Crude Column Optimization 1

Crude Column Optimization

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1.3 Crude Column Optimization.pdf
2 Crude Column Optimization

Workshop
A crude column with pump arounds and side-strippers can converge in
a few seconds using a wide variety of product quality specifications.
However, the complexity of the model and intrinsic interaction between
variables can make it very difficult to use the model alone as a decision-
making tool.

For example, in a typical oil refinery, the operation must be adjusted so

that different feed stocks can be processed to yield products with tight
quality specifications, while meeting a desired economic performance.
How does one use the model to choose the best operating conditions?

HYSYS includes additional modelling and decision support tools that

can be used to enhance the usability of your models. In this module, you
will use the HYSYS optimization tool available in HYSYS.RTO to
investigate the debottlenecking and optimization of a crude column.

Learning Objectives
After completing this module, you will be able to use the Derivative
Utility to:

• Define Process Constraints and Variables.

• Define the Objective Function.
• Run the Optimizer and check the results.

Prerequisites
Before beginning this module you will need to know how to:

• Create and modify active specifications in the column.

• Create utilities and select variables through the HYSYS Object
browser.

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Process Overview
4 Crude Column Optimization

Description of the Problem

In the Atmospheric Crude Column module we defined and converged
the tower based on a predetermined set of performance criteria. The
profit of this column operation is dependent on the price of its various
products and on its operation costs (e.g., energy and steam). It should be
possible to operate the column with better performance: maximizing
the profit from the column while keeping the product quality
constraints within specified limits. However, the number of variables to
manipulate and the number of constraints to be met makes the
optimization problem impossible to do manually. Consequently, the
help of an optimization algorithm is needed. Let us examine the
variables involved:

Price Revenue
3
Revenues ($/m ) ($/h)
Naphtha 14.00 2100
Kerosene 12.00 743
Diesel 10.00 1300
AGO 6.00 180
Residue 2.00 580
Costs ($/MM kJ)
Condenser 0.12 15
Flash zone duty 3.00 287
Profits (approximately) 4600

From the cost and revenues table above, we can determine that it would
be most desirable to get the maximum quantity of Naphtha possible,
since it is the highest value product, and of course, concurrently
minimise the energy consumption. This is not a simple task because the
market requires that product quality standards be taken into account.
The following table shows these standards:

Product Specification type Minimum (°C) Maximum (°C)

Naphtha D86 / 5% 40.00 50.00
Naphtha D86 / 95% 160.00 180.00
Kerosene D86 / 5% 170.00 190.00
Kerosene D86 / 95% 240.00 260.00
Diesel Pour point -15.00 5.00

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 Crude Column Optimization 5

Diesel Flash point 90.00 110.00

AGO Pour point 0.00 20.00
AGO Flash point 130.00 150.00

What will happen to the Naphtha product's distillation curve if we extract a

very high quantity of this product?

More components from the heavier Kerosene range will go to the

Naphtha extraction and consequently the distillation curve (i.e., D86
95% will be higher and thus will overpass the maximum value needed
to meet quality requirements).

Expanding the Flowsheet

1. Load the simulation case from the Atmospheric Crude Column
module. You can use the case you created, or load pre-made case
Crude6.hsc from your Solution Cases folder.

In this module, we will optimize the performance of the atmospheric

crude column based on the product quality specifications.

Changing the Units

As you know, HYSYS allows you to create your own set of units. If a
desired unit can not be selected from the database, we can define our
own unit by specifying an appropriate conversion factor.

In this case, the prices for the Energy values are given in MMKJ/h and,
since this unit is not available in the HYSYS unit library, we will need to
define it.

1. From the Tools menu, select Preferences.

2. Go to the Variables tab and select the Units page.

If the Refinery unit set is

3. Select the Refinery package that we defined in the Oil
missing, use a clone of the Characterization module.
SI unit set.
4. Move the cursor to the Energy cell and click on the Add button.

