Heavy Vacuum Gas Oil (HVGO). The

vacuum bottoms exit the process as vacuum residue. The vacuum Distillation Unit

simulator, the entering feed passes through a preheat furnace where partial

vaporization occurs before the feed enters the distillation column. Vacuum column

operates below atmospheric conditions. The vacuum product cooling section consists

of steam generation facilities and tempered water cooling facilities. Vacuum is

maintained by a two stage ejector system. The vacuum column overhead vapor flows

to the pre-condensers where steam & products are condensed out. The balance vapor

passes through the first stage ejector. The discharge from the first stage goes to

the inlet condenser and the non-condensed vapors are sent to the second stage. The

discharge of the second stage goes to the after condenser and the non-condensable

are routed to atmosphere. Condensate is routed to the hot well, from which it is

pumped to the desalting water drum by sour water pumps. The condensed steam and

the slop oil are let into the Hot well from where it is pumped away.

MAJOR EQUIPMENT Vacuum Furnace Vacuum Distillation Column Product stripper Product cooling Overhead ejector system Hot well

TRAINING EXERCISES Feed failure Coil steam failure Heater fuel failure Cooling Water failure Vacuum failure Pump Failures Change in Heater Efficiency Change in Steam Jet Ejector Efficiency Change in Circulating Reflux Change in Internal Reflux



TRAINING BENEFITS The Vacuum Distillation Unit simulator helps beginners, experienced operators and

engineers to achieve the following objectives:

To teach trainees and to recognize, understand the operating fundamentals of

a Vacuum Distillation unit using dynamic simulation.

To describe about the operation of a Vacuum Distillation unit.

To Startup and shutdown of the process using documented procedures.

To respond safely and efficiently to disturbances and malfunctions in the

process.



PS3003: FLUID CATALYTIC CRACKING UNIT

PROCESS DESCRIPTION

FCC unit simulator consists of the following major sections:

Feed and pumping section

Reactor and Regenerator section

Fractionation section

Gas concentration section

The Fluidized Catalyst Cracking Unit (FCCU) upgrades relatively heavy hydrocarbon

to high grade lighter products via fluidized catalytic cracking and fractionation. The

heavy hydrocarbon oil makes contact with hot powdered catalyst under selected

conditions of time, temperature and pressure. The unit cracks the heavy hydrocarbon

oil into fuel gas, LPG, Gasoline, TCO and CLO. In Preheater section, feed is preheated

through heat exchanger with the help of slurry from fractionator bottom.

In Reactor/Stripper section, the oil feed enters the base of the reactor risers in a

liquid or partially vaporized state, and is then completely vaporized by contact with

the hot regenerated catalyst dropping from the regenerator standpipes into the

riser lines. In Regenerator section, the coke deposits accumulated on the catalyst in

the reactor are burned off at high temperature in the presence of air In

Fractionator section, it separates the reactor vapor effluent into a wide range of

cracked hydrocarbons as product streams.

In Gas concentration section, Dry gas, LPG and Stabilized gasoline are separated

from wet gas and unstabilized gasoline. The gas concentration section mainly consists

of Wet Gas Compressor (WGC), Primary Absorber, Sponge Absorber, C2 Stripper and

Debutanizer.

UNITS SIMULATED Feed Surge drum and preheat exchangers Riser, Reactor, stripper Regenerator Flue gas waste recovery Air Blower Fractionator Furnace Main Fractionator Slurry Steam generators Product Strippers Wet Gas Compressor

TRAINING EXERCISES Feed failure Air blower failure WGC failure Cooling water failure Power failure Instrument air failure Fail stack slide valve Fail spent catalyst slide valve Fail regenerator standpipe slide valve Pump Failures



High Pressure Separator Primary Absorber Sponge Absorber C2 Stripper Debutanizer

Valves failures Change in catalyst activity Water in feed Change in feed CONCARBON Number Heat exchanger / cooler / reboiler fouling Passing of FG in DFAH Passing of torch oil to regenerator Passing of BFW in regenerator

TRAINING BENEFITS The Fluid Catalytic Cracking Unit simulator helps beginners, experienced operators

and engineers to achieve the following objectives: To teach trainees and to recognize, understand the operating fundamentals of a

Fluidised Catalytic Cracking using dynamic Simulation.

To identify the main equipment and operations associated with Fluidised Catalytic Cracking

To Startup and shutdown of the process using documented procedures

To respond safely and efficiently to disturbances and malfunctions in the process.

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PS3004: HYDROGEN GENERATION UNIT

PROCESS DESCRIPTION The Hydrogen unit is designed for a capacity of 4754 kg/hr of Hydrogen. The feed to the

unit is Naphtha. The Hydrogen unit is divided into five main sections:

Desulphurization

Reforming

CO conversion (shift section)

Separation of H2 (excluding PSA unit)

Steam Generation

Desulphurisation unit consists of three reactors, Hydrogenator R401 followed by two H2S

absorbers – R402 A/B in series. In reforming section, the hydrocarbon feed is converted into

synthesis gas consisting mainly of H2, CO and CO2, besides a minor amount of CH4.

