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© 2000 AEA Technology - Hyprotech. All rights reserved.

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Documentation Credits
Authors of the current release, listed in order of historical start on project:
Lisa Hugo, BSc, BA; Conrad Gierer, BSc; Chris Strashok BSc; Peter deJonge, BSc; Adeel Jamil,
BSc; Muhammad Sachedina, BASc; Allan Chau, BSc; Nana Nguyen, BSc; Yannick Sternon,
BIng; Kevin Hanson, PEng; Chris Lowe, PEng
Since software is always a work in progress, any version, while representing a milestone, is
nevertheless but a point in a continuum. Those individuals whose contributions created the
foundation upon which this work is built have not been forgotten. The current authors would
like to thank the previous contributors.
A special thanks is also extended by the authors to everyone who contributed through
countless hours of proof-reading and testing.

Contacting AEA Technology - Hyprotech

AEA Technology - Hyprotech can be conveniently accessed via the following:
Website: www.software.aeat.com
Technical Support: support@software.aeat.com
Information and Sales: Info@software.aeat.com

Detailed information on accessing Hyprotech Technical Support can be found in the

Technical Support section in the preface to this manual.
 Refinery Oil Manager 1-1

1 Refinery Oil Manager

BETA DOCUMENTS - March 31, 2000

1.1 Introduction .................................................................................................. 3

1.2 Quick Start Example .................................................................................... 5

1.2.1 Initialization .............................................................................................. 5
1.2.2 Refinery Assay Synthesis Environment ................................................... 7

1.3 The Refinery Oil Model .............................................................................. 16

1.3.1 Refinery Assay Matrix ............................................................................ 16
1.3.2 Physical Properties ................................................................................ 18
1.3.3 Calculation Methods .............................................................................. 19

1.4 Refinery Oil Characterization View........................................................... 19

1.4.1 Viewing a Continuous Assay.................................................................. 22
1.4.2 Importing from a Refinery Assay Database File .................................... 25
1.4.3 Synthesizing a Refinery Assay From Laboratory Data .......................... 26

1.5 Physical Property Methods and Synthesis Parameters ......................... 37

1-1
1-2

1-2

Oil Environment button
For further details relating to
HYSYS oil characterization,
refer to Chapter 3 - HYSYS
Oil Manager.
Refinery Oil Manager 1-3
1.1 Introduction
The Oil Manager tab of the Simulation Basis Manager allows access to
the HYSYS Oil Characterization Environment. You can also enter this
environment by clicking the Oil Environment button from the button
bar. To enter the HYSYS Oil Characterization environment, at least one
Fluid Package must exist in the case.
The Refinery Assay tab located within the HYSYS Oil Characterization
environment allows access to the Refinery Oil Characterization
environment where all Refinery Assays are handled.
Figure 1.1
The Refinery Oil Manager
environment is only accessible
through this tab located within the
HYSYS Oil Manager - Oil
Characterization view.
It is important to note that both the HYSYS Oil Characterization and
Refinery Oil Characterization environments each provide alternate
methods for dealing with oils. Within a single HYSYS flowsheet, oils
from either (but not both) oil characterization environments can be
used.
Using HYSYS oil characterization, a list of hypothetical (hypo)
components are generated through (laboratory) assay data input and a
series of assay calculations and cut/blending techniques. The oil must
then be installed into the flowsheet.
When describing oils generated using Refinery oil characterization, the
term assay is also used to define the oil. However, these Refinery Assays
are of a completely different nature to those handled by HYSYS oil
charcterization and are designed for use with refinery operations.
1-3
1-4 Introduction

Refinery Assays are generated based on the Refinery Oil Model which is
a conceptual model with an associated collection of software methods
for characterizing the measurements and properties of hydrocarbon
materials. It is based on a matrix which holds properties for the
chemical components that make up a material and on being able to
calculate property values for combinations of those components in the
form of streams or substances.

In Refinery oil characterization, Refinery Assays are generated through

a series of characterization and synthesis techniques. Hypothetical
components are not generated but rather a standard hypothetical
component list is required for each Refinery Assay. This component list
holds both a standard set of pseudos along with any other pure
components you may have added.

The fundamental concepts within the Refinery Oil Model are described
in the following sections.

1-4

New Case button
Refer to Chapter 1 - Fluid
Package for details on
installing a Fluid Package.
Refinery Oil Manager 1-5
1.2 Quick Start Example
In this example, a crude oil based on four Plant Data groups will be
created and synthesized from laboratory data to generate a Refinery
Assay. It is desired to define the assay based on the following structure.
Plant Data Group No. of Properties No. of Cuts
Light Ends 7 2
Distillates 28 6
Residues 15 2
Naphthas 25 1
In total, 75 different properties are required for this synthesis.
......ADD A TABLE DESCRIBING DIFFS BETWEEN TERMINOLOGY IN
HYSYS OIL MANAGER AND REFINERY OIL MANAGER.
1.2.1 Initialization
Before you can start the actual synthesis process, you must:
1. Open HYSYS.Refinery and start a new case by selecting File-New-
Case from the menu bar or select the New Case button.
By default you will be placed in the Simulation Basis Manager on the
Components tab. This tab displays the component lists available in
your current case. In this case, only a blank default Master Component
list will be listed.
2. Click the Import button to import a component list file containing
hypothetical refinery components. From the current directory,
select the file Default.cml. This will define the component list you
will use in this synthesis.
3. By default, the component list will be named: Component List - 1.
4. Move to the Fluid Pkgs tab and click the Add button to add a Fluid
Package to this simulation.
5. Select the Peng Robinson property package and set the
Component List Selection to Component List - 1.
With the Fluid Package fully defined, you may now proceed to the Oil
Characterization environment.
1-5
1-6 Quick Start Example

6. Select the Oil Manager tab from the Simulation Basis Manager.
This tab allows access to both the HYSYS Oil Manager environment
and the Refinery Oil Manager environment. Each environment
handles components and properties differently.