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6 Crude Column Optimization

5. Complete the view as shown below.

Figure 1

Building the Simulation

Column Product Specs
In this case, we will converge the column using simple specifications
(e.g., flowrates and duties) since the optimizer will need to run the
column many times (and simple specifications enhance convergence).
We will make sure Cut Point quality specifications are selected as
estimates but are not active.

1. Open the Column Property View.

2. Change the Temperature of the feed to 320°C.
3. Click the Design tab and click the Monitor page.

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 Crude Column Optimization 7

4. Enter the Kerosene flowrate as 62 m3/h. The specifications on your

Monitor page should appear as shown:

Figure 2

The Column property view should display a “Converged” status.

Save your case!

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8 Crude Column Optimization

Derivative Utility
The Derivative Utility is used to hold all the data used for defining the
HYSYS Optimizer variables, constraints, and the Objective Function.

The first step in setting up an optimization problem is creating a

Derivative Utility. The Derivative Utility is responsible for gathering all
necessary information for the optimizer. Notice that several different
Derivative Utilities can be added to the same simulation, that is, the
same simulation model can be used in the analysis of several different
scenarios.

To install a Derivative Utility:

1. From the Tools menu, select Utilities.

2. Click Derivative Utility in the list box on the right.
3. Click on the Add Utility button. The Derivative Utility property view
appears as shown:

Figure 3

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 Crude Column Optimization 9

Selection of Unit Operation(s)

The first step in the implementation of the Derivative Utility is the
selection of the unit operations to be considered.

4. Click the Operation button.

We will use only the distillation column as the desired unit operation.
Using this mode will optimize variables pertaining to the Atmospheric
Crude Tower unit operation.

5. Add the Atmos Tower to the Scope Objects list as shown:

Figure 4

6. Click Accept List.

Installing Optimization Variables from the Utility

The next step is to define the variables that we would like to optimize in
our case. The Optimization variables will be product flowrates, steam
flowrates, and energy values.

The needed optimization objects for the utility (in the case of the
Derivative Utility: Optimization Variables, Constraints, and Objective
Function variables) can be added directly from this view. In the
Derivative Utility Configuration group, there is a drop-down list on the
right side of the group.

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The drop-down list contains three options:

• Process Constraints: ProcCons

• Optimization Variables: OptVars
State Variables are on/off • Objective Function: ObjFunc
variables which are not • State Variables: StateVars
being used in this case.

Figure 5

7. Select OptVars and click the Add button to the left of the drop-down
list. The selection view is displayed:

Figure 6

8. By making the selection as shown, an Optimization Variable is

created (Bttm Steam Mass Flow) and is added into the utility. By
default, the new object is given the next available name. However,
you can edit the name of the object directly from the utility view by
highlighting the name in the Object Name column and typing a new
string.

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From the list of variables, if
you uncheck the “Optimize
flag” check box for certain
variables, the Master list will
still show you all the
variables (selected and non-
selected) whereas the
Runtime list shows only the
selected ones.
Crude Column Optimization 11
Figure 7
The Object Name column lets you modify the name of the created
variables. In addition, the Attached Object and attached Property
columns are also displayed in the view, as well as the variable's current
value.
The Master and Runtime radio buttons toggle the display between all
objects and those being considered for the current evaluation. The
properties can be filtered into the following:
• All. All properties.
• Input. Properties requiring user input.
• Output Calculated and outputted values.
• Results. Solution results.
Required Input for Variables
The input for optimization variables are:
• Optimize flag
• Minimum
• Maximum
• Range (optional)
• Global Minimum
• Global Maximum
The Global inputs are appropriate only for real time applications and
can be set at the same values as the minimum and maximum.
The Optimize flag works in conjunction with Runtime and Master lists.
When the optimization problem is being set up, this flag is evaluated for
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each variable. If the flag is false, then the variable is not exposed to the
Optimizer and the value remains at its starting value for the length of the
solution. With this, you can easily switch between optimization
problems by turning variables and constraints on and off. The value for
the variable Range is used in the calculation of a perturbation (= range x
perturbation factor). If none is provided, the span (maximum -
minimum) is used for the calculations.

