Blending atmospheric distillation unit

Jet fuels are typically prepared from either straight-run kerosene or from wide-cut kerosene/naphtha blends off of the atmospheric distillation unit. TABLE 3-10 briefly describes the composition of some typical jet fuel grades. 

The fractions obtained by vacuum distillation of the reduced crude (atmospheric residuum) from an atmospheric distillation unit depend on whether or not the unit is designed to produce lubricating or vacuum gas oils. In the former case, the fractions include (1) heavy gas oil, which is an overhead product and is used as catalytic cracking stock or, after suitable treatment, a light lubricating oil (2) lubricating oil (usually three fractions—light, intermediate, and heavy), which is obtained as a side-stream product and (3) asphalt (or residuum), which is the nonvolatile product and may be used directly as, or to produce, asphalt, and which may also be blended with gas oils to produce a heavy fuel oil. 

The next step in building the set of hypothetical components is creating a blend. A blend represents a combination of two or more assays on a weight or volume basis. The combined blend is the input to the hypothetical component generator in Aspen HYSYS. For the purposes of this simulation, we use the data from the representative atmospheric distillation unit of Section 2.7. We can use the blend... 

Atmospheric residue oil (Residue), containing compounds that boil above about 340°C (650°F). This is normally sent to a vacuum distillation unit to recover more light products, but parts of it may be blended into high sulfur fuels such as heating oil or bunker fuel (marine fuel). 

The vacuum distillation unit cuts deeper into the atmospheric topped bitumen. It distills off the remaining light gas oil and heavy gas oil that are sent directly to hydrotreaters. The remaining vacuum topped bitumen can be blended with atmospheric topped bitumen and then sent to bitumen conversion units. 

Jet fuel is kerosene-based aviation fuel. It is medium distillate used for aviation turbine power units and usually has the same distillation characteristics and flash point as kerosene. Jet fuels are manufactured predominately from straight-run kerosene or kerosene-naphtha blends in the case of wide cut fuels that are produced from the atmospheric distillation of crude oil. Jet fuels are similar in gross composition, with many of the differences in them attributable to additives designed to control some fuel parameters such as freeze and pour point characteristics. For example, the chromatogram (Figure 27.4) of a commercial jet fuel (Jet A) is dominated by GC-resolved n-alkanes in a narrow range of n-C-j to n-Cig with maximum being around n-Ci. The UCM is well dehned. 

The teed to the cat cracker in a typical refinery is a blend of gas oils from such operating units as the crude, vacuum, solvent deasphalting, and coker. Some refiners purchase outside FCC feedstocks to keep the FCC feed rate maximized. Other refiners process atmospheric or vacuum residue in their cat crackers. In recent years, the trend has been toward heavier gas oils and residue. Residue is most commonly defined as the fraction of feed that boils above 1,050°F (565 C). Each FCC feed stream has different distillation characteristics. 

The catalytic cracking unit is often referred to as the gasoline workhorse of a refining unit. As shown in Fig. 18.9, feeds to the catalytic cracking unit are gas oils from the atmospheric and vacuum distillation columns and delayed coker. These heavier fractions also carry metals such as nickel, vanadium, and iron. More important, sulfur compounds concentrate in the heavier product fractions. Table 18.8 lists a typical mass balance for sulfur.25 FCC blend-stocks comprise 36 percent of the volume of the gasoline pool. However, this stream also contributes 98 percent of the sulfur concentration to blended procucts.25 As specifications on sulfur concentrations in diesel and gasoline tighten, more efforts are focused on how feeds and product streams from the FCC are pre- and posttreated for sulfur concentrations. 

The DCC has two reactor operating modes DCC-I (Riser-plus fluidized dense-bed reactor, maximum propylene mode) and DCC-II (Riser reactor, maximum iso-olefins mode). The DCC can process different heavy feeds— VGO, DAO, coker gasoil, atmospheric residue, VR, etc. Paraffinic feedstocks are the best feeds for DCC. In DCC maximum propylene operation mode, over 20 wt% propylene yield can be obtained from paraffinic feedstocks. The naphtha and middle distillates streams from the DCC unit can be used as blending components for high-octane, commercial gasoline and fuel oil, respectively. 

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