Amghizar, Ismaël

Marin, Guy

Munoz, AE

Van Geem, Kevin

Vervust, Alexander

English

Ghent University Academic Bibliography

Full Furnace Simulations and Optimization with COILSIM1DKevin M. Van Geem1Alexander J. Vervust1Ismaël Amghizar1Andrés E. Muñoz G.2Guy B. Marin11 Laboratory for Chemical Technology, Ghent University - www.lct.UGent.be2 AVGI – www.avgi.be2016 AIChE Spring Meeting – 28th Ethylene Producers’ Conference Houston, TX, April 13th, 2016Change is inevitable2And it’s usually for the best!Ethylene Producers’ Conference, Houston-TX, Apr 13th 20161977 2016LCT’s steam cracking timeline3Pilot plantstarts operationFirst simulations of steam crackingCOILSIM1D’s GUIimplementationFirst commercial license sold1974 1976 1978 2004 2015First kinetics of coke formation2001 2006Large expansionof kinetic networkTLE model2010COILSIM3D,continuous expansion of kinetic network,…Kinetic expansion; Firebox andconvection modelsEthylene Producers’ Conference, Houston-TX, Apr 13th 20162012 20162008Implementation of GCxGCPilot plant revampedFirst there was a coil…4Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Reactor CoilTransfer Line ExchangerConvection sectionFireboxLong Flame BurnersWall Burners… and now the entire plant5Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Downstream simulators...Upstream simulators…Outline• Introduction • COILSIM1D: The Simulation Package• New Features of COILSIM1D• I/O files and Interfacing• Conclusions6Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Outline• Introduction• COILSIM1D: The Simulation Package• New Features of COILSIM1D• I/O files and Interfacing• Conclusions7Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Key elements of COILSIM828th EPC, Houston, TX, April 13th, 2016SIMCOCRACKSIMFurnaceSIMCO: Feedstock Reconstruction• A detailed model requires a detailed molecular composition9Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Gaseous feeds NaphthasGas condensates Kerosene HVGOVGO…Bulk properties / Commercial indicesSIMCOMolecularfeed compositionDetailed product distributionVOLATILITYPOLARITYnC12 nC13 nC14 nC15nC12nC11nC10nC9BiphenylNaphthaleneValidation by means of  GCxGCSIMCO: Feedstock ReconstructionInput given via the GUI 10Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Bulk properties :• Average Molecular Weight• Specific Density• Elemental analysis• PIONA• Distillation data• TBP• ASTM D86• ASTM D2887Reactor definition• Built-in library of commercial coil geometries• ‘New coil Geometry’ tool:• Dedicated correlations for enhanced heat transfer of 3D geometries:11Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016𝑵𝒖𝑫 = 0.242 𝑅𝑒𝐷0.645 𝑃𝑟0.4𝑃𝐷𝑒−2.95 𝑅𝑒𝐷−0.23𝐵𝐷𝑒0.0045 𝑅𝑒𝐷0.31𝑇𝑇𝑤0.5𝑵𝒖𝑫 = 4.11 𝑅𝑒𝐷0.326 𝑃𝑟0.4𝑃𝐷𝑒−1.4 10−6 𝑅𝑒𝐷1.07𝐷𝑖𝐷𝑒Transfer Line Exchanger• Various boundary conditions• Dedicated condensation coke model12Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Simulation Strategies13Profiles:• Process gas temperature• Tube wall temperature• Heat flux to coilOutlet conditions:• Common severity indices• Yield maximization• Sensitivity analysesEthylene Producers’ Conference, Houston-TX, Apr 13th 2016Simulation Strategies: Run length 14Run length simulation:• Dedicated radical coking modelso Catalytic regime can be included• User-defined max TMT and/or max ΔPEthylene Producers’ Conference, Houston-TX, Apr 13th 2016Outline• Introduction• COILSIM1D: The Simulation Package• New Features of COILSIM1D• I/O files and Interfacing• Conclusions15Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Kinetic Model for Steam Cracking16• Broadest kinetic model for steam crackingo 720+ moleculeso 43 radicalso 300,000+ reactions• Based on high level Ab initio data, and kinetics re-fitted with experimental data (pilot and industrial)Kinetic model 1D reactor modelEthylene Producers’ Conference, Houston-TX, Apr 13th 2016Kinetic Model for