Figure 1.2

7. Click the Enter Oil Environment button from this tab or click the
Oil Environment button from the button bar to access the oil
characterization environment.
Oil Environment Button

1-6
 Refinery Oil Manager 1-7

8. You are now in the HYSYS Oil Manager environment which

contains all the standard HYSYS Oil Manager characterization
tools with the addition of the Refinery Assay tab. This tab acts as
an etry point into the Refinery Oil Manager. Click the Refinery
Assay tab.

Figure 1.3

Refinery Assay Data Source dialog:

9. Click the Add button to add a new Refinery Assay to the simulation.
You will be presented with a dialog window that has two choices.
You can either import a pre-built assay from the database file, or
you can synthesize a new Refinery Assay from laboratory data.
10. Select the Synthesize Lab Data option and then click the OK
button.

1.2.2 Refinery Assay Synthesis

Environment
To synthesize a Refinery Assay, data for one or more properties of one
or more contiguous cuts must be supplied. There are a number of
minimum data requirements for a successful synthesis. Refer to
Section 1.4.3 - Synthesizing a Refinery Assay From Laboratory Data
for further details.

1-7
1-8 Quick Start Example
Decide how to create Plant Data
group dialog window
1-8
Adding a Plant Data Group
You have now entered the Refinery Oil Characterization — synthesis
environment and are ready to add Plant Data groups. Plant Data groups
allow the user to group like cuts in an assay. Each Plant Data group can
have different property lists and any number of cuts.
11. Click the Add button from the Input Summary tab. You will be
presented with a dialog window with a number of options for
creating a Plant Data group.
12. Since this Plant Data Group will be used to store “light ends”
related property and cut details, rename this group to Light Ends.
13. Click the Create from a built-in template option and then click the
OK button.
You have now successfully added your first Plant Data group which will
be used to store the “light ends” property data. The Plant Data Group :
Lights Ends property view will appear by default without any data.
Refinery properties are added within this view to the grid. The grid
starts out with basic information about one cut. As you add properties
and cuts, the grid will fill out. By default, the grid shows a number of
mandatory rows. These define:
• Cut Name - a unique name for the cut. One is created for you
as you add a cut but you can overwrite with your own
• Cut Type - choose from various cut types
• Cut Status - shows you whether a cut contains the minimum
data necessary for use. Rules are defined at the start of this
section
• Input/Calc - shows you whether the column contains input
data or calculated values.
 Refinery Oil Manager 1-9

Appending a Cut
The next step now involves adding your first cut to this Plant Data
Group.

14. Click the Append Cut button to add your first cut. A dialog window
will appear as follows:

Figure 1.4

This window allows the selection of your cut name, cut type. The Status
Information group lists details relating to the current cut status. The
missing information will added in the following steps.

15. Rename the cut name to Gas.

16. Ensure that the Contiguous cut type is selected. For this type, the
synthesis assumes that the set of contiguous cuts make up the
original material.
17. Click the OK button to add the cut.
18. Repeat steps 14 through 17 but name this new cut C5 Data instead.

Adding Properties
You now have the two desired cuts for this Plant Data Group. The next
streps involves adding the appropriate properties based on the “light
ends” laboratory sample data results. The properties required are:

• Percent Weight Yield (wt%) and

• Component Composition by Weight (for ethane, propane, Iso-
butane, n-butane, iso-pentane and n-pentane).

These properties are added using the Setup Properties button which
opens the Cut Property Selection property view. This view lists all
available Refinery property values which you can use to define your
Plant Data Group. You may then select a Refinery property from the list.
Properties may only be added once to each plant group.

1-9
1-10 Quick Start Example
For some properties such as
Component Composition and
Viscosity, you will also have to
select the qualifier(s). For example,
component composition requires
you to select all qualifying
components to include in your cut.
1-10
19. Click the Setup Properties button. The Cut Property Selection
property view will appear.
20. From the Available Properties list, highlight the Percent Weight
Yield property by clicking on its name.
21. Click the Add button and the property becomes added to the
Selected Properties list.
22. Now, highlight the Component Composition by weight property
and click the Add button again. Since this property requires
qualifying components, a separate Cut Property dialog window will
appear allowing you to select all components you wish to include.
23. From the window, click the check boxes for components: ethane,
propane, iso-butane, n-butane, iso-pentane and n-pentane.
Selected components will appear with an x in their check box.
Figure 1.5
24. Click the OK button since you have completed your property
selections for this Plant Data Group.
25. From the Cut Property Selection property view, click the OK
button to be placed in the input data view.
 Refinery Oil Manager 1-11

Adding Measured Data

26. You now must define this Plant Data Group with measured
laboratory data. Enter the values from the table below into the
appropriate cells on the grid. Leave any blank value empty.

Gas CD Data
Percent weight yield (wt%) 0.91 1.58
Component composition by weight_Ethane (wt%) 0.02
Component composition by weight_Propane (wt%) 0.18
Component composition by weight_Iso butane (wt%) 0.18
Component composition by weight_N butane (wt%) 0.53
Component composition by weight_Iso pentane (wt%) 0.52
Component composition by weight_N pentane (wt%) 0.62

Once you have completed entering your measured data, the input data
view will appear as shown in Figure 1.6. The status bar now reads Plant
Data Group ready in green. Note that the Show blanks as empty cells
option has been enabled here.

Figure 1.6

27. Click OK to close this view and return to the Refinery Assay Source
(Synthesized) property view.

1-11
1-12 Quick Start Example

28. Add another Plant Data Group by following the procedure outlined
in steps 11 through 13. Name this Plant Data Group - Distillates.
29. Add 6 cuts following the procedure outlined in steps 14 through 17.
Name each cut with the following names:

Cut Number Name

1 C5-165
2 65-165
3 175-225
4 225-365
5 365-410
6 410-560

30. Once you have completed entering all 6 cuts, click the Setup
Properties button and add the required properties to this Plant
Data Group. Follow the procedures outlined in steps 20 through 24
for the properties listed below (their qualifiers are supplied if
applicable).