In Shift section, CO is converted to CO2 by reaction with H2O hereby generating H2. At

startup and during upsets it is possible to bypass the shift section at the expense of a

reduced H2 production. In Separation of H2, the shifted process gas contains H2, CO2 and

steam, besides a minor amount of CO and a slip of methane. The produced H2 is separated in

the PSA unit (Pressure Swing Adsorption) which also treats HCU off-gas as a feedstock. In

Steam generation section, 42 kg/cm2 steam is produced in the H2 generation plant can be

used as process steam for heat transfer within the unit and for steam export.

UNITS SIMULATED Feed drum and preheat exchangers Desulphurization Reactors Pre reformer Tubular reformer Medium Temperature Shift converter Low Temperature Shift converter Recycle compressors Deaerator and BFW pumps BFW preheaters Process Condensate separators

TRAINING EXERCISES Feed failure Pump failures BFW failure IF, FD fan failures Cooling water failure Power failure Fail Recycle Hydrogen compressor Start-up N2 compressor Reformer trip PSA trip Reforming plugging H2 gas leak Fouling of heat exchangers Sulpur in feed naphtha Feed naphtha temperature Desulphurization reactor catalyst activity ZnO bed catalyst activity Reformer catalyst activity MTSC / LTSC catalyst activity PSA Efficiency Ambient air temperature Cooling water temperature



PS3005: HYDRODESLPHURIZATION UNIT

PROCESS DESCRIPTION HydroDesulphurization unit Simulator is a dynamic simulation model with following

sections:

Feed Section – Heavy gas Oil along with the recycle stream enters into the

Feed Drum which is then sent to Preheaters for Preheating.

Preheat Section and Heater – Feed is heated in series of exchangers and in

Fired Heater before entering the Reactor.

Reactor System - The hot Hydrogen charged feedstock stream enters the top

of Reactor for Substitution reactions to occur, removing Sulfur from the

Hydrocarbon chains and replacing it with Hydrogen.

High Pressure Accumulator system -

Product Section - The liquid process stream from the Cold Flash Drum, and

Hot Flash Drum are stripped in Product Stripper to strip out remaining

Hydrogen sulfide and the other contaminants from the petroleum product.

UNITS SIMULATED Feed drum and preheat exchangers Fired heater Reactor HP Accumulator Medium Temperature Shift converter Low Temperature Shift converter Recycle compressors Deaerator and BFW pumps BFW preheaters Process Condensate separators

TRAINING EXERCISES Makeup compressor failure Recycle compressor failure Pump failures Reactor feed heater air preheater Fan failures Cooling water failure Power failure Fail reactor feed heater fuel gas flow Fouling of heat exchangers Reactor catalyst activity Maximum DEA supply rate Hydrogen supply pressure Hydrogen supply purity Fresh feed olefin content Fresh feed sulfur content Reactor feed heater tube rupture Reactor no. 1 plugging



PS3006: CATALYTIC REFORMING UNIT

PROCESS DESCRIPTION The Catalytic Reforming unit treats sweet naphtha from the naphtha hydrotreating

unit to produce high octane reformate, naphtha and hydrogen rich gas. The Catalytic

Reforming reactions involve aromatization, dehydrocyclisation of napthenes,

isomerisation and hydrocracking to a certain extent. The Catalytic Reforming unit has

four sections, namely, Feed preheat section, Reactor section, Product separator

section, Debutaniser section.

In Feed Preheat section, Feed is preheated with the help of heat exchangers

In Reactor section, it comprises of a reactor and the interstage heaters

where an endothermmic reaction takes place and further it is heated through

interstage heaters.

In Product Separator section, the two-phase mixture from the condenser

flows to the separator. The vapors rich in hydrogen are separated,

compressed and recycled back to the CFE.

In Debutaniser section, it processes the hydrocarbon liquids which contains

the maximum constituents of reformate naphtha and LPG from the separator

section.

UNITS SIMULATED Feed tank Combined feed exchanger Product condenser Charge heater Catalytic reformer – 3 stage reactors Inter Heater 2 & 3 Separator Debutaniser

TRAINING EXERCISES Feed Naphtha supply Pressure Feed Naphtha supply Temperature

Pump failures Cooling water failure Power failure Fuel gas failure Recycle gas compressor failure Ambient Temperature

Fouling of heat exchangers FO, PG supply pressure Catalyst Activity



PS3007: CONTINUOUS CATALYST REGENERATION UNIT

PROCESS DESCRIPTION The CCR regeneration section performs two functions, namely, Catalyst transfer and

Catalyst Regeneration

In catalyst Transfer, it is transferred from the Catalytic reforming reactors to the

Regenerator and back again to regenerate the catalyst.

