11-5240 JS DelayedCoker Refresh

Jump Start: Delayed Coker Model in Aspen HYSYS
Petroleum Refining
A Brief Tutorial (and supplement to training and online documentation)
Caleigh Holden, Product Management, Aspen Technology, Inc.
2014 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-5240-0214
Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scope of this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Example Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Petroleum Assay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Properties Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Simulation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Setting up the Delayed Coker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Calibrating the Delayed Coker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting up the Fractionation Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Combined Feed Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CVb
Introduction
The new Delayed Coker model in Aspen HYSYS Petroleum Refining rigorously models the delayed coker unit in a refinery,
helping to optimize and debottleneck the process. This new feature allows users to:
Calibrate the simulation model to match the behavior of the unit in the refinery
Predict coke and liquid product yields in scenarios away from calibration point
Use the capabilities of Aspen HYSYS Petroleum Refining assay management to accurately characterize heavy crude
feed streams
This feature is a part of Aspen HYSYS Petroleum Refining, which allows users to seamlessly integrate with existing models
for Refinery simulation, making modeling easier and more accurate.
Scope of this Document

This document is intended as a getting started guide. It will cover the process of creating a delayed coking model,
including setting up a heavy crude feed with a petroleum assay, configuring a delayed coker unit operation, calibrating the
coker unit, and putting a recycle network together. It is not meant as a standalone reference document. We recommend
pairing this guide with a range of other resources, including:
AspenTech knowledgebase items, training, and sample models available in aspenONE Exchange
AspenTech Computer Based Training modules available from within Aspen HYSYS
AspenTech support website (support.aspentech.com)
AspenTech courseware available in on-line and in-person versions
AspenTech Business Consultants
Knowledge of Aspen HYSYS V8 is assumed for this guide. Aspen HYSYS V8.4 needs to be installed to access the
functionality. If you do not know how to build a flow sheet in Aspen HYSYS, you should first consult reference material on
this subject. We recommend the following:
Jump Start Guide: Getting Started with HYSYS V8
AspenTech support website (support.aspentech.com)
Aspen HYSYS training course
Computer Based Training Module: Getting Started with Aspen HYSYS
2014 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-52400214
Example Cases
An example Delayed Coking case ("DelayedCoker_RigorousColumn.hsc") is available in the Samples\Refining Cases
folder within Aspen HYSYS V8.4. This sample case can serve as a starting point for your modeling.
For this Jump Start Guide, we will be creating a similar model as the sample case mentioned above, but with a simple
component splitter in place of the rigorous column for the coker fractionator.
Petroleum Assay Setup

The first step in building any HYSYS flowsheet is setting up the Properties Environment. In this environment, the user
selects the components that will be used in the simulation and groups them into Component Lists. The user must also
select one or more Property Packages, which contain the thermodynamic properties and calculations used in the model.
The combination of a Component List and a Property Package is called a Fluid Package, and the user must define it
completely before they can move on to the Simulation Environment.
Properties Environment
When modeling a Delayed Coker in Aspen HYSYS, you are required to use a feed characterized with a petroleum assay.
Creating a petroleum assay will automatically set up the fluid package for you. First, we need to import the petroleum
assay into the properties environment using the Petroleum Assays button, as shown in Figure 1. When you open the
Assay Management tab, you can then find the New Assay button to the far right and select between these options, as
shown in Figure 2.
Figure 1. The Petroleum Assays button is the starting point for modeling a Delayed Coker in HYSYS
Figure 2. The New Assay Button allows you to select the source of the Assay used in the Delayed Coker model
In this example, we will import an existing assay file in .AFAM format, named VacuumResid, which contains assay data
from a typical vacuum column residual stream. This file can be found here:
http://www.aspentech.com/email/afam/VacuumResid.afam. After the file has been imported, you can verify stream
properties by checking the Input Assay and Conventional Results pages in the left hand Navigation Pane, as well as
viewing the distillation and property plots. When this input is complete, you can move on to the Simulation Environment.
Simulation Environment
The first step for setting up the Delayed Coker feed stream in the Simulation Environment is to add a Petroleum Feeder to
the flowsheet. The Feeder can be found in the Palette under the Refining tab, as shown in Figure 3. After the Feeder has
been added, it can be setup by double-clicking it. The Feed Assay should be set to the imported assay and the Product
Stream, which will be the initial input stream to the Delayed Coker and can be created within this page. In this case, it has
been named VR Feed, as seen in Figure 4.
Figure 3. Palette showing Petroleum Feeder among Refining units