Property Qualifier(s)
Percent Weight Yield (wt %) n/a
Initial Cut Point n/a
Final Cut Point n/a
Specific Gravity n/a
Sulphur Content (wt %) n/a
Nitrogen (wt %) n/a
Aromatics Content by Volume (vol %) n/a
Aromatics Content by Weight (wt %) n/a
Naphthenes Content by Weight (wt %) n/a
Paraffins Content by Weight (wt %) n/a
Iso Paraffins Content by Weight (wt %) n/a
Research Octane Number 0
Motor Octane Number 0
Cloud Point n/a
Pour Point n/a
Freeze Point n/a
Cetane Index ASTM D976-80 n/a
Cetane Number D976-80 n/a
Diesel Index n/a
Aniline Point n/a
Refractive Index_20 C 20°C (68°F)
Refractive Index_70 C 70°C (158°F)

1-12
 Refinery Oil Manager 1-13

Property Qualifier(s)
Viscosity (Kinematic) 40°C (104°F)
60°C (100°F)
100°C(212°F)
Conradson Carbon Content (wt %) n/a

31. Next, add the following measured values for the Distillates Plant
Data Group.:

Figure 1.7

32. Click OK to close this view and return to the Refinery Assay Source
(Synthesized) property view.
33. Add another Plant Data Group by following the procedure outlined
in steps 11 through 13. Name this Plant Data Group - Residues.
34. Add 2 cuts following the procedure outlined in steps 14 through 17.
Name each cut with the following names:

Cut Number Name

1 560+
2 410+

1-13
1-14 Quick Start Example

35. Click the Setup Properties button and add the required properties
to this Plant Data Group. Follow the procedures outlined in steps
20 through 24 for the properties listed below (their qualifiers are
supplied if applicable).

Property Qualifier(s)
Percent Weight Yield (wt %) n/a
Initial Cut Point n/a
Final Cut Point n/a
Specific Gravity n/a
Sulphur Content (wt %) n/a
Nitrogen (wt %) n/a
Pour Point n/a
Nickel Content (ppmwt) n/a
Sodium Content (ppmwt) n/a
Vanadium Content (ppmwt) n/a
Viscosity (Kinematic) 70°C (158°F)
100°C(212°F)
150°C(302°F)
Conradson Carbon Content (wt %) n/a
Asphaltenes Content (wt%) n/a

36. Next, add the following measured values for the Residues Plant
Data Group:

Figure 1.8

1-14
 Refinery Oil Manager 1-15

Synthesizing the Assay

With all the Plant Data Groups are fully defined (based upon the format
laboratory results are received), and all measured data values (based on
laboratory data results) are entered, the next step in synthesizing the
assay.

37. Close all Plant Data Group (Input Data) views and click the
Synthesize button from the Assay Source (Synthesized) property
view.

The status bar on this view will change from yellow to green once the
synthesis calculations are complete (assuming the synthesis was
susccessful) and read: Synthesis Successful.

Any errors that were encountered during the synthesis operation will
be reported on the Synthesis Messages tab. It is a good idea to review
the message information and examine any warnings or errors which
may have occurred. For further details relating to the Synthesis
Messages, refer to the Synthesis Messages Tab subsection in Section
1.4.3 - Synthesizing a Refinery Assay From Laboratory Data .

1-15
1-16 The Refinery Oil Model

1.3 The Refinery Oil Model

A Refinery Assay is the collection of measured and calculated property
values for a set of hypothetical (pseudo) components, together with its
generated Refinery Assay matrix. The set of information that makes up
an oil model is shown below, with shading used to indicate the extent of
the model.

Figure 1.9

Lab Data

Origin Data

Assay Synthesis Property Methods

Synthesis Methods Calculations and Parameters
and Parameters

Assay Matrix Property Calculations

Calculated Property
Values

The Refinery Oil Model implemented in HYSYS encapsulates the

technology for Refinery Assay synthesis and physical property
calculations along with the necessary supporting structure to store and
retrieve an assay matrix from an external Assay database file.

1.3.1 Refinery Assay Matrix

A Refinery Assay matrix is defined as a collection of information about a
hydrocarbon-based material. The matrix holds the basic data needed
to drive the Refinery Physical Property system. This system calculates
values for several hundred physical, transport and thermodynamic
properties from this basic data which is organized as a series of
property contribution values for Hypo components.

1-16

Note that Synthesis is not restricted
only to crude oils. It can be used for
parts of crudes (e.g. synthesizing an
atmospheric residue from vacuum
unit products), for reactor products
or any other refinery stream
containing Hypo components.
Refinery Oil Manager 1-17
Origin Data
The term origin data is used to describe the raw data leading to the
generation of the Refinery Assay matrix. Currently the only source
tracked is Synthesis, although future versions will keep track of blends
and other information.
Synthesis origin data consists of measurements of the physical
properties of parts of the material. This is termed laboratory data. For
example, a laboratory may take a crude oil, fractionate it into gas,
naphtha, kerosene, diesel and residue fractions and measure the
important properties of each of those fractions. The process of
Synthesis combines the properties of each fraction to generate the
Refinery Assay of the whole crude. The fractions (or cuts) that, when
added together, exactly reconstitute the original material are termed
contiguous cuts. Origin data for a Refinery Assay must consist of data
for a complete set of contiguous cuts. A Refinery Assay can be
synthesized from a single contiguous cut.
Extra properties may be measured for combinations of contiguous cuts
or for new cuts. This data is used in the synthesis, because it adds extra
information, and is termed overlapping cut data.
Minus streams can be specified whose contribution to the overall
composition and property curves will be subtracted from the resulting
synthesis. This is to allow for the situation where a Refinery Assay is
being synthesized from fractionator product data and a wild naphtha
(or other extraneous stream) is fed to the fractionator and it is desired
to synthesise the feed without the contribution of this extraneous
stream.
1-17
1-18 The Refinery Oil Model

The following figure shows the origin data that makes up the laboratory
data for a residue with two cuts.

Figure 1.10

1.3.2 Physical Properties

Not all the physical properties supported in the Refinery Oil Model are
calculated from a contribution from each Hypo component. Those that
are calculated in this way are termed Refinery Assay properties. There
are currently 30 assay properties. The rest are termed Non-assay
properties: values for a stream are calculated from the stream values of
one or more Refinery Assay properties.

