HT

Reformer

Straigh Run: Kerosene, Diesel

ADU

Cat.
Cracker

HT

VDU

Coker

Above is my simplified version of a refinery that illustrates the barebones version that Im using for the trial calculations. There are
formulas and equations for more complex refinery set-ups, but this
seemed the easiest to generalize. Specific cases can be put through
the more rigorous numbers if necessary.
Outline of some simplifications/assumptions that are occurring in this
assessment:
1. Gasoline blending is not taking into consideration. Because of
this paraffins, aromatics and naphthenes from the reforming
process are not separated into different percentages. Rather,
they are all considered gasoline. Additionally, RON is assumed to
be 94 for all calculations (this is on the high side and will give an
estimate on the low side of gasoline output).
2. Numerous advanced processes are being ignored, most noteably,
alkylation and catalytic hydrocracking. The consequence of
ignoring alkylation puts the gasoline production estimate on the
low side. Catalytic hydrocracking can produce both gasoline and
distillates (jet fuel, diesel). There are formulas to determine the
percentage of output, but requires additional linear logic to
decide what portion of the initial feed goes to the hydrocracker.
This information was not included in the initial set-up. It has the
potential to be considered later. The calculations are more
complicated because the hydrocracker has the capability of

3.
4.
5.

6.

being set up to provide more gasoline, diesel or jet fuel based on

the needs of the refinery.
The calculations are done on broad specifications. Exact refinery
production calculations are considered as proprietary
information.
Distillates are isolated as a single category, but contain both
diesel and jet fuel. There is no exact amount to separate the
two. Diesel comprises the majority.
Another important assumption is that the streams can only flow
in a straight line. For example, once fractions are sent to the
vacuum distillation unit, they can only be sent to the coker or
produce what they will from the vacuum distillation unit (VDU).
This is going to give low estimates, as certain fractions of VDU
can be sent to catalytic crackers and reformers as well, but this
starts to get outside the scope of the simple programing we
wanted.
Corrections for sulfur content are also being ignored. This would
cause a slight over-estimate in product, especially for samples
that are high in sulfur content. This calculation can be done on a
case by case basis, but was too complicated for this simple first
generation model.

Step 1: Initial Distillation: CDU output.

1. CDU unit (initial distillation): Important fractions to be
considered for calculation data:
a) 190-380 F: Naptha fraction proceeds to a hydrotreater
to remove sulfur and other impurities and onto the
catalytic reformer to produce gasoline.
b) 380-580 F: These cuts are assumed to be used as
straight run, with minimal purification in a hydrotreater,
but can be taken as a percentage of the initial input.
c) 580-650 F: This gas oil fraction goes through the
hydrotreater, on to the catalytic cracker. The catalytic
cracker is assumed to operate at 75% efficiency to
produce gases, gasoline, gasoil (distillates?) and coke.
d) 650-1050 F: This fraction comprises light, medium and
heavy gas oils. The lighter hydrocarbons in this fraction
can be used in marine diesel, while 800+ heads to the
vacuum distillation unit (VDU) is isolated via the vacuum
distillation unit and produces vacuum gas oil (light,
medium and heavy) along with vacuum residue. The
residue heads to the coker.
e) 1050+ F: This is the residue fraction and after the VDU,
it will head to the coker, where it will produce gasoline,
distillate, gases and coke.

