JohnJechura jjechura@mines.eduUpdated:July21,2014

ProductBlendingChapters12

Light Naphtha

CrudeOil

Desalter

Atmospheric Distillation

Vacuum Distillation

Gas Separation &

Stabilizer

Solvent Deasphalting

Coking

Visbreaking

Fluidized Catalytic Cracking

Hydro-cracking

NaphthaReforming

Isom-erization

Sat Gas Plant

Polymer-ization

Alkylation

NaphthaHydro-treating

Treating & Blending

Coke

Fuel Gas

LPG

Aviation Gasoline

Automotive Gasoline

Solvents

Jet Fuels

Kerosene

Solvents

Heating Oils

Diesel

ResidualFuel Oils

Lubricant

Greases

Waxes

Asphalts

HeavyNaphtha

Kerosene

DistillateAGO

LVGO

HVGO

VacuumResiduum

CatDistillates

Gas Oil Hydro-treating

DAO

Isomerate

Gas

AlkylFeed

Alkylate

PolymerizationNaphtha

Gases

Butanes

LPG

Reformate

Naphtha

Fuel OilBottoms

Distillates

DistillateHydro-treating

CatNaphtha

Cycle Oils

SDABottomsCokerNaphtha

HeavyCokerGasOil

Light CokerGas Oil

SulfurPlant Sulfur

Fuel Oil

SolventDewaxing

Lube Oil

Waxes

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Topics

Blendingspecifications/targets Typicalgasolineblendstockproperties

Adjustingupstreamoperationstomeetdownstreamtargets

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TypicalBlendGasolineStockProperties

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Table12.1BlendingComponentValuesforGasolineBlendingStreamsPetroleumRefiningTechnology&Economics 5th Ed.byJamesGary,GlennHandwerk,&MarkKaiser,CRCPress,2007

No. Component RVP,psi (R+M)/2 MON RON APl1 iC4 71.0 92.5 92.0 93.02 nC4 52.0 92.5 92.0 93.03 iC5 19.4 92.0 90.8 93.24 nC5 14.7 72.0 72.4 71.55 iC6 6.4 78.8 78.4 79.26 LSRgasoline(C5180F) 11.1 64.0 61.6 66.4 78.67 LSRgasolineisomerizedoncethrough 13.5 82.1 81.1 83.0 80.48 HSRgasoline 1.0 60.5 58.7 62.3 48.29 Lighthydrocrackate 12.9 82.6 82.4 82.8 79.010 Hydrocrackate,C5C6 15.5 87.4 85.5 89.2 86.411 Hydrocrackate,C6190F 3.9 74.6 73.7 75.5 85.012 Hydrocrackate,190250F 1.7 77.3 75.6 79.0 55.513 Heavyhydrocrackate 1.1 67.5 67.3 67.6 49.014 Cokergasoline 3.6 63.7 60.2 67.2 57.215 Lightthermalgasoline 9.9 76.8 73.2 80.3 74.016 C6+lightthermalgasoline 1.1 72.5 68.1 76.8 55.117 FCCgasoline,200300F 1.4 84.6 77.1 92.1 49.518 Hydrog.lightFCCgasoline,C5+ 13.9 82.1 80.9 83.2 51.519 Hydrog.C5200FFCCgasoline 14.1 86.5 81.7 91.2 58.120 Hydrog.lightFCCgasoline,C6+ 5.0 80.2 74.0 86.3 49.321 Hydrog.C5+FCCgasoline 13.1 85.9 80.7 91.0 54.822 Hydrog.300400FFCCgasoline 0.5 85.8 81.3 90.2 48.523 Reformate,94RON 2.8 89.2 84.4 94.0 45.824 Reformate,98RON 2.2 92.3 86.5 98.0 43.125 Reformate,100RON 3.2 94.1 88.2 100.0 41.226 Aromaticconcentrate 1.1 100.5 94.0 107.027 Alkylate,C3= 5.7 89.1 87.3 90.828 Alkylate,C4= 4.6 96.6 95.9 97.3 70.329 Alkylate,C3=,C4= 5.0 93.8 93.0 94.530 Alkylate,C5= 1.0 89.3 88.8 89.731 Polymer 8.7 90.5 84.0 96.9 59.5

GasolineBlendingConsiderations Availableblendstocks

Amounts Properties

Appropriatetodetermineproductproperties

Associatedcosts/values

Specificationoffinalproduct(s) Amount(s) Properties

Volatility/RVP(maximum)

Octanenumber(minimum)

DrivabilityIndex

Distillation

o T10(minimum)

o T50(range)

o T90(maximum)

Composition

o Sulfur(maximum)

o Benzene&totalaromatics(maximums)

o Olefins(maximum)

Value

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GeneralGasolineBlendingConsiderations

ReduceRVPgiveaway iC4hashighervaporpressurethannC4.Alsomorevaluableasalkylationfeedstock.