Adding Variables
We need to add all of the optimization variables in the same way. Notice
that only those variables shown as blue in the simulation (input values)
can be selected since they must be available for updating during the
optimization. In this example, those variables that are specified as
Active specs in the column will need to be accessed through this
derivative utility.

9. Click the Add button with the OptVars option selected in the drop-
down list.
10. Add the steam flowrates. Since the specified value (blue) in this case
is in the stream itself, you will be able to access it through this object
directly as you did with the Bttm Stream Flowrate.

Figure 8

This displays how to access

a column Active
specification through the
Object ANavigator.

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 Crude Column Optimization 13

11. Repeat the steps in order to complete the list of Optimization

variables as follows:

Figure 9

Make sure that all values from the Current Value column are in blue,
since they’ll be changed later by the optimizer.

12. Select the Input view from the Variables tree on the left.
13. Complete the minimum and maximum values for each of the
variables.

Minimum Maximum
Minimum and maximum
values are the boundaries Flowrates Steam (kg/h)
for the variables in the
700 AGO Steam Flow 1600
optimization; this is the valid
range for the optimization. 2000 Bttm Steam Flowrate 4800
800 Diesel Steam Flow 1900
Flowrates Products
0 Off Gas Flowrate (kgmole/h) 10
110 Naphtha Flowrate (m3/h) 190
46 Kero Flowrate (m3/h) 80
104 Diesel Flowrate (m3/h) 156
20 AGO Flowrate (m3/h) 40

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14 Crude Column Optimization

Minimum Maximum
Energy (MMKJ/h)
-33 Kero PA Duty -60
-25 Diesel PA Duty -50
-25 AGO PA Duty -50
Pump Around Draw Rates (m3/h)
240 Kero PA Flowrate 400
150 Diesel PA Flowrate 250
150 AGO PA Flowrate 250
Additional Specs
6 Kero Reb Duty (MMKJ/h) 10
17 Liq Flow Stg 27 (m3/h) 30

Save your case!

HYSYS SQP Optimizer is able to solve constrained optimization
problems. In the presented case, we want the product quality to remain
inside certain values. We can set this need as constraints in an
optimization problem.

Required Input for Constraints

The required inputs for constraints are as follows:

• Use flag
• Minimum
• Maximum
• Scale

All constraints are treated by the Optimizer as ranged constraints (i.e.,

the value of the constraint should lie between the minimum and
maximum at solution, within the prescribed Scale tolerance). The scale
can be considered as an approach, or as the boundary around the
minimum and maximum values that defines whether the constraint is
active, or violated. This information is reported during and after the
solution as the status of the constraint.

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 Crude Column Optimization 15

14. Click on the Add button with the ProcCons option activated in the
drop-down list as shown:

Figure 10

We could add the distillation points from the Boiling point Curves utility,
but that would take more time than if we took the values from the
Column’s Monitor page (they will save calculation time).

Use a descriptive name as 15. Add the required Distillation Points on the Monitor page of the
this will make it easier to find Column Property view if they are not already there.
with the Object Navigator.
Figure 11

The products must meet the following quality specifications:

Product Specification type Minimum (°C) Maximum (°C)

Naphtha D86 / 5% 40.00 50.00
Naphtha D86 / 95% 160.00 180.00
Kerosene D86 / 5% 170.00 190.00
Kerosene D86 / 95% 240.00 260.00
Diesel Pour point -15.00 5.00
Diesel Flash point 90.00 110.00
AGO Pour point 0.00 20.00
AGO Flash point 130.00 150.00

