Refinery wide simulation

Process simulation has been widely used in refineries for more than 30 years. Steady state and dynamic simulations are established tools for the design of new process units and optimisation (off and online) of existing facilities. While mathematical models of separation systems and other unit operations are available in most commercial process simulators, refinery reactors are very specialised models and, in most cases, are simulated as standalone units. As a consequence, the interactions between different processing units are not fully explored and the true operating window is never captured. Many refiners have recognised the potential benefits of extending rigorous modelling to refinery wide simulations that model all of the process units as an integrated system. This approach would provide a powerful tool to help optimise refinery operations, and would be an important element in sustaining a competitive advantage in light of new regulations, growing competition and decreasing margins. However, such refinery wide models were expensive and time consuming to create. In response to this need, AspenTech and UOP have developed a new simulation tool called Aspen RefSYS, which enables refiners to create rigorous refinery wide models using a standard, easy to use solution. This product combines AspenTech’s refining industry process simulation flowsheet technologies and the refinery reactor models developed by UOP and AspenTech. This article illustrates a typical example of how rigorous refinery wide modelling can be used to help companies make more informed operational and investment decisions. This article analyses different strategies for benzene control in gasoline: an important issue facing many refiners because of its significant health and environmental implications.