oduction planning is vital in the operation of a modern refinery due to increasing crude prices, fluctuation in production practices by petvoleam-proclucing countries and shifting warket desnand. Linear programming/non-linear programming (LPINLY) is uscd to simulate the effect of changing crude types on ylelds fom the crude distillation unit (COU), vacuum distillation unit (DU), visbreaker and product blender luis, Centeal composite experimental Uesign (CCD) and response surface ‘methodology (RSM) are used to obtain a second-degree polynomial model to ‘maximise the operating profitability of these «nits Simulation background SM explores the relationships between several explanatory variables ancl one ot more responsive variables. The method twas introduced by G &.P Box and KB ‘Wilson in 1931, The main idea of RSMAS to use a set of designeel experiments to obtain an optimal response. Box and Wion suggest using a fistdegree polynouniat model to do this. They acknowledge that this model is only an approximation, but use it because It is easy to estimate and apply, even when little i known about the proces. An easy way to estimate m fst-degree polynomial model is to use a factorial experiment ot fractional factorial design. This is sufficent to detecmine Which explanatory variables have an impact on the response variables of terest. Once itis suspected that only significant explanatory variables. are left, a more complicated design, such as CCD, can be implemented to estimate 2 second-degree. polynomial. model, which is still only an approximation at best. However, the seconciegree model ‘an be used to optimise (le, maximise, minimise or attain a specific target for) response. Some extensions of RSM deal with saultiple response problems, Multiple pues gence anab giemeninaseeh (Cheer hos 7 eo ‘B-Teyeur 702 oe | Awaz Anais 2895 Od ‘Bangosian 4753 be, vin 2656 ‘ante? Site Figure 1 Simulation of COU, VOU, visbreaker and LPG unit because what is optimal for one response may not befor ather responses, Other extensions are used to reduce variability in a single response while targeting a specific value, or attgining a heat maximum or minimum while preventing variability In that response from getting 100 large. OM” refineries are increasingly concerned with improving the planning ff their operations and optimising not only single-production units but the whole enterprise. However, the modelling of the overall refinery, ‘operation, from the crude oils arival 0 the distribution of oil products, gives tise to Intractable mathematical models, Nevertheless, with the current margin, Alifferentials between heavy feedstocks and conventional feedstocks, it has become financially viable for many refiners 10 upgrade more of the heavier poseenonne rs eid aeeeebeventenpntie Gusasicnee Soro eea LP modelling for profit maximisation Optimisation of a feed blender, CDU, VDU, visbreaker and product blender under changing feed specifications. Central composite experimental design and response surface methodology are used to obtain a second-degree polynomial model for maxit ing profitability Reza Seif Mohaddecy Islarnic Azad University Sepehir Sadighi, M Bahmani and $ Zahedi Research Institute of Petroleum Industry Gad pocoetyd si sasbge ve s68cs ra | as diesel and propylene, Consequently, refinery conversion. units are continuously operated under more severe conditions. As a result, the blending of refinery feeds and products has become more important from a processing and profitability perspective, Which is where the role of LP modelling a5 a tool to maximise profitability takes precedent. LP's historical role in refining Since the introduction of LP in the 1950s, the optimisation of production planning has been possible. Symonds! and Manne* applied LP to the Longe term supply and production planning, of crude ol) processing. Moreover, the availability of commercial software thas Increased the use of this approach to solve real-life problems In the refining and petrochemical industry seal eaFw, bbls/day Sp. ge Feed conditions Cheleken 5000 0.5387 ASTM D1160 (18P-8), °C 65-645, Sulphur, we Nitragen, ppm Nickel, ppm Table 1 Product name LG sno SRG Booophthe Kerotene Leese Resi Table 2 Product name H cies Fed Lube Hops Vac bottom Table 3 Product name Vib gasoline vetar Table 4 15 310 a COU products Simulated flow rate, bpd 2403 4768 14917 6582 16527 16199 48351 YDU products Simulated flow rate, pd 2381 sae 14266 2090 ver Visbreaker products Simulated flow rate, bp 1679 16453 Actual low rate, bpd 2508 4310 15020, 5401 17 163, 16507 49.095 Actual flow rate, bpd 8346 5302 14140 1949 18990 ‘Actual flow rate, bpd 17 17 580) Specification of crude types used for blending Maran Chesmeh-Khosh AB-Teymour Bangestan Ahwaz Asmar sp.gr 0.8905 089770047 0.8621 Sulphur, 9% 328 191 341 1s Nitogen, wt 0.17 022 024 027 017 ast p1t60 ((8?-F8), °C 15-700 15-700 15-700 15-700 elds, volte 181927 15-773 1-19.07 389-1416, VP, pla 556 96 94 86 Nickel, ppm 15 2 a 49 Table s Due to the complexity of the previously noted NLP algorithms, their algorithm for better energy utilisation, The problem with this approach is that application in plant-wide problems is limited. Consequently, alot of previous stuslies have dealt with the application of mixed-integer linear programming (MILD) algorithms to solve these plant= Wide problems. For this effort, Zhang, tal) considered a refinery as a combination of process systems and ei i ara it can only be applied to a small or medium-sized refinery. Lundgren, et al used a MILP algorithm to. optimise the scheduling and production planning of one distillation unit and two hyde treatment units, Reddy, et al used MILP for the short-term optimisation Paar eae eee Designated flow rate of crudes for feed blending Crude name Current case, bp