Many physical properties are uniquely defined by their name alone. For
example specific gravity is defined as the density of the material at 60°F
divided by the density of water at 60°F. It is a dimensionless quantity.
Other properties require some qualification. For example, kinematic
viscosity can be measured at a wide range of temperatures. The
viscosity of heavy material is usually measured at relatively high
temperatures. Therefore, to uniquely define the property kinematic
viscosity, it must be qualified with the temperature at which it is
measured. For example, a fully qualified property might be kinematic
viscosity at 50°C and this is a different property with a different value to
kinematic viscosity at 60°C. The dimension of a property (or qualifier)
indicates the units in which it can be measured or reported. The full list
of supported properties in the Refinery Oil model, the qualifier values

1-18
 Refinery Oil Manager 1-19

they can take and their dimensions are defined in the Refinery Physical
Properties manual.

1.3.3 Calculation Methods

Some physical properties have more than one calculation and/or
synthesis method. Methods are given names in the user interface which
align with the methods described in Section 1.5 - Physical Property
Methods and Synthesis Parameters .

1.4 Refinery Oil

Characterization View
The refinery oil characterization functionality is accessed through the
Refinery Assay tab of the HYSYS Oil Manager. The Refinery Oil
Manager is an entirely separate environment from the HYSYS Oil
Manager and handles oil properties uniquely for use with Refinery
operations.

Figure 1.11

The source of a Refinery Assay

can be either through Synthesis
or as an Import from an external
Refinery Assay database file.

A default fluid package must

be selected here.

The Refinery Oil Manager environment is only

accessible through this tab located within the
HYSYS Oil Manager - Oil Characterization view.

From here you can load additional Refinery Assays into the system from
Refinery Assay database files (*.adb), or create Refinery Assays from
laboratory data through synthesis. Refinery Assays must be known to

1-19
1-20 Refinery Oil Characterization View

the Refinery Oil Manager before they may be used in the flowsheet.

The left hand side of the view shows you available Refinery Assays,
letting you manipulate them through the buttons. The right hand side
shows information about the highlighted Refinery Assay.

• The View button brings up more information about the

highlighted Refinery Assay, giving you information dependant
on the source of the Refinery Assay.
• The Add button is the mechanism for adding a Refinery Assay
through import or by synthesis. For synthesis see Section
1.4.3 - Synthesizing a Refinery Assay From Laboratory
Data ).
• The Delete button removes the Refinery Assay from the case.
Be careful where the Refinery Assay is used in your simulation:
you will not be asked to confirm!
• The Import button let you bring a saved Refinery Assay from a
database file into the current case (see Section 1.4.2 -
Importing from a Refinery Assay Database File ).
• The Export button let you save an Refinery Assay to disk so
that it can be used in other cases.

View Button
When a Refinery Assay is highlighted from Available Refinery Assays
list and the View button is clicked, a Refinery Assay dialog box will
appear displaying various Refinery Assay details along with two buttons
to access other options.

1-20
 Refinery Oil Manager 1-21

Figure 1.12

Select this button to enter For synthesized assays,

the continuous assay select this button to enter
viewing environment. the synthesis environment.

Selecting the View Continuous Assay button will allow access to a wide
array of assay property plotting and reporting features. See Section
1.4.1 - Viewing a Continuous Assay for further details.

Selecting the View Refinery Assay Source button allows access to one of
two views:

1. The Refinery Assay Source (Imported) dialog window for the case
of an imported assay.
2. The Refinery Assay Source (Synthesis) environment for the case of
a synthesized assay.

Export Button
Select Export Type dialog
Clicking the Export button from the Refinery Assay tab (see Figure
1.11) will open an export type selection dialog window. This feature
allows you to export assay information an external file using several
options:

• Export Template Assay - this option exports the complete

Refinery Assay including all synthesis properties, specified
property values, Plant Data Groups, cuts and measured
property values to an external *.asy file

1-21
1-22 Refinery Oil Characterization View

• Export Assay as Template - this option exports all the same

Assay template files (*.ast) are useful
when dealing with standardized
Refinery Assay information as the Export Template Assay
laboratory data. It can be quite option except it will not contain any measured property data.
tedious to set up a matrix of Information is exported to an external *.ast file.
properties and cuts each time you • Export to Assay Database - this option exports the complete
want to synthesize an assay. Since Refinery Assay to an existing external database file (with an
most laboratories perfrom assays in a *.adb extension). This database file may hold several Refinery
standard way with standard cuts and Assays at once.
properties, the assay template file
may be used as a starting point to
enter your sample data.
1.4.1 Viewing a Continuous Assay
The Continuous Assay property view allows you to display the selected
Refinery Assay data either in tabular or graphical format. Both
Synthesized Refinery Assays and imported Assays may be viewed in this
format. It can be access by pressing the View Continuous Assay button
on the Refinery Assay dialog (see Figure 1.12).

Assay Property Table Tab

Figure 1.13

This tab display all the assay properties, for the selected assay, in tables.
The Use the Select Assay Properties to Display group to select the
properties, which you want to display. Assay properties can be selected
by activating the checkbox in front of each property. The selected
properties are displayed in the Assay Properties Value matrix. Use the
appropriate radio button in the Properties Sort Order to sort the

1-22
 Refinery Oil Manager 1-23

properties in the Use the Select Assay Properties to Display group

either by name or by both dimension and name.

The Select All Properties button allows you to select all the listed
properties by activating their respective check box. The Clear All
Selections button allows you to unselect any or all of the previously
selected properties.

Assay Property Plot Tab

Figure 1.14

The Assay Property Plot tab allows you to manage graphical

presentation of various assay properties. The Available Property Plots
group display the all the plots setup for the selected assay. The Plotted
Assay Property Curves group displays the chosen properties for the
selected plot. The following three buttons are present on this tab.

Button Function
This buttons opens up the Refinery Assay Property
Create Plot
Plot view, which is used to setup new plots.
This button displays the Refinery Assay Property
View Plot
Plot view for the selected plot.
Delete Plot This button deletes the selected plot.

