CDU

Optimize Your Operation With A Digital Twin of
Your Integrated CDU & Pre-heat Train Unit

Ankita Mangal & Ricardo Gutfraind
Today’s Presenters
Ankita Mangal
Senior Product Manager, Product Management
Ricardo Gutfraind
Director, R&D
© 2019 Aspen Technology, Inc. All rights reserved. 2

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optimizing asset performance in complex,
industrial environments.
May 13 – 15 ● Hilton America’s, Houston, TX
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▪ Business-focused technical training
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to the latest software. work simultaneously on the most current release and
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Aspen eLearning: Rigorous Exchanger Design and Rating (EDR)
Beginner to Advanced
Bite-sized On-demand
modules delivery
Process Engineering
and
Manufacturing and
Supply Chain
Learning paths Certifications CLICK HERE TO TRY

Agenda
Challenges of Operating CDU
Things to Consider When Operating CDU
AspenTech’s Solution
Analyze CDU Column
Analyze Crude Pre-heat Train
Integrated Solution: CDU + Pre-heat Train
Online Solution: Analyze Operation with Real-time Plant Data
Next Steps and Q&A

Challenges in Crude Distillation Unit
Crude Distillation Column

Crude pre-heat train


Variation in
crude mix


Variation in Fouling of heat High energy
crude mix exchangers consumption

Variation in
product quality

Flooding in
columns

Variation in
product quality

Flooding in
columns
Highly integrated unit requires simultaneous optimization

Things to Consider in CDU Operations

Change in
Petroleum
Properties

Heat Exchanger Cleaning

Sequence
Change in
Petroleum Exchanger fouling and Furnace efficiency
Properties efficiency reductions reduction

Variable
Product Purity

Sequence
Change in
Column
Flooding

Variable
Product Purity

Sequence
Change in
Column
Flooding
Pump Power and utilities management

Aspen HYSYS®: ONE Environment to Optimize CDU

High-Fidelity Assay
Management

High-Fidelity Assay Integrated Rigorous Heat Exchanger

Management & Fired Heater Models

High-Fidelity Assay Integrated Rigorous Heat Exchanger Visual Column

Management & Fired Heater Models Analysis

High-Fidelity Assay Integrated Rigorous Heat Exchanger Visual Column

Management & Fired Heater Models Analysis
Online Data Easy-to-Use Process Optimization & Fast Data Reconciliation

Connectivity Flowsheet Interface With Equation-Oriented Aspen HYSYS®

Assay Management in Aspen HYSYS
Lab Data

Assay Manager
Lab Data

Assay Manager Aspen HYSYS Petroleum Refining
Assay Library
Over 800 assays
Lab Data
Create assays directly on a HYSYS
stream
Two Characterization methods:

conventional and molecular

Conventional Characterization
Proven curve fitting technology
API, ASTM correlations
Proprietary enhancements and consistency checks

built in
Molecular Characterization
Based on 44,000+ representative molecules & their Predict properties for which measurements are
properties not available
*patent pending
Crude Oil distillation, API gravity etc. used to identify

optimal subset of molecules
Extrapolate properties with limited data

Hydraulic Visualization for Distillation
Visually depicts how close

your column is to its
operating limits –
maximizing throughput and
minimizing downtime
Avoid the Pain And Time Spent in Manually

Interpreting Complex Hydraulic Data

Rigorous Analysis of Heat Exchanger Operations
Shows fouling
levels for each HX
units –
reducing energy costs
Predicts potential
vibrational &
erosional issues –
minimizing downtime
Gain Full Visibility To Potential Operational Issues

With Rigorous Heat Exchanger Models Within Process Flowsheets
Software Demo
Analysis of Columns &

Heat Exchangers

Optimizing Fully Integrated Process Units
with equation oriented modeling
Aspen HYSYS offers

‘Equation Oriented’ Solver for
Crude Distillation Unit Model

Crude Distillation Unit in Sequential Modular Simulation
Recycle Blocks for Nested Loops
Adjust Blocks for Calibration
Optimization is a Challenge

Crude Distillation Unit in Sequential Modular Simulation
Setup is Straightforward
Solution Time can be prohibitive for

large data reconciliation models

Crude Distillation Unit in Equation Oriented Simulation
Nested Loops Solve Simultaneously
One Model for Calibration & Optimization
Optimization is Feasible

Solution Time is in Seconds
Significant Expertise to Setup

Solution Time is in Seconds
Significant
Objective:Expertise to Easy
Make Setup Setup

Software Demo
Analysis of Integrated
CDU + Preheat Train
Unit

Crude Distillation Unit Calibration using Data Reconciliation
170
150
130
110
90
70
50
30
0 20 40 60 80 100
280
260
240
220
20 Measured Qualities
5 Point D86 Distillation
200
0 20 40 60 80 100 for Naphtha, Kerosene,
350
330
Diesel, AGO
310
290
270
250
0 20 40 60 80 100
420
400
380
360
Calibrate 4 Column Efficiencies 340
Main Tower, Diesel, Kerosene, AGO Side Strippers 320

0 20 40 60 80 100
Crude Distillation Unit with Pre-Heat Train Optimization
Pump around streams
Naphtha
Kerosene
Optimize
Pump Around Flows
Condenser and preheat
temperatures
AGO
Diesel
Residue
Maximize Profit
Product Price – Feed cost – (Steam & Fuel cost)
KPI Dashboard Monitoring Solution
Online Operational
Guidance
• Easy to read real-time
operations dashboard
showing KPIs
• Review historical trends of
fouling

A Scalable Solution to Meet Your Requirement

1 Preheat train (simple heat exchangers)

1 Preheat train (simple heat exchangers)
2A Preheat train (rigorous heat exchangers &

fired heaters)

