Modeling and Simulation of Catalytic Reactors for Petroleum Refining E-Book

Jorge Ancheyta

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch
• Veröffentlichungsjahr: 2011

Seitenzahl: 799

Beschreibung

Modeling and Simulation of Catalytic Reactors for Petroleum Refining deals with fundamental descriptions of the main conversion processes employed in the petroleum refining industry: catalytic hydrotreating, catalytic reforming, and fluid catalytic cracking. Common approaches for modeling of catalytic reactors for steady-state and dynamic simulations are also described and analyzed. Aspects such as thermodynamics, reaction kinetics, process variables, process scheme, and reactor design are discussed in detail from both research and commercial points of view. Results of simulation with the developed models are compared with those determined at pilot plant scale as well as commercial practice. Kinetics data used in the reactor model are either taken from the literature or obtained under controlled experiments at the laboratory.

Leseprobe

Table of Contents

Cover

Title page

Copyright page

PREFACE

ACKNOWLEDGMENTS

ABOUT THE AUTHOR

1 PETROLEUM REFINING

1.1 PROPERTIES OF PETROLEUM

1.2 ASSAY OF CRUDE OILS

1.3 SEPARATION PROCESSES

1.4 UPGRADING OF DISTILLATES

1.5 UPGRADING OF HEAVY FEEDS

2 REACTOR MODELING IN THE PETROLEUM REFINING INDUSTRY

2.1 DESCRIPTION OF REACTORS

2.2 DEVIATION FROM AN IDEAL FLOW PATTERN

2.3 KINETIC MODELING APPROACHES

2.4 REACTOR MODELING

NOMENCLATURE

3 MODELING OF CATALYTIC HYDROTREATING

3.1 THE HYDROTREATING PROCESS

3.2 FUNDAMENTALS OF HYDROTREATING

3.3 REACTOR MODELING

NOMENCLATURE

4 MODELING OF CATALYTIC REFORMING

4.1 THE CATALYTIC REFORMING PROCESS

4.2 FUNDAMENTALS OF CATALYTIC REFORMING

4.3 REACTOR MODELING

NOMENCLATURE

5 MODELING AND SIMULATION OF FLUIDIZED-BED CATALYTIC CRACKING CONVERTERS

5.1 INTRODUCTION

5.2 REACTION MECHANISM OF CATALYTIC CRACKING

5.3 SIMULATION TO ESTIMATE KINETIC PARAMETERS

5.4 SIMULATION TO FIND CONTROLLING REACTION STEPS DURING CATALYTIC CRACKING

5.5 SIMULATION OF STEADY OPERATION OF THE RISER REACTOR

5.6 SIMULATION TO SCALE UP KINETIC FACTORS

5.7 SIMULATION OF THE REGENERATOR REACTOR

5.8 MODELING THE CATALYST STRIPPER

5.9 SIMULATION OF A CONTROLLED FCC UNIT

5.10 TECHNOLOGICAL IMPROVEMENTS AND MODIFICATIONS

5.11 CONCLUSIONS

NOMENCLATURE

Index

Copyright © 2011 by John Wiley & Sons, Inc. All rights reserved

Published by John Wiley & Sons, Inc., Hoboken, New Jersey

Published simultaneously in Canada

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, [phone], fax [phone], or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, [phone], fax [phone], or online at http://www.wiley.com/go/permissions.

Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.

For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at [phone], outside the United States at [phone] or fax [phone].

Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com.

Library of Congress Cataloging-in-Publication Data:

Ancheyta, Jorge.

 Modeling and simulation of catalytic reactors for petroleum refining / Jorge Ancheyta.

p. cm.

 Includes bibliographical references and index.