1-23
1-24 Refinery Oil Characterization View

Refinery Assay Property Plot view

Figure 1.15

The Refinery Assay Property Plot view allows you to customize

individual plots to display the chosen property type. The Plot Name
and Assay Name shown on the top of the view displays the selected plot
and assay names. You can select assay properties from the Select Assay
Properties To Plot group by activating the respective check box. Once
you have activated a property type the Select Assay Properties To Plot
group is updated to display only the related properties. If you want to
display the property data on a dry basis then the Dry Basis check box
must be activated.

After selecting a property, use the Select All Shown Properties button to
select all of the listed properties and the Clear All Selections button to
unselect the chosen properties.

As soon as you select a property type the graph will display the property
data. You can display as many properties as you like on the graph, but
for clarity we recommend displaying no more than six properties on a
single plot. Object inspecting the graph area allows you to access the
Graph Control view and printing capabilities, see Chapter 6 - Output
Control of the User Guide manual for further details.

1-24
 Refinery Oil Manager 1-25

1.4.2 Importing from a Refinery

Refinery Assay Data Source dialog: Assay Database File
Clicking the Add button from the Oil Characterization view (see Figure
1.11) opens a dialog window to select your Refinery Assay data source.
Click the Import from an assay database radio button and then click
the OK button to open the import dialog window:

Figure 1.16

Use the Browse button to select a Refinery Assay database file (with a
*.adb extension) and then choose an assay to import from the database
file. Only valid Refinery Assay database files will accessible.

When a Refinery Assay is imported from an external database

file, no synthesis information is available for viewing.

1-25
1-26 Refinery Oil Characterization View
Refinery Assay Data Source dialog:
The term “naphtha range piano” is
an acronym for paraffins, iso-
paraffins, aromatics, naphthenes
and olefins.
1-26
1.4.3 Synthesizing a Refinery
Assay From Laboratory
Data
Clicking the Add button from the Oil Characterization view (see Figure
1.11) opens a dialog to select your Refinery Assay data source. Click the
Synthesize lab data radio button and then click the OK button to enter
the synthesis environment.
To synthesize a Refinery Assay, data for one or more properties of one
or more contiguous cuts must be supplied. The minimum data
required for a cut is:
Minimum data required for a cut:
mass flow or molar flow or volume flow or gas vol
One of... flow or mass percent yield or volume percent
yield
And either:... a complete component composition
Or... density at any temperature or SG or API gravity
A distillation or both initial and final cut points
Plus... (unless the stream is a residue stream, in which case
the distillation may be omitted
The choice between distillation or initial and final cut points applies to
all streams in a single synthesis. If one cut is specified with a
distillation, they all must be. The only exception is that cuts specified by
a composition can be mixed with either type of stream specified by
distillation or cut points. These rules are encapsulated in the Refinery
Oil Manager and a cut cannot be used (is not ready) unless these rules
are met.
Synthesis data is entered into one or more grids of information called
Plant Data Groups. Each Plant Data group grid contains data on one
or more cuts of the material, with properties forming rows of the grid
and cuts forming the columns. A typical laboratory assay for a whole
crude will contain data on lights ends composition, naphtha range
piano distribution from GC and a number of distillate and residue cuts.
Arranging your laboratory data into Plant Data groups will help you
make sense of the information and avoids too sparse a grid.
 Refinery Oil Manager 1-27

The Refinery Assay Source (Synthesized) property view appears as

follows:

Figure 1.17

The grid shows you the Plant Data Groups you have set-up for your
Refinery Assay. The Add, Edit, Clone & Delete buttons let you manage
these, with the Template buttons letting you save existing plant data
groups for use as templates to speed entry of other Refinery Assays.

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1-28 Refinery Oil Characterization View

The Add button opens a dialog with options on how to create your
plant data group. Various options exist for building an input plant data
group, select the most appropriate. You can also enter a unique name
for your newly created plant data group in the name field.

Figure 1.18

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 Refinery Oil Manager 1-29

The Plant Data Group appears as follows:

Figure 1.19

Use this button

to add/remove
available
properties from
the master list.

Cut edit
buttons

Refinery properties are added within the Plant Data Group view to the
grid. The grid starts out with basic information about one cut. As you
add properties and cuts, the grid will fill out. By default, the grid shows
a number of mandatory rows. These define:

• Cut Name - a unique name for the cut. One is created for you
as you add a cut but you can overwrite with your own
• Cut Type - see following table
• Cut Status - shows you whether a cut contains the minimum
data necessary for use. Rules are defined at the start of this
section.
• Input/Calc - shows you whether the column contains input
data or calculated values

There are a number of Cut Types available, each described in the

following table:

Cut Type Description

synthesis assumes that the set of contiguous cuts
Contiguous (default)
make up the original material
this cut's boiling range overlaps the contiguous set
Overlapping
and provides supplementary information

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1-30 Refinery Oil Characterization View

Cut Type Description

this cut should be subtracted from the set of
contiguous data. Often used in synthesizing column
Minus feeds where you wish to subtract the effect of
secondary feeds such as gas streams and wild
naphtha feeds
cut contains naphtha component data deriving from
Naphtha
GC analysis. Information will typically overlap a
Components
distillate contiguous cut
Exclude this cut should be excluded from synthesis.

Adding Property Data to a Plant Data Group

Refinery properties are added to a Plant Data Group by clicking the
Setup Property button which opens the Cut Property Selection

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 Refinery Oil Manager 1-31

property view.

Figure 1.20

The Available Properties list shows all available Refinery property

values for selection. You may then select a Refinery property from the
list. Properties may only be added once to each plant group.

When a refinery property needs a qualifier, that qualifier must be

defined before the property can be added. For example, Component
composition by weight requires the component(s) of interest as the
qualifier. When you attempt to Add this property, a dialog window will
appear allow you to select your qualifying components as shown in
Figure 1.21. Qualifying components are selecting by clicking their
associated checkbox.

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1-32 Refinery Oil Characterization View

Figure 1.21

Each refinery property added appears as a row in the Plant Data Group
view. Once you have finished adding and defining all necessary
properties and cuts to your Plant Data group, the status bar should read
“Plant Group Ready” in green.