Figure 4. Petroleum Feeder Setup, showing Feed Assay selection and Product Stream selection, in this case, VR Feed
After the Feeder has been setup, you can change the characteristics of this new stream. For the purposes of this guide, we
have set the temperature, pressure, and flow rate as shown in Figure 5.
Figure 5. Setup characteristics for Feeder output stream, which will become the initial Delayed Coker input
Setting up the Delayed Coker

After the feed stream has been set up, the Delayed Coker should be added to the flowsheet. It can be found in the Refining
tab of the Palette, as shown in Figure 6.
Figure 6. Delayed Coker model in the Refining tab of the Palette
After the Delayed Coker model is added to the flowsheet, it will need to be setup
starting with streams. In an actual refinery, there is usually a complicated recycle
scheme. For easier model convergence, we are going to first solve the reactor feeding
the vacuum column residue stream directly into the coker. In a later part of this jump
start guide, we will show you how to set up the recycle scheme. The output stream
from the Feeder, which we named VR Feed, should be connected to the Delayed
Coker as the Crude Feed to Heater. The Coker Drum Effluent can be created within
this window, and in this case well call it Coker Effluent. The Coker is then ready for
the basic Input setup, which we have done using the numbers shown in Figure 7.
Figure 7. Setup for the Delayed Coker, including connected streams and model characteristics
When all the input is complete, the Delayed Coker should converge. Within the model window under the Design tab, you
can find Product Yields, Product Properties, and Tuning Factors. It is important to note that during the initial setup of the
Delayed Coker, we are using default Tuning Factors which will later change when the model is calibrated. Under the Solver tab,
you can also see the Solver Settings. Users having convergence issues can increase the number of iterations or change
tolerance and step size to converge the model.
Calibrating the Delayed Coker

After the Delayed Coker has been solved, it is necessary to calibrate it. As mentioned previously, the model this far has
been solved using default factors which are not plant-specific. To calibrate the model, open the Calibrate tab within the
Delayed Coker window. The first page on the left will ask for specific cuts if its different from the value set by default. In
the second and third pages, the user should enter information about the composition of the light and heavy end cuts.
Example data is shown in Figures 8 and 9 below.
Figure 8. Example of light end calibration data for Aspen HYSYS Delayed Coker model
Figure 9. Example of heavy end calibration data for Aspen HYSYS Delayed Coker model
In addition to cuts and heavy and light end data, you also need to enter drum temperature and coke sulfur percentage.
When all of this data has been entered, the Calibrate button under the Calibration Targets ply will become available
and the system will be ready to calibrate, as shown in Figure 10. Once the calibration is successful, the option to Transfer
to Simulation will also become available. This step transfers the calibration results to the HYSYS model and the button
must be clicked before the data is transferred.
Figure 10. After all the calibration data has been entered into the model, the option to Calibrate the Delayed Coker will become available and
after a successful calibration, the Transfer to Simulation button will become available
Setting up the Fractionation Column