 ISBN 978-0-470-18530-8 (cloth)

1. Catalytic reforming–Simulation methods. I. Title.

 TP690.45.A534 2011

 665.5′3–dc22

2010030993

oBook ISBN: 9780470933565

ePDF ISBN: 9780470933558

ePub ISBN: 9781118002162

PREFACE

The reactor is the heart of a chemical process, and a thorough understanding of the phenomena occurring during the transformation of reactants into the desired products is of vital importance for the development and optimization of the process. Particularly in the petroleum refining industry, in which apart from the reactors, other operations (separations, heating, cooling, pumping, etc.) are carried out in series or in parallel and each plant is connected with others, improper design and operation of reactors can cause shutdown of a plant or, even worse, of the entire refinery, with the consequent loss in production and income. It is thus essential to have a thorough knowledge of the fundamental equations critical to chemical reactor design, such as reactor sizing and optimal operating conditions.

The reactors used during petroleum refining are among the most complex and difficult to model and design. The composition and properties of the various petroleum fractions that are converted in reactors is such that the reaction system can involve various phases, catalysts, reactor configuration, continuous catalyst addition, and so on, making the development of a model a challenging task. In addition, the presence of hundreds of components undergoing different reaction pathways and competing for the active sites of catalysts, contributes to increasing the complexity of the formulation of the kinetics and reactor models.

Over the years, many excellent textbooks have been published dealing with various aspects of reactors: chemical reactor design, modeling of chemical reaction kinetics, reaction mechanisms, chemical reaction engineering, scale-up, and so on. The level of sophistication in each book varies from academic reactions (e.g., A → B), represented by simple kinetic models (e.g., the power-law model, ) and using integrated equations for the design of ideal reactors (e.g., PFR, CSTR), to complex catalytic reaction systems employing a set of differential equations to solve for mass and energy balances. However, detailed descriptions of the various reactor models, reaction kinetics, and real examples of the application of these models for the simulation of experimental reaction units and commercial plants have not previously been treated in detail. Moreover, most books do not discuss the modeling of the reactors that are typically used during the conversion of oil distillates in the petroleum refining industry, and do not describe reactor models in an uncluttered or thorough manner.

Modeling and Simulation of Catalytic Reactors for Petroleum Refining is designed to give an up-to-date treatment of all the important aspects of reactor modeling, with particular emphasis on reactors employed in the petroleum refining industry. We explain and analyze approaches to modeling catalytic reactors for steady-state and dynamic simulations and discuss such aspects as thermodynamics, reaction kinetics, process variables, process schemes, and reactor design. To validate the models developed, experimental data obtained directly from laboratory and commercial plants are used. Our goal is that the book will become an essential reference for chemical and process engineers, computational chemists and modelers, catalysis researchers, and professionals in the petroleum industry, as well for use as a textbook either for full courses in chemical reaction engineering or as a supplement to related courses.

The book is organized in five chapters, each with individual reference and nomenclature sections. About 500 references are cited and discussed, covering most of the published literature regarding the modeling of reactors used in the petroleum refinery industry. Chapter 1 provides an in-depth introduction to topics related to petroleum refining, such as petroleum properties, separation processes, upgrading of distillates, and upgrading of heavy feeds. A brief description of all the conversion and separation processes is given in this chapter. Detailed experimental data on light, medium, and heavy crude oil assays are also provided.

General aspects of reactor modeling in the petroleum refining industry are treated in Chapter 2. The emphasis is on reactors, deviations from ideal flow patterns, kinetic modeling approaches, estimation of model parameters, and classification and description of reactor models. The fundamental equations are given for each reactor model, together with their advantages and disadvantages. A generalized reactor model is proposed from which each previously reported reactor model can easily be derived.

Chapter 3 is devoted to the modeling of catalytic hydrotreating reactors. The most important features of this type of reactor are highlighted in the first sections, such as the characteristics and classification of hydrotreating reactors, process variables, other process aspects (quench systems, reactor internals), and fundamentals of hydrotreating (chemistry, thermodynamics, kinetics, and catalysts). The final section covers hydrotreating reactor modeling, with examples of the modeling and simulation of reactors operating with catalysts of different particle shapes, steady-state operation, hydrotreating reactors with quenching, dynamic simulation, and co-current and countercurrent operations for both laboratory and commercial reactors.

