Investigating the possibility of reducing energy consumption in the Cat Cracker Unit (FCCU) of Abadan Refinery through the optimization of process variables

Master thesis

Abstract

In this project, the coat cracker unit of Abadan refinery has been simulated using Hysys refinery software. In simulating and receiving information, feed properties and solving mass and energy balance equations have been used. The simulation data and operational data of the Abadan Cat Cracker unit have been compared.

Also, by changing some important operating variables of the unit, their effect on molecular weight and octane number has been investigated and the optimal conditions for the operation of the unit have been introduced. It is used in the unit and its economic value has been calculated.

keywords:

1- Catalytic failure 2- Regeneration tower 3- Riser 4- Octane number 5- Fluid bed 6- Catalyst activity

The creation of the idea of ??energy at the end of the 19th century became the source of a tremendous transformation in the world of science and technology, so that its impact on the environment has been revealed day by day. The most important source of energy production for humans has always been the sun, whose amazing effect on the lives of living beings has been evident for a long time. However, man's access to fossil fuels has greatly increased his ability and power in the last century and has profoundly "transformed" his living conditions. The combination of fossil fuels with the air surrounding the inhabited planet has given mankind a power that has quickly turned into a technological monster. Speeds have increased, tasks have become easier, and it has become possible to achieve many undiscoverable things. This great blessing, at the same time, has also brought great trouble. Due to the essential role of the air around the globe in the life of living beings, including humans, the change in the chemical composition of the air due to the excessive consumption of oxygen, the increase of gaseous products of fossil fuels and the entry of greenhouse gases such as chlorine into the atmosphere has severely affected the lives of living beings and endangered human health and happiness.

Man's current life is highly dependent on fuel and energy sources both in terms of his strong need for cheap and usable stored energy and for chemical reactions and metal production. One of the most effective uses of computers in the oil, gas and petrochemical industries is the simulation of production units by means of special software. This is due to the competitive atmosphere of global markets and the movements that are observed in the field of increasing production efficiency, using resources as best as possible and reducing costs. , has grown significantly in recent years, but many of the benefits of this work are not yet known. In this section, some fields of application of simulation software are briefly explained with the aim of reviewing the most important advantages of these software.

1-1- modeling and simulation

Process modeling means describing the nature of the production system (i.e. mass and energy balances) in the form of mathematical equations. The main characteristics of good models are accuracy, quantity and brevity. Of course, less accurate, qualitative, or detailed models also have special uses that are out of the general discussion of this article. These equations are generally non-linear and in the form of algebraic, differential, or a mixture of the two, which, by putting them together, creates a model of the process. .

Simulation, that is, obtaining output information (for example, product specifications) through solving the above models based on input information (for example, feed specifications), meanwhile, the information related to the specifications of the devices are considered part of the model and part of them is given to the software by the user.

1-2- Applications of simulation

1-3- In spite of the simple definition above, the applications of simulation are very diverse and varied.. Here, these applications are reviewed in three parts:

1-3-1- Simulation applications in process research and development

Traditionally, research on new production methods or systems has been carried out with the help of advanced units. However, due to the high cost of building and maintaining these units, since In the past, the idea of ??using simulation software has been proposed to reduce these costs. By using these software, it is possible to check different options of the production line, study the increase of unit capacity, and finally, optimally design and build the vanguard unit. On the other hand, the parts of the process that by simulating them provide enough information for the design of the unit can be removed from the vanguard unit.

1-3-2- Simulation applications in process design

Today, simulation software is widely used in process design. The applications of these softwares in this field, in terms of the scope of work, start from the simple calculation of thermophysical properties of flows or even pure materials and reach the design of complete factories by taking into account ancillary facilities, feed supply pipelines, or product transfer and checking control systems. Since this method is simpler, faster and more accurate than manual calculations, by repeating it in different conditions easily and with much less time, it is possible to predict a complete set of process performance in different states, and in this way, while reducing additional costs of fixed investment (additional devices) and reducing operating costs (water, energy consumption, etc.), it creates more flexibility in the process design and obtains the optimal point in terms of costs, operational smoothness, safety, environment, etc.

In addition, since process design is not separate from the design of mechanical devices and equipment, piping, precision tools, electrical systems and structures and buildings, the phase of information obtained from simulation in different modes can be used to help design these systems. New simulation softwares benefit from the ability to connect to the design software of these systems and transfer information to them. rtl;"> 

1-3-3- Applications of simulation in the optimal use of existing facilities:

In existing factories, with the help of simulation software, the production process of raw material can be carefully examined and evaluated and in this way, the operation can be improved in general. If more advanced software is used, it is possible to optimize on the spot based on production conditions (such as feed temperature and conditions climate) is also there.

Reducing materials and energy consumption is also one of the studies that can be done with the help of these softwares. However, one of the very important applications of using simulation software is to discover the maximum available and usable production capacity in the production line, which sometimes has a very low cost and a significant income.