Once the calibration is complete and the tuning parameters are applied to the simulation, the Delayed Coker model needs
to be connected to a Fractionation Unit for product separation. In the actual process, the bottoms stream from this column
is the inlet into the Delayed Coker, so it is necessary to change the model accordingly after calibration. In this example, for
the sake of length, we will add a simple Fractionation Column. The model is available in the palette under the Column tab
as a Component Splitter, as shown in Figure 11.
Figure 11. The addition of the Fractionation Column, available as a Component Splitter under the Columns tab in the Palette
Once the Fractionation Column is added, the feed streams must be connected. The connection between the VR Feed and
the Delayed Coker must be broken, as both this stream and the Coker Effluent will be the inlet streams into the column. By
double-clicking the Fractionation Column, you can set the Inlet, create Overhead and Bottoms Outlets, and add an Energy
Stream (in this case, Q). At first, only the VR Feed should be connected to the column. The overhead outlet streams of
the column in this case, include the Fuel Gas, Liquefied Gases, Naphtha, and Gas Oils, while the bottoms outlet will be fed
to the coker, as shown in Figure 12.
Figure 12. Streams being connected to the Fractionation Column, including the VR Feed, overhead outlets, and bottoms outlet
After all the streams have been connected, more data needs to be entered for the column to solve. The temperature and
pressure of the overhead streams need to be determined in the Parameters ply, and the cut points for the product
streams must be added in the TBP Cut Point ply. At the end of this process, the column should converge.
Connect the bottoms outlet of the fractionation unit to the Delayed Coker as the feed. The model should converge. The
Coker Effluent stream is essentially a recycle stream and will be treated as one in this case. The converged reactor set
up in the previous steps is a good starting point for the recycle calculations, and will help converge the final solution
quickly. Therefore, before connecting it to the Fractionation Column, we will add a Recycle block, which can be found
under the Common tab in the Palette, as shown in Figure 13.
Figure 13. Location of the Recycle block in the Palette
The Coker Effluent stream should then be connected to the Recycle block and a new stream, which weve called
Coker Product stream, should be created as the Recycle outlet. After the recycle is set up, the "Coker Product" stream
can be connected to the Fractionation Unit, and the full model should solve. The final flowsheet should look like the one
in Figure 14.
Figure 14. Completed flowsheet for a delayed coking processCombined Feed Ratio
Combined Feed Ratio

The combined feed ratio (CFR), also known as recycle ratio, is the ratio of the flow into the coker furnace to the total
Vacuum Resid feed to the entire unit. In the above flowsheet, this is the ratio of the Bottoms to Coker stream to the VR
Feed stream. In a typical refinery, this number will be greater than 1 because the heavier portion of the coker product
comes out of the bottom of the column with the fresh feed.
In the Aspen HYSYS Delayed Coker model, the user is required to enter this value into the input page. When calibrating
the model, this value is used for product flowrate calculations and for property calculations. For simulation, however, this
value is only used for property prediction and does not affect the flowrates of streams in the Aspen HYSYS flowsheet. For
the most accurate model, the CFR should be consistent with the flowrates in the Aspen HYSYS flowsheet, but it is not a
requirement for the model to solve.
10
Additional Resources
Public Website:
www.aspentech.com/products/aspen-refsys-delayed-coker.aspx
Aspen Online Training:

www.aspentech.com/products/aspen-online-training
On-demand Short Presentation:

Intro to HYSYS Petroleum Refining V8.4
www.brainshark.com/aspentech1/reactors-assays-v84
Jump Start Tutorial Series:

Jump Start: Aspen HYSYS V8.0
www.aspentech.com/JumpStart_HYSYSV8/
11
About AspenTech
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practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
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2014 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved.
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Jump Start: Delayed Coker Model in Aspen HYSYS

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Scope of this Document

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Petroleum Assay Setup

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Figure 3. Palette showing Petroleum Feeder among Refining units

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Setting up the Delayed Coker

Figure 6. Delayed Coker model in the Refining tab of the Palette

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Calibrating the Delayed Coker

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Setting up the Fractionation Column

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Figure 13. Location of the Recycle block in the Palette

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Combined Feed Ratio

Jump Start: Delayed Coker Model in Aspen HYSYS Petroleum Refining

Aspen Online Training:

On-demand Short Presentation:

Jump Start Tutorial Series:

For a complete list of offices, please visit

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