The modeling of catalytic reforming reactors is the subject of Chapter 4. The description and types of processes, process variables, and fundamentals of catalytic reforming are described at the beginning of the chapter, followed by a section on reactor modeling in which the development of a kinetic reforming model is reported. Validation of the model developed, with bench-scale isothermal reactor experiments and simulation of commercial semiregenerative reforming reactors, is discussed. The effect of benzene precursors in the feed in both laboratory and commercial reactors is also simulated, and use of the reactor model to predict other process parameters is highlighted.

In Chapter 5, Dr. Maya-Yescas describes the modeling and simulation of the fluid catalytic cracking reactor. Descriptions of the process, reaction mechanism, transport phenomena, thermodynamics, and kinetics are provided in the initial sections. Simulations used to estimate kinetic parameters from laboratory and commercial reactors, to determine the controlling reaction steps, of steady-state operation, of scale-up kinetic factors, of the regenerator reactor, of burning nonheterogeneous coke, of side reactions during the burning of heterogeneous coke, and of the energy balance in the regenerator are discussed in detail. Other sections deal with modeling a catalyst stripper, simulation of the controlled unit, pilot-plant emulation, and industrial plant emulation.

Detailed experimental data and comparisons with reactor model predictions are provided in each chapter. Also, all data and parameters required to build up each reactor and kinetic model are detailed, so that readers can adapt their own computer programs for use in reactor simulation, optimization, and design purposes.

It is our intention that Modeling and Simulation of Catalytic Reactors for Petroleum Refining will quickly become a leading book in this field through its emphasis on detailed descriptions of catalytic reactor modeling used in the petroleum refining industry, its use of laboratory and commercial data for model validations, the details provided of results of simulations in steady-state and dynamic operations, and in general its focus on more practical issues regarding reactor modeling than have been available in previous textbooks on chemical reactor engineering.

ACKNOWLEDGMENTS

I would like especially to acknowledge Dr. Rafael Maya-Yescas, Professor of Chemical Reaction Engineering. Universidad Michoacana de Nicolás de Hidalgo, Morelia, Michoacán, México, who kindly agreed to write Chapter 5. I also thank all the M.Sc., Ph.D., and postdoctoral students who over a period of many years have contributed enormously to the preparation of this book.

JORGE ANCHEYTA

ABOUT THE AUTHOR

Jorge Ancheyta, holds a bachelor’s degree in petrochemical engineering (1989), a master’s degree in chemical engineering (1993), and a master’s degree in administration, planning, and economics of hydrocarbons (1997) from the National Polytechnic Institute of Mexico. He split his Ph.D. between the Metropolitan Autonomous University of Mexico and the Imperial College London (1998), and was awarded a postdoctoral fellowship in the Laboratory of Catalytic Process Engineering of the CPE-CNRS in Lyon, France (1999). He has also been a visiting professor at the Laboratoire de Catalyse et Spectrochimie, Université de Caen, France (2008, 2009, 2010), and Imperial College London (2009).

Dr. Ancheyta has worked for the Mexican Institute of Petroleum (IMP) since 1989, where his present position is project leader of research and development. He has also worked as a professor on the undergraduate and postgraduate levels at the School of Chemical Engineering and Extractive Industries at the National Polytechnic Institute of Mexico since 1992 and for the IMP postgraduate program since 2003. He has supervised about 100 B.Sc., M.Sc., and Ph.D. theses as well as a number of postdoctoral and sabbatical-year professors.

Dr. Ancheyta has worked on the development and application of petroleum refining catalysts, kinetic and reactor models, and process technologies, primarily in catalytic cracking, catalytic reforming, middle distillate hydrotreating, and heavy oils upgrading. He is the author or co-author of a number of patents, books, and about 200 scientific papers, and has been awarded the highest distinction (level III) as a national researcher by the Mexican government and is a member of the Mexican Academy of Science. He has also been guest editor of various international journals: Catalysis Today, Petroleum Science and Technology, Industrial Engineering Chemistry Research, Energy and Fuels, Chemical Engineering Communications, and Fuel. Dr. Ancheyta has also chaired numerous international conferences and is a member of the scientific boards of various prestigious journals.