ReduceOctanegiveaway commonmistakes Settingconstantreformerseveritytarget hydrogen&octanebalancehighlydynamicconstraints

Blendinglowoctanecomponentstoreduceoctanegiveaway maybetheresjusttoomuchhighoctaneblendstock?

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http://www.refinerlink.com/blog/Redefining_Gasoline_RVP_Giveawayhttp://www.refinerlink.com/blog/Top_3_Refinery_Octane_Blending_Mistakes/

GeneralGasolineBlendingConsiderations

Manyblendingproblemsfixesrequireupstreamoperationchanges RVP

Poordepropanizer operationallowingpropaneintothebutanepool?

PropersplittinginDeisobutanizer &isostrippers?

Octane Correctcutpointsbetweenheavynaphtha&kerosene?

Reducereformerseverity?

o Maynotbepossibleifhydrogenneeded.

Batchoperatingreformerseverity?

o Wouldprovidebalancebetweenoctaneenhancement&volumetoblending

Reducingreformerfeedrates

Sellinghighoctanecomponents

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http://www.refinerlink.com/blog/Redefining_Gasoline_RVP_Giveawayhttp://www.refinerlink.com/blog/Top_3_Refinery_Octane_Blending_Mistakes/

GasolineBlendExample 2BlendStocks,1Spec Example,blendingLSRonlywithReformate

onecase100RON,other94RON

TomakeRegularorPremiumspec,essentiallydilutingtheReformate

94RONReformatealonecannotbringLSRuptofinalspec

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GasolineBlendExample 3BlendStocks,2Specs

Use3blendstockstomakepremiumgasoline(92roadoctane)forbothsummer(9psiRVP)&winter(15psiRVP)

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nC4 LSR Ref

1.25 1.25 1.25 1.25nC4 LSR Ref

nC4 LSR Ref

R+M 92.5 64.0 94.12

RVP 71.0 11.1 3.21

v v v

v v vv v v

GasolineBlending ModifyUpstreamOperations

HowmuchgasolinecanbeproducedbyblendingReformate+LSR withrespecttotheReformersseverity?

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DieselBlendingConsiderations Availableblendstocks

Amounts Properties

Appropriatetodetermineproductproperties

Associatedcosts/values

Specificationoffinalproduct(s) Amount(s) Properties

Cetane index(minimum)

FlashPoint(minimum)

Distillation

o T90(minimum&maximum)

Coldproperties

o Cloudpoint(minimum)

o Pourpoint(minimum)

Composition

o Sulfur(maximum)

o Aromaticity (maximum)

o Carbonresidue(maximum)

Color

Value

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Kerosenevs.Jetvs.Dieselvs.HeatingOil

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Property No.2Kerosene JetA JetB No.2DS15 No.2DS500 No.2HOS500CetaneNumber min 40 40Aromatics [vol%] max 25 25 35 35Sulfur [wt%] max 0.3 0.3 0.3 0.0015 0.05 0.05FlashPoint [C] 38 52 52 38Distillation(D86)

T10 [C] max 205 205T20 [C] max 145T50 [C] max 190T90 [C] min 282 282 282

[C] max 245 338 338 338EP [C] max 300 300

DistillationResidue [vol%] maxDistillationLoss [vol%] maxFreezingPoint [C] max 40 50PourPoint [C] max 6CarbonResidue [wt%] 0.35 0.35 0.35KinematicViscosity

@40C mm/s min 1.9 1.9 1.9mm/s max 4.1 4.1 4.1

ASTMSpecificationsforMiddleDistillates

Cutpoint Economics

Adjustupstreamcutpoints tomeetneedsinthedownstreamblending HeavyLSRvalueasblendingcomponentversusReformerfeed

