The energy and exergy analysis of FCCU of Kaduna Refining and Petrochemical Company (KRPC) Nigeria is presented. The primary objectives of this work were to analyze the system components separately and to identify and quantify the sites having largest energy and exergy losses. The performance of the plant was estimated by a component wise simulation using Aspen Hysys software and a detailed break-up of energy and exergy losses for the considered plant has been presented. The ideal work was calculated to be (-74.169 MW) which characterized the system as work producing. Energy losses mainly occurred in the fractionator column where 46.6MW is lost to the environment while only 3.69, 1.77 and 0.68 MW was lost from the condensers, other equipment and absorbers respectively. The percentage exergy and second law efficiencies of the system was found to be 61.20 and 24.77 %.
Steady state and dynamic modelling and simulation of catalytic reforming unit of Kaduna Refining & Petrochemical Company, NNPC (Nigeria) was carried to find out the behaviour of the reactions under both steady and unsteady state conditions. The basic model together with kinetic and thermodynamic parameters and properties were taken from the literature but is developed in gPROMs (an equation oriented modelling software) model building platform for the first time rather than in MATLAB or other modelling platform used by other researchers in the past. The simulation was performed using gPROMs and the predictions were validated against those available in the literature. The validated model was then used to monitor the behaviour of the temperature, concentrations of paraffins, naphthenes and aromatics with respect to both time and height of the reactor of the industrial refinery of Nigeria. Hydrogen yield, Research octane number (RON) and temperature profiles are also reported. The components behave similarly in terms of reactions in the reactors but the time to attain quasi-steady state is different. The results are in good agreement with the industrial plant data.
A detailed steady-state catalytic-reforming unit (CRU) reactor process model is simulated in this work, and for the first time, different compressibility Z factor correlations have been applied using gPROMS software. The CRU has been modeled and simulated with the assumption that the gas phase behaves like an ideal gas. This is assumed for the four reactors in series and for different conditions of hydrogen-hydrocarbon ratio (HHR), operating temperature, and pressure. The results show that the Z factor varies at every point along the height of the reactors depending on reaction operating pressure, temperature, and HHR ratio. It also shows that the magnitude of deviation from ideal gas behaviour can be measured over the reactor height. The Z factor correlation of Mahmoud (J Energy Resour Technol Trans ASME 136:012903, 2014) is found to be suitable for predicting the Z factor distribution in the reactors. Keywords Catalytic reforming unit • Hydrogen-Hydrocarbon ratio • Compressibility factor • Naphtha • Fluid bed reactor Abbreviations a, b, c Parameters from hydrogen reaction rate equation P Paraffins N Naphthenes A Aromatics A, B, C, D Constants for calculating heat capacities Aa, Bb, Cc, Dd, Ee Constants for calculating research octane number (RON) A 10 Aromatics having ten atoms of carbon N 10 Naphthenes having ten atoms of carbon P 10 Paraffins having ten atoms of carbon Cp Heat capacity (kJ/kmol k) d p Particle diameter (m) E A Activation energy (kJ/kmol)
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