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16 Crude Column Optimization
We can also view these
properties with the
corresponding utility but it
will be better to gather all
the information within the
Monitor page.
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16. Repeat the steps in order to complete the whole list of Constraint
variables as displayed in the previous table.
17. For the heavy streams, we will include Flash Point and Pour Point
specifications by selecting them from the column.
18. Go to the Monitor page.
19. Click the Add Spec button.
20. Click the Add Spec button again and select Cold Properties.
Figure 12
21. Remember to take into account the equipment limitation
constraints.
Equipment Min Duty (MM kJ/h) Max Duty (MM kJ/h)
Condenser 105.00 125.00
Flash Zone 70.00 90.00
 Crude Column Optimization 17

22. Add two new process constraints for the Energy streams (you can
select these directly from the stream).

Figure 13

If any current value

exceeds the boundaries, Your view should appear as shown:
the optimizer will put it
within the limits.
Figure 14

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Is there any constraint variable currently beyond the specified Minimum

and Maximum boundaries? _________________________________________

Objective Function Variables

Objective Function variables are installed individually which facilitates
the calculation of the gradient during the course of Jacobian
evaluations. Alternatively, an Objective Function can be built in a
spreadsheet operation, with a single cell representing the results, and
having a single Objective Function object attached to this result cell.

All the variables with a cost associated may be listed into the
Constraints/Objective Function tab. The HYSYS SQP optimizer will only
minimize the Objective Function. For this reason the revenues have to
be expressed as negative, and the cost values positive.

Thus, every single variable will have, as a result, its current value
multiplied by the associated cost/revenue. The Jacobian will minimize
the individual values that will end in a total minimum (the sum of all the
values from the list).

Price
3
Revenues ($/m )
Naphtha 14.00
Kerosene 12.00
Diesel 10.00
AGO 6.00
Residue 2.00
Costs ($/MM kJ)
Condenser 0.12
Flash zone duty 3.00
Profits

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23. To add Objective Function variables, click on the Add button with
the ObjFunc option selected.

Figure 15

24. For this problem, individual objective function objects are installed
as shown below. Select the Naphtha product Volume Flowrate
(because the price is in $/m3).

Figure 16

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Figure 17

Which would be the formula of the global Objective Function?

Naphtha flowrate * price Naphtha + Kero flowrate * price Kero +

Diesel flowrate * price Diesel + AGO flowrate * price AGO + Residue
flowrate * price Residue - Condenser Heat Flow * cost Energy
Condenser - Flash Zone Heat Flow * cost Energy

And its value? ________________________________

Save your case!

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Optimizer
The Optimizer interface is used to collect all of the derivative utilities
within the current simulation case and provide them to the
optimization algorithm. The Optimizer is invoked by pressing F5 or by
opening the Simulation menu and selecting Optimizer.

Remember that we can use several utilities in the same case.

1. On the Configuration tab, select Hyprotech SQP as the optimization

algorithm.
2. After all the information is configured (leave the defaults), the
model can be run. Click the Hyprotech SQP tab and click the Start
button to run the Optimizer.

Figure 18

To examine the results on the variables and constraints, open the

appropriate Derivative Utility and view the Results page.

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Examining the Results

Go to the Optimizer Property View (press F5).

Did the model find a solution? ________________________________________

What is the Objective Function value? __________________________________
Have we improved it? ________________________________________________

Go to the Derivative Utility and select the Results option, in the

Constraints/Objective Function tab.

Was any constraint violated? _________________________________________

And active? _________________________________________________________

An active constraint means the variable is in one of its boundaries.

Exploring the Simulation

Since Naphtha is the more valuable product, increasing the flowrate
should also increase the profit. We can do so by relaxing the constraints,
however, we are constrained to the quality specifications.

Change the D86 95% Temperature value to 185°C.

What is the new Objective Function? ___________________________________

What are the active specifications? _____________________________________
Did the profit increase after these changes were made? ___________________

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