A typical completed Plant Data Group view might appear as follows:

Figure 1.22

In this example, 3 cuts have been added

All added
Refinery
Properties
are listed
here.

In the example shown in Figure 1.22, the Plant Data Group is named

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 Refinery Oil Manager 1-33

Distillates and contains three cuts along with a number of added

refinery properties. The status bar reads “Plant Data Group Ready” in
green showing that the Plant Data Group is ready for Synthesis.

Display Control Checkboxes Controlling the Plant Data Group Display

As well as buttons to manage cuts & properties, there are two check
boxes to control the displayed values:

• Show Calc Values - adds a column per cut that shows back-
calculated values for the entered properties once synthesis is
complete
• Show blank as empty value - makes all empty cells display
nothing rather than <empty>.

Performing the Synthesis

When you are finished entering data, you can return to the main assay
view and Synthesize your refinery assay by clicking the Synthesize
button from the Refinery Assay Source (Synthesized) view. The status
bar will display the results of the synthesis.

Figure 1.23

All Plant Data

Groups which
were created
are listed here.

The Synthesize button In this example, the Synthesis

was successful.

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1-34 Refinery Oil Characterization View

Once a Synthesis has been performed, the status bar will display the
current status of the Synthesis operation. For a successful Synthesis, the
status bar will display Assay Creation Succeeded in green as shown in
Figure 1.23. It is important to examine the Synthesis Messages tab after
performing a Synthesis operation in order to examine any warnings or
errors which may have occurred. For further details outlining the
various Synthesis Messages, refer to the following sub-section —
Synthesis Messages.

Synthesis Messages Tab

Figure 1.24

The Synthesis Messages tab displays any warnings or errors that have
occurred during the synthesis. All of the messages generated are
displayed in the Available Messages list. The messages are ordered
from most significant to least significant, with the most signigicant
messages at the top of the list. Highlighting a message in the list will
display information about the message in the Details of Selected
Message group box. The Details of Selected Meassge group box is

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 Refinery Oil Manager 1-35

comprised of 5 objects.

Object Description
Displays the message type. The message can be
Type
one of two types; Warning or Error.
Displays the severity of the message.
Severity Severity numbers range from 1 to 10, with 6 or over
defined as errors and 5 or less defined as warnings.
Class Displays the message class.
Displays the serial number of the class.
Synthesis messages that have the same serial
number represent messages that are similar in
Class Serial No. content. For example, the serial number will be the
same for each message that warns you about a
composition stream that does not sum to 100% and
will be normilized.
Meassage Text Displays the actual message text.

If any errors are generated during the synthesis the status bar will
display “Synthesis Failed” in red. The errors must be resolved before the
assay can be synthesised.

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1-36 Refinery Oil Characterization View

Synthesis Diagnosis Tab

Figure 1.25

The Synthsis Diagnosis tab allows you to view the results of the
synthesis. In order to print the results place the cursor in the text
window and click the secondary mouse button. This wil display the
following menu.

Figure 1.26

Select the Print Text option to print the synthesis diagnosis.

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 Refinery Oil Manager 1-37

1.5 Physical Property

Methods and
Synthesis Parameters
The key refinery properties (along with the various alternative
calculation methods) available during a Refinery Assay synthesis are
described in the following sections. Refinery physical property
methods are also described in detail in the Refinery Physical
Properties guide.

The Synthesis Methods page of the Calculation Defaults tab allows the
modification of each Synthesis method used to calculate refinery
properties. Each method holds a number of alternate calculation
options which may be selected before a Synthesis is performed.

Figure 1.27

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1-38 Physical Property Methods and

C to H RATIO
Two methods exist for the C to H Ratio. The Based on component SG
and ABP method, the default, calculates the carbon-to-hydrogen ratio
using one of a series of correlations based on the feed average boiling
point. Derived from n-paraffins C/H curve method uses a single
equation over the whole boiling range

CLOUD CUT WIDTH

Cloud Cut Width defines the TBP cut range width calculation method
for Cloud Point calculations. Three methods exist for this calculation.
1% to 99% method, the default uses the 1% - 99% distillation values to
determine the width of the stream for cloud point calculations. TBP
Cut Points method uses the TBP cutpoints of the stream as the width of
the stream. User specified cut width method makes a linear
extrapolation through the TBP 70% and 30% distillation points to
determine a pseudo TBP cut range for cloud point calculations. With
the later, you can adjust the distillation points used through the
CLOUD CUT RANGE parameter.

CLOUD POINT
Fourteen methods exist for the determination of Cloud Point. Each
method is outlined in the following table:

Method Description
Factor method + This method, the default, is the Refinery
stream width pseudocomponent factor method.
correction
Factor method + This method is similar to the previous method, but
adjustment for has a different adjustment for the distillation tail
distillation tail above 90%.
Factor method + This method is the Refinery pseudocomponent
extra correction for factor method, but with an extra adjustment for very
very wide cuts wide streams.

Factor method; Bulk This method is based on a combination of the Factor

method + stream width correction and the KBC
index method in the
bulk index method, which is used in the Blender
blender model.
Factor method + This method is a combination of the Factor method
wide cut correction; + extra correction for very wide cuts and the KBC
Bulk method in bulk index method used in the Blender model.
blender

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 Refinery Oil Manager 1-39

Method Description
This method is special, and is based on the Refinery
Factor method + pseudocomponent factor blending method where a
delta adjustment delta value is applied. For more information about
this method, contact your HYSYS support engineer.

Factor method + Tis method applies the Factor method + delta

adjustment throughout Petrofine, except in the
delta adjustment;
Blender model where the KBC bulk blending index
Bulk method in
method is used. For more information about this
blender method, contact your HYSYS support engineer.
This method is similar to Factor method + stream
width correction method except that it does not
apply a stream width correction to calculated cloud
Factor method, no
points. This method has been used as a base
width correction method to calculate required correction factors. We
do not recommend this as a general purpose cloud
point prediction method.
Factor Method, no This method is the same as Factor method, no
width correction; width correction method except in the Blender
Bulk method in model, where the bulk index blending method is
blender used.

