Dynamic Simulation study for the analysis of Delayed Coker Pressure Relief Scenarios:
Dynamic simulation is a valuable tool to evaluate operational problems in dynamic or transient mode. A dynamic simulation model of Delayed Coker Unit was developed in Hysys dynamics for a major EPC client. The overarching objective was to protect the plant in case of a safety emergency and ensure that the flare relief system had the capacity to handle such an event. The related objective of the dynamic simulation was to find the time required for the relief to occur after the onset of a pressure increasing scenario, & determine the relief stream properties and the relief load. The simulation study included Feed Heater, Coke Drums, Main Fractionator, Blow-down Tower and Wet Gas Compressor along with internal pipes and fittings, instruments, heat exchangers as well as controls. The following scenarios were simulated:
- Unit Wide Power Failure
- Unit Wide Cooling Failure
- Coke Drum Blocked Outlet
- Unit Wide Cooking Water Failure
A summary report was prepared which had information about the relief load and time taken to reach the set point of the safety device and for the relief to occur. The load on the flare header for each case was also reported.
Strategic planning study for Grassroots Refinery:
Problem: Implement a conceptual planning study for a grassroots hydroskimming & hydrocracking refinery. Evaluate optimum configuration with right blend of crude oils using LP and strategic planning ProPlan software. Scope of work included evaluating crude oils with generic new refinery configurations to maximize diesel production for
- A Hydroskimming refinery (including catalytic reformer)
- A Conversion-Hydrocracking refinery (hydroskimming refinery plus VDU, Hydrocracker, Hydrogen Production Unit (natural gas feedstock) and Isomerization units)
Ingenious developed 4 cases with 4 different individual crudes for a hydroskimming refinery configuration, and 9 cases with 7 different individual crudes and 2 crude blends for hydrocracking refinery configuration. For all 13 cases, the unit capacities and operating conditions were optimized for diesel maximization. Each case presented the client with a detailed economic analysis consisting of Gross revenue, Capital cost, Utility and operating cost, product slate and net profit.
Conclusion:
The client was able to analyze each alternative with techno-economical considerations and choose the optimum configuration based on market demand and profitability.
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