In Catalyst regeneration, the coke is burned off at a high temperature and low

oxygen concentration and the catalyst passes into the Chlorination Zone where it is

oxidized at high temperature and high oxygen concentration (18 to 20 mole %)

The "Logic" is divided into the following:

1. Master Controller

2. Lock Hopper No.1 Controller

3. Lock Hopper No.2 Controller

4. Miscellaneous Logic

Master controller logic contains the logic for the following:

1. Emergency Stop System

2. Regenerator Run-Stop Circuit

3. Catalyst Flow Controller

4. Chemical Selector System

5. Heater Shutdown System

6. Lift Gas Interlock

7. Lock Hopper Selector System

8. Verification

CONTROL SCHEME Purge gas Flow Controller Lift Gas Flow Controller Hopper Pressure Controller Air Heater Outlet Temperature Controller Regenerator Heater Outlet Temp Controller Air Flow Controller

TRAINING EXERCISES Lock Hopper failure

Pressure Differential Controller failure Chloride Flow failure Downstream failure Regeneration Heater Trip



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PS3008: HYDROCRACKER UNIT

PROCESS DESCRIPTION The Hydrocracking process is a versatile process for catalytically hydrocracking

heavy petroleum fractions into lighter, more valuable products.

The simulated plant processes a feedstock of vacuum gas oil from the vacuum

distillation Column. The feed is converted into lower molecular weight components

namely sour gas, heavy naphtha, light naphtha, diesel oil and kerosene. The desired

degree of hydrocracking takes place as the feed is processed over a fixed bed of

catalyst at elevated hydrogen pressure and temperature. The amount of catalyst

required per volume of fresh feed and the pressure level required depend on the

nature of the feed and the products desired. When the feed and hydrogen contact

the catalyst, nitrogen compounds are converted to ammonia and hydrocarbons, sulfur

compounds are converted to hydrogen sulfide and hydrocarbons, and the hydrocarbon

feed is hydrocracked into the lower molecular weight products. The effluent from

the reactors is sent to the fractionation section where the products and bottoms are

separated. The simulated plant is divided into two major sections to accomplish the

hydro cracking process:

A Reactor section, in which the feedstock is processed through two hydrogen-

charged catalytic bed reactors namely lead reactor and main reactor.

A Fractionator section, in which the reaction product is separated into several

grades of hydrocarbon products, some of which go on to further treatment

and some to storage.

MAJOR EQUIPMENT Feed preheat exchangers and surge drum Lead and Main reactors HP, LP Hot Separators HP, LP Cold Separators H2S absorber Recycle Gas compressor Makeup Hydrogen compressor trains Fractionator furnace Main Fractionator Product strippers

TRAINING EXERCISES Pump failures Cooling water failure Power failure Fuel gas failure Recycle gas compressor failure MUG compressor failure Ambient Temperature

Fouling of heat exchangers FO, PG supply pressure Catalyst Activity for R1, R2 Make-up H2 Purity Heat Exchangers fouling



PS3009: SULPHUR RECOVERY UNIT

PROCESS DESCRIPTION The process consists of controlled combustion of a hydrogen sulfide gas stream,

followed by a (catalytic or thermal) reaction between hydrogen sulfide and sulfur

dioxide to produce sulfur as a vapor. The vapor is collected and condensed, and the

liquid is collected in the sulfur pit. The objectives of the unit operation are not only

the production of sulfur, but also the reduction of undesirable gases (such as SO2)

being released into the atmosphere. These objectives must be achieved in spite of

changes in feedstock properties and upsets to the various operating conditions.

MAJOR EQUIPMENT Feed gas knockout drums

Combustion chamber Reaction furnace Sulfur condenser 1,2,3, 4 Steam re-heater 1,2,3 Catalytic converter 1,2,3 Sulphur pit

TRAINING EXERCISES Pump failures Cooling water failure Power failure Fuel gas failure BFW failure

Plugged S Line To Coalescer Fouling of heat exchangers Feed gas composition Feed gas temperature



PS3010: AMINE TREATING UNIT

PROCESS DESCRIPTION

In Amine plant, CO2 present in the feed synthesis gas is reduced from 54.0% to

0.06% by selective absorption using MEA (Mono Ethanol Amine). Gas handling

capacity of the simulated amine plant is 114 TPH of synthesis gas.

Amine plant consists of the following three sections:

Absorber Section

Turbines and Pumps Section

Stripper Section

MAJOR EQUIPMENT Absorber Column K.O Drum Lean Amine Cooler Lean Amine Heat Exchanger Amine Guard Inhibitor system Lean Solvent Pump A - Motor Driven Lean Solvent Pump B - Turbine Driven Hydraulic Turbine Stripper Column Flash Drum Reflux Drum (D-02) Lean Solvent Exchanger 1 Stripper Overhead Condenser Steam Reboiler Hot Oil Reboiler

TRAINING EXERCISES Pump failures Power failure Blow absorber relief valve Blow stripper relief valve High CO2 in feed gas Fouling of heat exchanger Cooling water temperature Feed gas temperature Exchanger fouling Stripper efficiency Absorber efficiency FOAMING IN STRIPPER

PS3000 Refinery Operations

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Transcript of PS3000 Refinery Operations