Further calculations will be performed on the coker, catalytic cracker

and reformer (although the reformer calculations will only be necessary
if gasoline blending is considered).
Calculations for CDU:
TBP-true boiling point (correction for the simpler technique used to
determine atmospheric distillation values in the lab): There are a
couple methods of calculation
TBP (R)= {(2.2ln(100/(100-LV%)))^2.7 +1}490
TBP=a(ASSAYBP)^b (%=% of sample distilled) reported as T% (i.e.
T10= TBP at 10%)
%
a
B
0
0.9167
1.0019
10
0.5277
1.0900
30
0.7429
1.0425
50
0.8920
1.0176
70
0.8705
1.0226
90
0.9490
1.0110
95
0.8000
1.0355
Additional values that may be of importance for subsequent
calculations:
VABP=volume average boiling point=(T10+T30+T50+T70+T90)/5
MeABP=mean average boiling point=VABP-
=-0.94402-0.00865(VABP-32)^0.667+2.99791(SL)^0.335 SL=(T90T10)/(90-10)
Watson Characterization Factor (K): Unit used to distinguish a crude
feed, used in multiple further calculations: K=(Tb)^1/3/SG or
K=(MeABP)^1/3/SG
API= -0.0004(LV%)^3 +0.05(LV%)^2-2.4(LV%)+800use mid. point
volume for each fraction. Can also calculate the
LV%=percent of accumulated liquid volume (this is total based on what
boiling point the fractions are collected at. The higher boiling point
fractions will have higher numbers.
IBP=initial boiling point
EBP=end boiling point
SG=specific gravity (usually provided in the assay, API=(141.5/SG)131.5)
M=average molecular weight of the fraction=42.965[exp(2.097X10^4Tb-7.78712SG+2.08476X10^-3TbSG]Tb^1.26007SG^4.98308
Wt%S can be determined if not given in the assay, but requires 3 other
calculations.
Tb=(((IBP+EBP)/2)-32)/1.8 (Can add 273 to get the temperature in
Kelvin if necessarywhich it is to calculate K value)

Cut Volume %: This can be determined from the initial percentages in

the crude assay: %vol at EBP-%vol and IBP.
Cut Volume=% in decimal form(BPD feed)this gives a BPD value. If
the product is a straight run product, this value can be used as the
output value of that fraction.
Calculations: Naptha Hydrotreater and Catalytic Reformer
BPD: This value will have been calculated in the CDU phase.
SCFB (standard cubic feet per barrel)
Sf=%wt of sulfur for fractioncan be calculated, but hopefully is given.
From the hydrotreater, need to calculate the paraffin (P), napthene (N)
and aromatic (A)volumes to get a C5+ vol% which is the amount of
gasoline produced.
Subscript p=product, subscript f=feed, Kf=Watson characterization
factor of the feed
Vol%P=12.8Kf^2-259.5Kf+1330
Vol%N=-78.5Kf^2+1776.6Kf-9993.7
Vol%A=38.4Kf^2-894.3Kf+5219.4
Hydrotreater:
SCFB H2 =191Sf-30.7
APIp=0.01(SCFB H2) +0.036(APIf)-2.69
APIp=APIf+ APIp
C5+ vol%=142.7914-0.77033 X RON +0.219122 X (N+2A)F The RON
number is based on the blend of gasoline desired. For the purpose of
this set up, assume that RON=94. This number will be a percentage
that will be multiplied by the BPD feed to give the BPD of gasoline
produced by this process.
Calculations: Middle Distillate Hydrotreater and Catalytic
Cracker:
Hydrotreater:
SCFB H2 =110.8Sf+10.2(100)-659 (assumes 100% severity of
hydrotreater)
APIp=0.00297(SCFB H2) -0.11205(APIf)+5.5419
APIp=APIf+ APIp
Catalytic Cracker: Assumption 75% conversion (CONV)
Coke wt%=0.05356XCONV-0.18598XAPI+5.966975
Light cycle oil (distillates) LV%=0.0047XCONV^20.8564XCONV+53.576
Gases wt%=0.0552XCONV+0.597
Gasoline LV%=0.7754XCONV-0.7778

Calculations: Coker
CCR-Conradson carbon residue: This is a physical property of the
crude, should be provided in the assay data. If it isnt, give a range
between 10-25%
Gas(C4-)wt%=7.8+0.144X(wt%CCR)
Naptha wt%=11.29+0.343X(wt%CCR)
Coke wt%=1.6 X(wt%CCR)
Gas Oil wt%=100-wt% of other three
Gas oil and naptha can be broken down further if necessary, but wont
do that in first generation example.