Factor method, user This method is again similar to Factor method, no

width correction method but the coefficients for the
supplied cut width
cut width correction are user-supplied using the
correction parameter CLOUD DELTA FACTORS (see later).
Factor method, user This method is the same as Factor method, user
width correction; supplied cut width correction method except in
Bulk method in the Blender model where the bulk index blending
blender method is used.

Crude dependant These two methods calculate a crude-dependent

cut width correction for cut width. Correction factors are stored
correction/Crude on the database separately, for each Refinery Assay.
dependant cut width The CLOUD14 PARAMETERS and POLYNOMIAL
POINTS instructions (see later) only apply to these
correction; Bulk
two methods.
method in blender
User supplied This method uses a pseudocomponent index
blending index blending method to derive a stream cloud point.
equation

The blending index equation is described under CLOUD INDEX

FACTORS and all the coefficients may be user-specified. HYSYS applies
a stream width correction with user-supplied coefficients (default
values are also available) as in Factor method, user supplied cut width
correction method. It then applies an offset based on the cloud point
value. The coefficients of the offset equation are set by the CLOUD
OFFSET FACTORS instruction.

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1-40 Physical Property Methods and

COMPONENT MOLECULAR WEIGHT

Two methods are available for this parameter. The Component
Molecular Weight controls the way to synthesize molecular weight. The
default is API (based on component SG and ABP) method.

API (based on component SG and ABP) method is the API method

without a correction for asphaltenes content.

API + asphaltenes correction above 400C method is the API method

based on the component specific gravity and boiling point. A
correction is applied to the molecular weight of the higher boiling
range material (above 400°C), for asphaltenes content. Use caution
when selecting this method, since the component molecular weights
are stored on the Refinery Assay database.

RESIDUE DISTILLATION GENERATION

The Residue Distillation Generation field determines which method to
use when calculating the volume interchange between the residue
stream and the next lighter product from a vacuum column. All three
calculation methods use a quadratic equation based on the stripping
steam rate. The only difference between the methods is in the
coefficients of the equation.

This instruction only takes effect if you set up a residue stream from an
atmospheric or vacuum column as a synthesis cut, without giving a
distillation, and synthesize a Refinery Assay using this cut as the
heaviest stream in the synthesis. To show that the residue stream is
from a vacuum column, use the property Stream type with a value of
Vac Residue in cut. Identify all other cuts from the vacuum column as
Stream Type VDU.

MOTOR OCTANE NUMBER

Calculate motor octane number distribution (clear and leaded) using
one of the following three methods: (1) the KBC index method, (2) the
straight volumetric average method or (3) the Ethyl RT-70 method. We
recommend you use the same method to calculate research and motor
octane numbers.

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 Refinery Oil Manager 1-41

NITROGEN SYNTHESIS
Two methods are available for synthesizing nitrogen content. The
quadratic spline fit method uses a quadratic spline fit procedure to
generate the nitrogen distribution curve in the nitrogen synthesis. The
logarithmic quadratic spline fit method uses a logarithmic quadratic
spline fit curve in the nitrogen synthesis. This produces a better match
of the very low nitrogen values in the light cuts.

OCTANE SYNTHESIS
Two methods are available for determining the basic shape of the
octane distribution. The Typical crude template method uses a
template based on crude assay octane distribution. The Typical FCC
gasoline template method is specifically for FCC gasoline. It takes a
single octane template, and manipulates it to match given octane
values of 1, 2 or 3 streams in the gasoline range.

POUR POINT
Three methods are available for determining the way pour point is
synthesized. The default, Factor method + stream width correction
method, is equivalent to the default cloud point 1% to 99% method.
The Factor method, no stream width correction method is similar, but
doesn't apply a delta correction based on stream width. The Factor
method + extra adjustment for very wide cuts method is equivalent to
cloud point User specified cut width method.

REFRACTIVE INDEX
Two methods are available for determining the refractive index. The
Weight blend method is the default method. HYSYS calculates assay
and stream refractive index values on a weight basis. Blending and de-
blending is also done on a weight basis. The Hot volume blend method
calculates refractive index on a volume basis, with volumes calculated
at the temperature of the refractive index measurement. HYSYS stores
Refinery Assay values for refractive index at 67ºC, so all blending and
de-blending calculations are done using liquid volumes at this
temperature.

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1-42 Physical Property Methods and

RESEARCH OCTANE NUMBER

The available methods for calculating research octane numbers (clear
and leaded) are the same as those for motor octane numbers (see
earlier). We recommend you use the same method to calculate research
and motor octane numbers.

REID VAPOR PRESSURE

Two methods are available for determining the Reid vapor pressure
contribution method. The Convert component TVP to RVP; Blend
RVP’s method first converts each component TVP value stored in the
assay to RVP, then blends stream RVP on a component volume index
basis. The Blend TVPs; Convert to RVP method first blends TVP on a
component molar basis, then converts the resulting TVP to RVP.

SG
Three methods are available for determining the way specific gravity
and liquid density are calculated.

The default, method 1, described in the Refinery Physical Properties

Manual, is derived from thermal expansion curves in Maxwell's book
(Maxwell, J B, Data Book on Hydrocarbons; Application to
Hydrocarbons, NY, Van Nostrand, 1950). At certain conditions this
method may be invalid, since a density calculated at 60°F is not the
same as the specific gravity of the stream.

Method 2 uses the Maxwell calculation method, but ratios the volume
expansion with the value calculated at 60°F. This method maintains the
rate of volume expansion with the temperature predicted by Maxwell,
and guarantees that a density calculated at 60°F is the same as the
specific gravity of the stream.

Method 3 is the API recommended procedure 6A3.6, 1992, which

guarantees that a density calculated at 60°F is the same as the specific
gravity of the stream. The stated accuracy is "an average error of 0.75%
when tested against a data set consisting of high molecular weight
hydrocarbons".

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 Refinery Oil Manager 1-43

SPECIFIC GRAVITY SYNTHESIS

Two methods are available for determining the way Specific Gravity is
synthesized. The Quadratic spline fit method uses a quadratic spline fit
procedure to generate the specific gravity distribution curve in the
specific gravity synthesis. The Cubic spline fit method, which uses a
cubic spline fit procedure to generate the specific gravity curve,
produces a smoother curve.

