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Simulation of Vacuum Distillation Unit (Vdu) and Improving Its Productivity Using Aspen Hysys

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Simulation of Vacuum Distillation Unit (Vdu) and Improving Its Productivity Using Aspen Hysys بسمميحرلا نمحرلا هللا Sudan University of Science and Technology College of Petroleum Engineering and Technology Department of Transportation and Refining Engineering SIMULATION OF VACUUM DISTILLATION UNIT (VDU) AND IMPROVING ITS PRODUCTIVITY USING ASPEN HYSYS محاكاة وحدة التقطير الفراغي وتحسين إنتاجيتها باستخدام برنامج الهايسيس Dissertation Submitted in Partial Fulfillment of the Requirement for the Bachelor of Engineering (Horns) Degree in Transportation and Refining Engineering Prepared by: - Abubakar Abdelazim Babiker - Ammer Ali Abdeljalil - Ola Mohamed Morad Supervisor: - Mrs. Nihad Omer Hassan October 2015 Simulation of Vacuum Distillation Unit (VDU) and Improving its Productivity Using Aspen Hysys Graduation project submitted to college of Petroleum Engineering and Technology in Sudan University of Science and Technology Submitted in Partial Fulfillment of the Requirement for the Bachelor of Engineering (Hones) Degree in Transportation and Refining Engineering Prepared by: - Abubakar Abdelazim Babiker - Ammer Ali Abdeljalil - Ola Mohamed Morad Supervisor: - Mrs. Nihad Omer Hassan This project is approved by College of Petroleum Engineering and Technology to Transportation and Refining Department Supervisor: Mrs. Nihad Omer Hassan Signature: ……………………………………………………………………... Head of Department: Ms. Abdelgadir Bashir Banaga Signature: ……………………………………………………………………… Dean of College: Dr. Tagwa Ahmed Musa Signature: ……………………………………………………………………… Date: / /2015 اﻹستهﻻل قال تعالى: " ًَ َها حَ ٌْفٍِ ِمً إِ اَّل بِا اَّللِ ۚ َع َل ٍْ ِو حَ ٌَ اك ْل ُج ًَإِ َل ٍْ ِو أُنٍِ ُب " طٌرة ىٌد اَّلٌت )88( i Dedication We dedicate this project to our parents for the love and support they have provided throughout our entire life, they have been there for every decision we have made and help our dreams become reality, to our friends and families for their help and encouragement. We also dedicate this project to our dear friends Ms. MuazTajaldeen and Ms. Mohamed Abuelgasem ii Acknowledgment Thankfulness and appreciation for Allah as always before and after. Without the encouragement and support of some people this thesis would have not been feasible. We would like to express our gratitude and appreciation to Dr. Dhallia Mamoun Beshir for all the help and for providing us with the data we needed to complete this project. We would like to express our gratitude to our supervision Mrs. Nihad Omer Hassan for her ideal supervision, her sage advice in significant criticisms and patient encouragement aided the writing of this innumerable ways. Also we would like to thank Ms. Abdelgadir Bashir Banaga whose steadfast support of this project was greatly needed and deeply appreciated. We are indebted to our colleges of Sudan University of science and technology. Once again, we thank all those who have encouraged and helped us iii Abstract The project studies the design of vacuum distillation unit (VDU) to process the atmospheric residue produced from Khartoum Refinery. It is simulated on Aspen HYSYS v8 Program. The project includes material and energy balance, designing the vacuum distillation unit (VDU), estimating cost of vacuum distillation unit, corrosion protection of the vacuum distillation and improving the production of (VDU).Cost estimation with the economic summary from ASPEN hysys allows us to assess the total cost of the unit. According to this study, it is found that it is possible to increase the production of heavy vacuum gas oil (HVGO) and light vacuum gas oil (LVGO) and this is a main objective we work for it. Keywords: Vacuum distillation unit, production of gas oil, cost estimation, ASPENHysys, process design. iv المستخلص ٌذرص ىذا الوشزًع حصوٍن ً هحاكاة ًحذه الخمطٍز الفزاغً لوعالدت الوخبمً الدٌي الناحح هن هصفاة الخزطٌم, اعخوذ الوشزًع على بزناهح ىاٌظضAspen Hysys V8 ً هٌاسنت الوادة ً الطالت ً حصوٍن ًحذه الخمطٍز الفزاغً ً حمذٌز الخكلفت ً ححظٍن اَّلنخاخٍت ًطزق حواٌت الوعذاث هن الخاكل. ًفما ليذه الذراطت ًخذ انو هن الووكن ححٌٌل نظبت كبٍزه هن الوخبمً الدٌي الً ً أٌضا ححظٍن ً حطٌٌز ىذا اَّلنخاج عن طزٌك الخحكن فً ظزًف الخشغٍل ٌؤدي لشٌاد هلحٌظ فً سٌج الخام الثمٍل )HVGO( ًسٌج الخام الخفٍف .)LVGO( v Table of Contents: i .................................................................................................................. اﻹستهﻻل Dedication ............................................................................................................. ii Acknowledgment ................................................................................................... iii Abstract ............................................................................................................... iv v ................................................................................................................ المستخلص Chapter 1:Introduction 1.1. Introduction ................................................................................................. - 1 - 1.2 Aspen Hysys: ................................................................................................. - 1 - 1.3 Vacuum distillation column: .............................................................................. - 2 - 1.4 Objectives: .................................................................................................... - 3 - 1.5 Scope of this study: ......................................................................................... - 3 - CHAPTER 2: Literature Review 2.1 Oil refinery .................................................................................................... - 4 - 2.2 Refining process: ............................................................................................ - 4 - 2.2.1 Distillation .................................................................................................. - 4 - 2.2.2 Cracking ..................................................................................................... - 5 - 2.2.3 Combining .................................................................................................. - 6 - 2.2.4 Treating (Removing Impurities) ....................................................................... - 6 - 2.2.5 Reforming .................................................................................................. - 6 - 2.2.6 Blending .................................................................................................... - 7 - 2.2.7 Quality Control ............................................................................................ - 7 - 2.3 Process Units in KRC: ....................................................................................... - 7 - 2.4 Petroleum Products and Characterization: ........................................................... - 8 - 2.4.1 Gas ........................................................................................................... - 8 - 2.4.1.1 Natural (kuff) gas: ...................................................................................... - 8 - 2.4.1.2 Associated gas: ......................................................................................... - 8 - 2.4.1.3 Dissolved gas: ........................................................................................... - 9 - 2.4.1.4 Refinery off gas: ........................................................................................ - 9 - 2.4.2 LPG (liquefied petroleum gas) ......................................................................... - 9 - 2.4.3 Gasoline ................................................................................................... - 10 - 2.4.4 Naphtha ................................................................................................... - 10 - 2.4.5 Kerosene .................................................................................................. - 10 - 2.4.6 Diesels ..................................................................................................... - 10 - 2.4.7 Lub Oil ..................................................................................................... - 11 - 2.4.8 Bitumen ................................................................................................... - 11 - 2.4.9 Coke ....................................................................................................... - 11 - 2.5 Crude assay: ................................................................................................ - 11 - 2.5.1 Bulk properties: ......................................................................................... - 12 - 2.5.2 Fractional Properties ................................................................................... - 15 - 2.6 Previous work: ............................................................................................. - 16 - 2.6.1 Deep Cut Vacuum Tower Incentives for Various Crudes: ..................................... - 16 - 2.6.2 Feed Characterization andDeepcut Vacuum Columns: Simulation and Design: ......... - 16 - 2.6.3 Improving crude vacuum unit performance: ..................................................... - 17 - 2.7 Process description: ...................................................................................... - 17 - 2.8 Deep Cut: ................................................................................................... - 18 - Chapter 3: Methodology 3.1 Project work: ............................................................................................... - 20 - 3.2 Methodology: .............................................................................................
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