AB-Teyrnou 7012 CChesmeh-Krosh 109 756 Manan 85 365 Ahwaz Asmad 43.293 Bangestan 4573 Total 250.000 Table 6 from largo crude carters to storage and DU units Validation of simulator with existing operating data Usor to unit optimisetion, the validity ofthe LP model developed in this study eas tested by simulating the existing Operating conditions shown in Figure | Yor this purpose, the properties of two {ype of normally used cre were input ito the model and the results were compared’ with actual plant data, The properties ofthe crudes used for model validation can be sen in Table 1, while {ables to 4 show comparisons between simulation and actual plaut data, Petroleum feedstock properties Upon testing the validity of the LP model for simulating the yields using the existing crude mix, five franian heavy crudes were used for blending as feed. Table § shows various properties of these crudes, and it can be seen that Bangestan and Chesmeb-Khosh are the heaviest, and Marun, AB-Teymour and Ahwaz’ Asmari_ are’ the lightest. Additionally, Bangestan and Chestueh= Khosh have the highest sulphur concentration. Experimental design for profit maximisation The flow rate of these crudes, as designated by the production planning office of the National franian Oil Refining and_Distsibution Company (MIORDC), is shown in Table 6, and this Provides the base ase in the study for profit maximisation, Using the validated LP model, two cases for blending these crudes were attempted, The fist involved a base case of five iranian heavy crudes at the specified bpd, as designated by NIORDC. The second involved optimised blending of these cludes, with a view to ‘maximising profit Tables 7 and 8 show the r-parametersed factors used for the CCD for different blending sirateges. ‘Applying CCD to the coded factors, 25 blending strategies were obtained. These were implemented into the LP ‘model. To estimate the expenditie and Income for the blending strategies, aR eetcomponent, utilities and product cuts were used. A second-degree polynornal Coded parameters for the optimisation algorithm fas fitted to these results, as follows: 2 | fatio —_(Chesmels Khash + AB-Teymourfotl PRAKL EARS SAAS OAXZ 6 AXE 4 — Ballo AB-Teymourl ABTeymour » Chesmeh-Khosh) MAE AASS OANA, Al +h, Ratio Marun(Marun + Awa Asm Bangestan) | SEK, AXA, gd «Agee, «—Hatlod Ahwaz Asmal(Marun + Awaz Asma + Bangestar) | AAR TA AK + ABE + ALE, TALIS AMA AAA, 1A, mak, Table 7 | in which XX, %y X, and X, are the ye levels for optimisation parameters in CCD of blending strategies flow rate of afer crude types and P at Leet rele } fs the profit obtained. The coefieients Coded parameters 2 1 ° 1 2 ! ‘A,to.A, were obtained by a non-linear Rao t 0.373650095 0.420366 0.467074 013781 OS6D4ED | regression Bt of the LP model results to ‘atio2 ©.048040559 0.054048 0.060051 G.066056 0.072061 ! the polynomial fat 3 0512582408 0.576656 0.640729 0.704802 0.768875, | ‘the profit for different blending Ratio4 0255957517 0.292452 0.324947 0.357482 0.289936, strategies was maximised by obtaining } the maximum of the polynomial. The Table & iI inaximam profit was obtained for two ! onstained and unconstrained cases In the constained ease, te low rate of aitferentcrudes was allowed t0 vary bY Crude name Designated ase, bpd Constrained, bd Unconstrained, bpd Comparison of designated case with optimised blending strategies only S% of NORDC's designated quota, pp-Teymour vot? ‘scei.t 10518, ; whereas in the unconstrained case nO Chesmmehekhosh 109756 108 232.65 54878 i bound to this quota was implemented. Marun 85 365, 89 633.25 1280475 Table 9 shows a comparison of the Abwac Avmuari 43293 4112535 49.697 designated case with the optimised — Bangestan 4573 434435, 6859.5 blending strategies. Table 10 shows that Total 250.000 250 000, 250 000 35% increase in profits would be obtained if the blending of crudes for Table 9 feed were to be optimised. Depending on the requirement for different cuts and considering the Comparison of profit made between the designated case economics, table 11 provides guldeincs and the optimised blending strategies eee ee Designed Constrained Unconstesined Profit 7.469106 8 7.720106 To.01" 06 5 Conclusion In thls study, using the commercial simulator ProPlan, the blending of Table 10 petroleum crude as. feed forthe Tehran, refinery has been optimised by LP/NLP Signin The cqgatuns Ural tie Comparison of the products dtbution obtained between the Sipoathims, The equations used in the ‘besionated cast and! the optimised blending seatepies we ted and validated guns E031 progut name esknated bpd Constrained bpd Uncnstaine bp Stee at deat eee eeS 3699.9 5709.4 62324 = Sere LSRG 198143 19 6768 16.936.5, Gyution was obtained, rlting promt 1S oe eee ae wth variations need specication. SS 0 cued oa The following feed blending strategies UE eae ao ve were simulsed wit a) views to $< ae pes a ‘maximising profit: Hdiesel 7551.6 7671.6 8436.5 Sending sntegy a5 designated by Wino Vetus veer ibaa morpe injec 332001 Soar Ban wallowing a 5% variation on Soper tao ‘oar ‘oes MORDCS esignated ow ‘ate of Wehuphiha tos ‘ero ‘ins een cues, te aver wet sloa7 No constsints on the lw rate of Gterent ces, Toble11 The inulition results show concsvly tat the Blending strategy, 3856 trad Unies cambrke, MA. Tera, ran. Ena setrgmacom couauuey ate ining ney 6s kan on ra sya Sistittes Bry Ssh, ht pp ta Di Bahmants whe oat econ ‘engineering department, catalysis research ete moons The centre, RIPI in Tehran, fran. Timon Gf kine trowrmndnt, 1% Reca Self Mohacdecy is with the $ Zahedi is with the catalytic reaction | a ee chy shemical engineering department, rok engineering department, catalysis research 2Manne AS, Schedeling ofPetrotewn Operator's, Branch, of the fslamaic Azad University in centre, RIPL in Tehran, Iran.