Advanced Refinery Process Modeling Using Aspen HYSYS

Learn how to implement trim duty in an atmospheric distillation column using an energy stream to dynamically adjust reboiler duty and column operating conditions in Aspen HYSYS.

Model a vacuum distillation column fed from atmospheric residue, heated by a vacuum heater, with steam and pump around reflux, producing light and heavy vacuum gas oil under pressure profile.

Converge vacuum column by setting overhead rate, light and heavy vacuum gas oil rates, and a 2600 kg/h draw from vacuum overhead; resolve two liquid checks in the solver.

Implement a second bumper round in the vacuum column to handle heavy and light vacuum gas oil, adjusting flow rate and duty within side operation settings.

Model a fluidized catalytic cracking reactor using an Aspen HYSYS FCC template, defining the feed via petroleum assay, and configuring the riser, reactor, and regenerator in simulation.

Import vacuum gas oil as the FCC feed from the library, configure essay lumps, and set top and bottom cut points, then review feed properties before defining the catalyst.

Import the FCC catalyst from the library and Excel sheet, set 100% weight fraction for a single zeolite–alumina–rare earths catalyst, and configure constant equilibrium catalyst metals in Aspen HYSYS.

Set the FCC operation by defining feed flow, temperature, and pressure in the riser, specify steam and regenerator conditions, then review yields and heat balance.

Create a hydrocracker template in Aspen HYSYS, configure two reactors with two and three catalyst bits, add a high-pressure separator, and set calibration options for future integration.

Define a component list and the float package for the hydrocracker template. See how the hcr fluid package uses base components and abbreviations such as C6 to model feeds.

Identify and set hydrocracker feed conditions—volumetric flow, temperature, and pressure—and configure reactor feeds, recycle gas loops, purge, and product heater specifications for a steady simulation.

Learn to calibrate the hydrocracker in Aspen HYSYS using calibration factors, input operation measurements, feed data, and product specifications, and interpret calibration results from the worksheet and linked Excel sheet.

Set up calibration parameters and objective function for a hydrocracker in Aspen HYSYS, define bounds and initial values, run pre-calibration, review results, and save calibration factors for simulation.

Push calibration data into the hydrocracker simulation, activate the reactor solver, and review hydrocracking results and yields. Save the hydrocracker as a template and integrate it into a refinery model covering desalter, distillation, and heavy vacuum gas oil feed.