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Unisim® Design Delayed Coker Unit (DCU) Reactor Product Information Note Connected Plant UniSim® Design Delayed Coker Unit (DCU) Reactor Product Information Note High fidelity kinetic reactor module helping refiners optimize unit performance and enhance the delayed coking process The Challenge: Increase the yield of valuable light refinery products at the expense of heavier products such as asphalt and residual fuel oil Among the various upgrading technologies currently used in oil refineries, many applications employ coking processes. Coking is the primary technique used to upgrade petroleum residues. It produces a solid coke, which has high carbon content. Amongst coking technologies, including delayed coking and fluid coking, delayed coking is the most prevalent with approximately 78 percent of the global installed coker capacity. Delayed coking is one of the few processes able to convert heavy products (atmospheric and vacuum residues) into lighter ones with high economic value through thermal ceacking. UniSim Design DCU Reactor, the latest offering in the The required heat for thermal cracking is provided by pre-heater UniSim Refining portfolio, provides access to key furnace. The cracking reactions happen inside a huge drum called performance indicators (KPIs) related to the delayed Coke Drum, which provides sufficient resident time for cracking and coking operation. coke creation. The produced coke stays in the coke drum for each cycle time, and the vapor effluent of the reactor is sent to the downstream fractionator to separate light gas, naphtha, coker gas oil and other distillates. WHY DO CUSTOMERS CHOOSE OUR SOLUTION? • • Proven technology • Enables the configuration Helps refinery personnel • Identifies the most • Includes models that can backed by decades of of “Once Through” and understand the cause and efficient and profitable be leveraged throughout refining industry “Conventional” Delayed effect of different feeds, operating strategy for the the plant lifecycle experience Coker Unit with the feed rates, drum pressure delayed coker unit given • Best-in-class support • Built on the UniSim option to choose multiple and other operating its process constraints through Honeywell’s EvOlution platform, coke drums where drums conditions • Enables an accurate Benefits Guardianship which enables process geometry can be determination of the Program (BGP) design and optimization specified yields for residual feeds under the same from various available environment crudes Honeywell Process Solutions is recognized for Today’s complex In recent years, as the worldwide crude providing advanced software solutions petroleum refineries slate has shifted to heavy and extra heavy enabling customers in refining and other rely on a number of feeds, refiners have had to rely on the industries to capture and share process processing of heavier materials and knowledge, improve plant profitability, and secondary conversion residues. The increase in coke production is maximize the return on their technology processes, including partly due to an increase in the amount of investments. For example, our UniSim® fluid catalytic cracking heavier crude refined. However, a greater software family substantially improves (FCC), to diversify their part can be attributed to the overall refinery simulation of online and off-line process unit product offering. goal of increasing the yield of more design and optimization applications. It also valuable light products at the expense of helps determine the workflow, equipment heavier products such as asphalt and needs, and implementation requirements for a residual fuel oil. particular process. The Opportunity: Optimize coking The UniSim solution is part of the Honeywell operations to lower energy costs, increase throughput, reduce emissions, and Connected Enterprise, which connects improve profits processes, assets and people to make the most of plant data and process domain In the current competitive climate, refineries expertise. are looking for ways to optimize the efficiency and productivity of their delayed coker The UniSim Design Suite provides intuitive operation. As the quality of crude oil inputs process modeling software that enables declines, delayed coking will serve to meet process engineers at refineries to create growing transportation fuel demands and also steady state and dynamic models for plant produce increasing quantities of fuel-grade design, performance monitoring, and needle petroleum coke. troubleshooting, business planning, and asset management. UniSim simulation technology Refinery engineers need answers to key also helps engineers gain the expertise they questions such as: need to work with a host of complicated refining processes. • How can we optimize our delayed coking unit to achieve energy savings, Employ the EO platform for comprehensive maximized throughput, decreased CO modeling: UniSim Design Suite now includes emissions and improved yields while modules representing specific refining increasing the overall profit of the conversion reactors. The UniSim Design DCU refinery? Reactor is one of the latest offerings in the • How can we eliminate most or all of the UniSim Refining portfolio. It includes the only low-value bottoms from crude oil to individual reactor models built from the achieve higher yield of lighter ground up on the next-generation Equation products? Oriented (EO) modeling platform, which solves all equations simultaneously (rather How can we maximize feed/throughput and than sequentially) and provides also the middle distillate yield, while keeping comprehensive, model-wide optimization. The the unit within equipment constraints? DCU reactor can be configured within the Bottoms upgrading technologies have gained UniSim EO environment, together with other greater importance as a way to effectively unit operations. It fits into Honeywell’s overall reduce the quantity of fuel oil products by UniSim refining model with interconnected producing valuable distillate products. processes allowing simulation of how one processing unit influences another. The result The Solution: UniSim Design DCU Reactor is a larger, refinery-wide simulation of how to run operations to produce more valuable and - PAGE 2 - The UniSim Design salable products. refineries to perform reactor calibration DCU Reactor software and/or kinetic parameter optimization to determine the best fit model depicting their is backed by the plant configuration and conditions. They can domain expertise of also keep LP programs up to date for Honeywell Process scheduling and planning purposes. Solutions and Better decisions about critical operations: leverages the deep The UniSim Design DCU Reactor is insights of Honeywell implemented in the UniSim EO environment, UOP. which enables engineers to arrive at key operational decisions faster—making it Figure 1: Honeywell’s UniSim Design DCU Reactor can be configured suitable for both design and optimization within the UniSim EO environment, together with other unit applications. Additionally, they can do simple operations. calibration and tuning. The reactor was specifically developed for refining end users, Take advantage of Honeywell UOP experience: eliminating the need for expert consultants. Validated by pilot plant data from Honeywell UOP, a global leader in advanced refining Knowledgeable Support technology, the UniSim Design DCU Reactor employs a high-fidelity kinetic reactor module The UniSim Design DCU Reactor software is and is able to handle highly integrated and backed by the domain expertise of Honeywell complex flowsheets. The reactor can be Process Solutions and the deep insights of configured with other unit operations to Honeywell UOP, which cover all aspects of the represent the entire delayed coker plant. It refining and petrochemical field. Customers allows simultaneous solving of the complete can rely on Honeywell’s Global Technical DCU flowsheet without nested convergence Assistance Center (GTAC) for the help they loops. need, no matter where they are located. With the versatile UniSim Design DCU UniSim Design Suite Support Services solution, refineries can eliminate heavy crude processing bottlenecks, optimize product This product comes with worldwide, premium yields and keep track of coke production and support services through our Benefits product specifications by accurately modeling Guardianship Program (BGP). BGP is designed to help our customers improve and their delayed coker. By allowing users to predict coker yields and product qualities for extend the usage of their applications and the all feedstock possibilities, coke drum benefits they deliver, ultimately maintaining operating conditions, and recycle rate options, and safeguarding their advanced this solution enables refiners to run their applications. coker unit more effectively and safely. Honeywell provides a complete portfolio of The Benefits service offerings to extend the life of the plant and provide a cost-effective path forward to Improved understanding of unit the latest application technology. The services performance: The UniSim Design DCU include: Reactor provides access to valuable and timely key performance indicators (KPIs) • Standard and Customized Training related to the overall delayed coking • Consulting operation. • Model Building • Engineering Studies Enhanced modeling capabilities: The . UniSim Design DCU Reactor enables - PAGE 3 - • Custom Thermo/Unit Operations Why Honeywell • With over 40 years of worldwide experience in the refining industry, Honeywell provides proven technologies to support a quick and safe
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