2B
Rigorous
column
1 Preheat train (simple heat exchangers) model

fired heaters)

3 Integrated plant-wide model in EO mode
2B
Rigorous
column
1 Preheat train (simple heat exchangers) model

fired heaters)

ONE Environment to Optimize CDU
Customer successes
Reduced project time Operational

with 30% faster optimization of
simulation using complex CDU with pre-
integrated Assay
Management heat trains
$4M USD/Year Maximize throughput to

saved from VDU-pre-heat CDU as crude mix
train fouling monitoring varies
$ 8.9MM saved
from better optimization 40% increase in column
of crude distillation unit capacity with column
analysis in Aspen HYSYS®

Webinar Summary
▪ Aspen HYSYS enables rigorous simulation of columns, heat
exchangers as well as the integrated CDU complex.
▪ Refineries stand to gain considerable benefits from improved

operations using
– an integrated CDU & preheat train simulation solution.
– individual unit monitoring solutions for distillation columns and heat
exchanger networks
▪ We have training materials available in Aspen Technology

customer support site that can help you develop simulation
models for your CDU.

Next Steps to Get Started
Click on the below links for step by step guidelines on

How can you get started?
1. How to Build a CDU Model in Aspen HYSYS
2. How to Evaluate Effects of Crude Change on CDU
3. How to Optimize CDU using an integrated CDU Preheat Train Model
4. How to calibrate engineering models with plant measurements
and many more helpful resources are available at our customer support site.
Want to learn more about Visit our website at: https://home.aspentech.com/

AspenTech Solutions? Customer Support site at: https://esupport.aspentech.com
Need help? Contact your Aspen Technology representative.

Promo Code*: CDU10
Additional Training Available
Modeling Heat Exchangers Using the
Model and Troubleshoot Refinery
Exchanger Design and Rating
Operations using Aspen HYSYS® (EHY102)
Suite(EHX1100)
Learning Outcomes: Learning Outcomes:
▪ Build, navigate and optimize steady state simulation models using ▪ Improve awareness about simulation tools under EDR to solve real
Aspen HYSYS and Aspen HYSYS Petroleum Refining process problems.
▪ Characterize crude feed assays and track key petroleum ▪ Explore the basic geometric inputs to simulate heat exchanger.
properties.
▪ Recognize the features and functional capability of the EDR to
▪ Perform case studies to analyze heat transfer equipment, model different types of heat exchangers
columns and maximize throughput.
Duration = 3 Day | Level = Basic Duration = 3 Days | Level = Basic

*10% training price discount valid till March 31, 2019.
Q&A
Email:
• Ankita.Mangal@aspentech.com
• Ricardo.Guitfrand@aspentech.com

Thank You

CDU

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Optimize Your Operation With A Digital Twin of

Your Integrated CDU & Pre-heat Train Unit

© 2019 Aspen Technology, Inc. All rights reserved. 2

OPTIMIZE 2019 is the premier conference on

▪ Business-focused technical training

See how top companies around the world are driving

© 2019 Aspen Technology, Inc. All rights reserved. 3

PRODUCTIVE COLLABORATIVE ALWAYS CURRENT

© 2019 Aspen Technology, Inc. All rights reserved. 4

© 2019 Aspen Technology, Inc. All rights reserved. 5

Challenges of Operating CDU

Things to Consider When Operating CDU

Analyze CDU Column

Analyze Crude Pre-heat Train

Integrated Solution: CDU + Pre-heat Train

Online Solution: Analyze Operation with Real-time Plant Data

Next Steps and Q&A

© 2019 Aspen Technology, Inc. All rights reserved. 6

Crude Distillation Column

© 2019 Aspen Technology, Inc. All rights reserved. 7

Crude Distillation Column

Crude pre-heat train

© 2019 Aspen Technology, Inc. All rights reserved. 8

Crude Distillation Column

Crude pre-heat train

© 2019 Aspen Technology, Inc. All rights reserved. 9

Crude Distillation Column

Crude pre-heat train

© 2019 Aspen Technology, Inc. All rights reserved. 10

Crude Distillation Column

Crude pre-heat train

Highly integrated unit requires simultaneous optimization

© 2019 Aspen Technology, Inc. All rights reserved. 11

Crude Distillation Column

Crude pre-heat train

© 2019 Aspen Technology, Inc. All rights reserved. 12

Heat Exchanger Cleaning

Crude Distillation Column

Crude pre-heat train

© 2019 Aspen Technology, Inc. All rights reserved. 13

Crude Distillation Column

© 2019 Aspen Technology, Inc. All rights reserved. 14

Crude Distillation Column

Pump Power and utilities management

© 2019 Aspen Technology, Inc. All rights reserved. 15

© 2019 Aspen Technology, Inc. All rights reserved. 16

© 2019 Aspen Technology, Inc. All rights reserved. 17

High-Fidelity Assay Integrated Rigorous Heat Exchanger

© 2019 Aspen Technology, Inc. All rights reserved. 18

High-Fidelity Assay Integrated Rigorous Heat Exchanger Visual Column

© 2019 Aspen Technology, Inc. All rights reserved. 19

High-Fidelity Assay Integrated Rigorous Heat Exchanger Visual Column

Online Data Easy-to-Use Process Optimization & Fast Data Reconciliation

© 2019 Aspen Technology, Inc. All rights reserved. 20

© 2019 Aspen Technology, Inc. All rights reserved. 21

© 2019 Aspen Technology, Inc. All rights reserved. 22

Assay Manager Aspen HYSYS Petroleum Refining

Two Characterization methods:

© 2019 Aspen Technology, Inc. All rights reserved. 23

Proven curve fitting technology

API, ASTM correlations

Proprietary enhancements and consistency checks

Crude Oil distillation, API gravity etc. used to identify

Extrapolate properties with limited data