TBP SYNTHESIS
Three methods are available for determining the TBP curve is
synthesized. The Quadratic spline fit method uses a quadratic spline fit
procedure to generate a TBP curve from Plant Data TBP cutpoints. The
Cubic spline fit method uses a cubic spline fit procedure to generate
the TBP curve from Plant Data TBP cutpoints. This gives a smoother
curve than the Quadratic spline fit method. The Cubic spline fit +
smoothing method uses a data reconciliation techniques to smooth the
crude TBP curve generated from Plant Data distillation data, greatly
reducing any noise in the distillation measurements.

TBP WEIGHT TO TBP VOLUME CONVERSION

Two methods are available for determining the connection between
TBP distillations on a weight and volume. The Stream SG method uses
specific gravity values to calculate TBP lv% from TBP wt% distillation
data, or the converse. The ASTM D2887 method uses the ASTM D2887
procedure, and is based on correlations using a D86 distillation. It can
only be used to convert TBP wt% to TBP lv%. The procedure is not
reversible. The correlations can only be applied accurately between -
45.5°C for the 1% point and 405.5°C for the 99% point. Outside this
range, the program reverts to the Stream SG method, and issues a
warning message.

VISCOSITY (KINEMATIC)
Two methods are available for determining the VISCOSITY parameter.
The Weight blend using VBN method is the default method. HYSYS
calculates assay and stream viscosity values on a weight basis. Blending
and de-blending is also done on a weight basis. The Hot volume blend
method calculates viscosity on a volume basis, with volumes calculated
at the temperature of the viscosity measurement. HYSYS stores assay
values for viscosity at 50ºC and 100ºC, so all blending and de-blending
calculations are done using liquid volumes at these temperatures.

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1-44 Physical Property Methods and

CRACKING FACTOR
The Cracking Factor parameter sets a global cracking factor correction,
for the current synthesis, though this is not normally recommended. If
you give a CRACKING FACTOR, the program uses the factor in all
calculations, to convert from D86 to TBP, and from TBP to D86. The
default of 0.0 means that no correction is made for cracking. A value of
1.0 means that the full cracking correction is performed, as given in the
API data handbook. Do not give a value outside the range 0.0 through
1.0.

COLD PROPERTIES MAXIMUM CUT WIDTH

The Cold Properties Maximum Cut Width parameter sets the
maximum cut width for overlapping cuts used in cloud point and pour
point syntheses. The default temperature range is 150.0°C. If an
overlapping cut width is outside the specified range, synthesis ignores
the cold property data and generates a warning message.

PEAK TEMPERATURE ON POUR POINT CURVE

The Peak Temperature on Pour Point Curve parameter gives the
temperature at which the pour point curve peaks. The default is
560.0°C.

POUR POINT CONVERGENCE TOLERANCE

The Pour Point Convergence Tolerance parameter sets the
temperature tolerance required for convergence on given pour point
values in the synthesis. The instruction does not apply to residue
streams. The default is 1.0°C.

POUR POINT TOLERANCE FOR RESIDUE STREAM

The Pour Point Tolerance for Residue Stream parameter sets the
temperature tolerance required to converge on the residue stream pour
point. The default is 2.0°C.

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 Refinery Oil Manager 1-45

USE POUR POINT OF RESIDUES

The Use Pour Point of Residues field indicates whether the synthesis is
to include the pour points for all residue streams. The No is selected by
default, which excludes residue pour points. However, in the final
section of the synthesis, the program always uses the widest residue
stream pour point to define the shape of the backend of the pour point
curve (beyond the peak).

USE POUR POINT OF STREAM WITH VISCOSITY AT 50C >

2000CST
This field determines whether the model is to include pour point data
for streams with high viscosities in the synthesis. The No is selected by
default, which excludes pour points for streams with viscosities greater
than 2000 cSt at 50.0°C.

CLOUD POINT CONVERGENCE TOLERANCE

The Cloud Point Convergence Tolerance parameter sets the
temperature tolerance required for convergence on given cloud point
values in the synthesis. The default is a tolerance of 1.0°C.

FIX ESTIMATE CLOUD POINT AT 600C

This option controls the addition of an extra fixed cloud point at 600°C
in the cloud point synthesis, provided there is not already a measured
or derived cloud point beyond 600°C. This fixed cloud point is based on
the highest measured or derived cloud point. By default the check box
is selected.

INITIAL FIXED CLOUD POINT AT 176.7C

The Initial Fixed Cloud Point at 176.7C parameter sets a fixed cloud
point at a boiling point of 176.7°C in the cloud point synthesis. This is
only used if a cloud point has not been given, the stream ABP is less
than 176.7°C, and a freeze point is not available. The default volume is -
69.4°C. For synthesis of FCC reactor products a value of -40oC is
recommended.

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1-46 Physical Property Methods and

USE CLOUD POINT OF RESIDUES

The Use Cloud Point of Residue option determines whether to include
residue stream data in cloud point synthesis. The default (unselected)
excludes residue streams cloud points.

TOP STREAM ABP FOR COLD/POUR CONVERSION

This parameter defines the average boiling point of a stream. For
streams with an ABP below the specified value, HYSYS converts cloud
point to pour point, and pour point to cloud point in the cold property
synthesis. The default is 500.0°C.

OCTANE CONVERGENCE TOLERANCE

The Octane Convergence Tolerance parameter gives the octane
tolerance required for convergence on given octane numbers. The
default is a tolerance of 0.01.

ALLOW SG INVERSION FOR HYDROCRACKER SYNTHESIS

ABOVE
The Allow SG Inversion for Hydrocracker Synthesis Above parameter
is used in conjunction with the synthesis of Hydrocracker reactor
product only. It gives the temperature above which the stream type
HYDROCRACKER instruction operates, allowing the SG curve
inversion. The default is 300.0°C.

USE SG OF RESIDUES
The Use SG Residues option indicates whether to include overlapping
residue stream data in the specific gravity synthesis. The default
(unselected) ignores overlapping residue stream SGs, and only the
contiguous residue stream SG is used in the synthesis.

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