Full Furnace Simulations and Optimization with COILSIM1D Kevin M. Van Geem 1 Alexander J. Vervust 1 Ismaël Amghizar 1 Andrés E. Muñoz G. 2 Guy B. Marin 1 1 Laboratory for Chemical Technology, Ghent University - www.lct.ugent.be 2 AVGI www.avgi.be 2016 AIChE Spring Meeting 28 th Ethylene Producers Conference Houston, TX, April 13 th, 2016
1977 2016 Change is inevitable And it s usually for the best! 2
LCT s steam cracking timeline Pilot plant starts operation First commercial license sold Implementation of GCxGC Pilot plant revamped 1974 1976 1978 2001 2004 2006 2008 2010 2012 2015 2016 First simulations of steam cracking First kinetics of coke formation Large expansion of kinetic network TLE model COILSIM3D, continuous expansion of kinetic network, COILSIM1D s GUI implementation Kinetic expansion; Firebox and convection models 3
First there was a coil Transfer Line Exchanger Convection section Reactor Coil Wall Burners Firebox Long Flame Burners 4
and now the entire plant Upstream simulators Downstream simulators... 5
Outline Introduction COILSIM1D: The Simulation Package New Features of COILSIM1D I/O files and Interfacing Conclusions 6
Outline Introduction COILSIM1D: The Simulation Package New Features of COILSIM1D I/O files and Interfacing Conclusions 7
28th EPC, Houston, TX, April 13th, 2016 Key elements of COILSIM SIMCO Furnace CRACKSIM 8
SIMCO: Feedstock Reconstruction A detailed model requires a detailed molecular composition Bulk properties / Commercial indices Gaseous feeds Naphthas Gas condensates Kerosene HVGO VGO POLARITY Biphenyl Naphthalene nc10 nc9 nc11 nc12 nc13 nc14 nc15 nc12 VOLATILITY SIMCO Validation by means of GCxGC Molecular feed composition Detailed product distribution 9
SIMCO: Feedstock Reconstruction Input given via the GUI Bulk properties : Average Molecular Weight Specific Density Elemental analysis PIONA Distillation data TBP ASTM D86 ASTM D2887 10
Reactor definition Built-in library of commercial coil geometries New coil Geometry tool: Dedicated correlations for enhanced heat transfer of 3D geometries: Nu D = 0.242 Re D 0.645 Pr 0.4 P Nu D = 4.11 Re D 0.326 Pr 0.4 2.95 Re D 0.23 B 0.0045 Re D 0.31 D e D e T w P 1.4 10 6 1.07 Re D D i D e D e T 0.5 11
Various boundary conditions Transfer Line Exchanger Dedicated condensation coke model 12
Simulation Strategies Profiles: Process gas temperature Tube wall temperature Heat flux to coil Outlet conditions: Common severity indices Yield maximization Sensitivity analyses 13
Simulation Strategies: Run length Run length simulation: Dedicated radical coking models o Catalytic regime can be included User-defined max TMT and/or max ΔP 14
Outline Introduction COILSIM1D: The Simulation Package New Features of COILSIM1D I/O files and Interfacing Conclusions 15
Kinetic Model for Steam Cracking Kinetic model 1D reactor model Broadest kinetic model for steam cracking o o o 720+ molecules 43 radicals 300,000+ reactions Based on high level Ab initio data, and kinetics refitted with experimental data (pilot and industrial) 16
Kinetic Model for Steam Cracking Extended to include oxygenates Validated with an extensive data set 17
Convection Section Model Dedicated evaporation model Various configurations and tube materials supported Geometry Process streams Flue gas side Feed composition 18
Convection Section Model Illustrative case Liquid feed, SIMCO reconstructed 72 different components Different mixing points 19
Demonstration case : Results Convection Section Model Bank name Duty pick up [MW] Evaporator 7.28 Economizer 5.95 HTC 1 2.65 HTC 2 2.53 HPSS 1 2.48 HPSS 2 2.78 DSSH 2.89 HTC3 3.53 CIT : 580 C 20
Flexible model: Geometry Fuel composition Various input conditions Burner arrangements Firebox Simulation Model 21
Firebox, Reactor and TLE Simulation Illustrative Millisecond case: Feed: 118.5 kg C 3 H 8 / h Dilution: 0.33 kg / kg CIT: 630.5 C CIP: 2.35 bara Fuel: 53.9 kg CH 4 / h 22
Firebox, Reactor and TLE Simulation Simulated process parameters: COT: 879 C TLE outlet T: 446 C Furnace efficiency: 43.2 % Bridge-wall temperature: 1138 C 23
Outline Introduction COILSIM1D: The Simulation Package New Features of COILSIM1D I/O files and Interfacing Conclusions 24
I/O files and interfacing Easy interaction with other software Human/machine readable I/O files: -Scripts for creation and result retrieval of simulations. 25
I/O files and interfacing Summary of main results displayed in GUI: 26
I/O files and interfacing Plots for rapid result evaluation in GUI: 27
Detailed result (output) files Easy to import in spread sheets I/O files and interfacing 28
I/O files and interfacing Batch simulations: - Manual (via GUI) - Automated (via code scripts) Clear overview of performed simulations 29
Global plant optimization I/O files and interfacing Interface Interface: Translation of molecule names Extraction of process conditions Coordination of the interaction 30
I/O files and interfacing Example: C 2 H 6 cracker case (incl. recycle) with Aspen Plus Feed 100% C 2 H 6 Recycle C 2 H 6 : 98.5 wt% C 2 H 4 : 1.48 wt% C 3 H 6 : 0.02 wt% Inlet Effluent H 2 : 3.88 wt% CH 4 : 4.80 wt% C 2 H 2 : 0.44 wt% C 2 H 6 : 34.8 wt% C 2 H 4 : 52.2 wt% C 3 H 6 : 0.50 wt% C 4 H 6 : 1.45 wt% C 6 H 6 : 0.46 wt% H 2 : 6.00 wt% CH 4 : 7.42 wt% C 2 H 2 : 0.68 wt% C 2 H 6 : 0.01 wt% C 2 H 4 : 79.8 wt% C 3 H 6 : 0.01 wt% C 4 H 6 : 2.24 wt% C 6 H 6 : 0.70 wt% 31
RTO Demonstration case carried out at demonstration unit in China I/O files and interfacing Integration in an external package for control of the unit 32
Outline Introduction COILSIM1D: The Simulation Package New Features of COILSIM1D I/O files and Interfacing Conclusions 33
Wrapping 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 software 34
Questions? 35