Steam Cracking17• Extended to include oxygenates • Validated with an extensive data setEthylene Producers’ Conference, Houston-TX, Apr 13th 2016Convection Section Model181• Dedicated evaporation model• Various configurations and tube materials supportedGeometryProcess streams Flue gas side Feed composition Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Convection Section ModelIllustrative case 19• Liquid feed, SIMCO reconstructed• 72 different components • Different mixing points Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Convection Section ModelDemonstration case : Results  20CIT : 580 °C Bank name Duty pick up [MW]Evaporator 7.28Economizer 5.95HTC 1 2.65HTC 2 2.53HPSS 1 2.48HPSS 2 2.78DSSH 2.89HTC3 3.53Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Firebox Simulation Model• Flexible model:– Geometry– Fuel composition– Various input conditions– Burner arrangements21Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Firebox, Reactor and TLE Simulation• Illustrative Millisecond case:Feed: 118.5 kg C3H8 / hDilution: 0.33 kg / kgCIT: 630.5 °CCIP: 2.35 baraFuel: 53.9 kg CH4 / h22Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Simulated process parameters:COT: 879 °CTLE outlet T: 446 °CFurnace efficiency: 43.2 %Bridge-wall temperature: 1138 °CFirebox, Reactor and TLE Simulation23Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Outline• Introduction• COILSIM1D: The Simulation Package• New Features of COILSIM1D• I/O files and Interfacing• Conclusions24Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacing25• Easy interaction with other software• Human/machine readable I/O files:-Scripts for creation and result retrieval of simulations.Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacingSummary of main results displayed in GUI:26Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacingPlots for rapid result evaluation in GUI:27Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacing• Detailed result (output) files • Easy to import in spread sheets 28Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacingBatch simulations:- Manual (via GUI)- Automated (via code scripts)29Clear overview of performed simulations  Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016I/O files and interfacingGlobal plant optimizationInterface:– Translation of molecule names– Extraction of process conditions– Coordination of the interaction30InterfaceEthylene Producers’ Conference, Houston-TX, Apr 13th 2016Example: C2H6 cracker case (incl. recycle) with Aspen Plus®I/O files and interfacing31Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Feed100% C2H6RecycleC2H6: 98.5 wt%C2H4: 1.48 wt%C3H6: 0.02 wt%Inlet EffluentH2: 6.00 wt%CH4:  7.42 wt%C2H2: 0.68 wt%C2H6: 0.01 wt%C2H4: 79.8 wt%C3H6: 0.01 wt%C4H6: 2.24 wt%C6H6: 0.70 wt%H2: 3.88 wt%CH4:  4.80 wt%C2H2: 0.44 wt%C2H6: 34.8 wt%C2H4: 52.2 wt%C3H6: 0.50 wt%C4H6: 1.45 wt%C6H6: 0.46 wt%I/O files and interfacingRTO• Demonstration case carried out at demonstration unit in China• Integration in an external package for control of the unit32Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Outline• Introduction• COILSIM1D: The Simulation Package• New Features of COILSIM1D• I/O files and Interfacing• Conclusions 33Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Wrapping up• COILSIM1D can now simulate entire furnaces, all in one package, with one click• Flexible, user-friendly and accurate simulations• Easy interaction with third-party software34Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016Questions?35Ethylene Producers’ Conference, Houston-TX, Apr 13th 2016

Full furnace simulations and optimization with coilsim1d

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Full furnace simulations and optimization with coilsim1d

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Ghent University Academic Bibliography