HeavyNaphthavalueasReformerfeedversuskeroseneblendstock

HeavyKerosenevalueaskeroseneblendstockversusdieselblendstock

HeavyDieselvalueasdieselblendstockversusFCCfeed

HeavyGasOilvalueasFCCfeedversusresid/asphaltproductionorcoker feed

TherefineryLPcandeterminetheoptimumcutpointforeachofthesegivenanysetofconstraints

Cutpoints ToMeetOperatingEconomies

Cut IBP EP Processing UseLSR 90 180 MinLSRcut

90 190 NormalLSRcut80 220 MaxLSRcut

Naphtha 180 380 Maxreformingcut190 330 Maxjetfuel220 330 Minreformingcut

Kerosene 330 520 Maxkerosenecut330 480 MaxJetAcut380 520 Maxgasoline

Diesel 420 650 Maxdieselcut480 610 Maxjetfuelcut520 610 Min diesel cut

GasOil 610 800 CatcrackerfeedVGO 800 1050 CatcrackerfeedResid 1050+ Cokerfeed,asphalt

TBP Cut Points (F) for Various Crude Oil Fractions

OptimizeFCCGasolineDistillation

Frametheanalysis Whatisthevalueofthemoleculesinthestreamabove?

Whatisthevalueofthemoleculesinthestreambelow?

Whatupstreamunitoperationsaffectthestreamvalue?

Whatdownstreamunitoperationsaffectthestreamvalue?

Whatunitspecificoperationsaffectthestreamvalue?

Whatproductblendingconstraintsaffectthestreamvalue?

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Ref:http://www.refinerlink.com/blog/Truly_Optimize_FCC_Gasoline_Distillation

OptimizeFCCGasolineDistillation

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LCN HCNValuetothestreamabove? Mayhavesuboptimalamountofolefins:

Alkylationunitdownstreamhavecapacityfortheolefins?

Typeofalkyunit?SulfuricAlkycantakemoreC5=olefins;HFAlkylimitedbystrengthconcerns

Timeofyear?Alkyeconomicsbetterduringsummer

Whendistillatemorevaluable thangasolineminimizetheLCN/HCNcutpointtomaximizedistillateproductionfromHCN

Valuetothestreambelow? Whendistillatemorevaluable thangasolineminimizetheLCN/HCNcutpointtomaximizedistillateproductionfromHCNcontributions

Dieselpriceshigherthangasoline,minimizeHCNendpoint&stillmakedieselflashlimitIfLCOisroutedtoaHydrocrackerHCNendpointcanbeadjustedtomakejetflashlimit.HCNendpointcanalsobeusedtooptimizeheavyfueloilblendingwhenLCOisusedasacutter

Upstreamunitaffects? Degreeofhydrotreatingpossibletogivelowsulfurcontentinfinalproduct

Degreeofhydrotreatingpossibletogivelowsulfurcontentinfinalproduct

Downstreamunitaffects? DestinationofLCN? GasolineHydrotreater&thentoblendpool SelectiveHydrogenationUnit&thento

ReformerHigholefincontentwillincreasehydrogenrequirementsindownstreamhydrotreaters

IfroutedtoGasolineHydrotreatermayreduceendpointtobettermakegasolinesulfurspecsIfroutedtoJetHydrotreaterthenmakeuphydrogenconstraintsmaylimitendpoint

Unitspecificaffects? Subtleconstraintssuchasolefincontentandoctanevaluewillbeinfluencedbyacombinationofriseranddistillationtargets.Cattooilratioaffectsproductmix,thusdistillationstrategies.

FractionatordrawconstraintsmaybehandledbyadjustingFCCreactorconditions&yields

Productblendingconstraints? Usuallyroutedtogasoline needtoolefins,sulfur,andaromatics

Whenroutingtogasoline,useHCNendpointtoadjustgasolinesulfur,endpoint,andaromatics.Whenroutingtojet,useHCNIBPtomeetjetflash&endpointtomanagejetfreeze&smokepoint.Whenroutingtodiesel,useIBPtomanagedieselflash

Ref:http://www.refinerlink.com/blog/Truly_Optimize_FCC_Gasoline_Distillation

Topics

Blendingspecifications/targets Typicalgasolineblendstockproperties

Adjustingupstreamoperationstomeetdownstreamtargets

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