Introduction to Mid-Conversion and Deep-Conversion Units Modeling for Refineries using the Symmetry Process Simulation Platform - Remote Instructor Led Series (RILS)

Session 1 – Feed Characterization and Distillation

• Thermodynamic environment set up
• Pseudo-components and PIONA slate set up
• Property calculations methods selection
• Crude Oil characterization “Direct” vs “Cut Yields” methodology
• Preheat train and rigorous furnace modeling
• Distillation tower: Complex rigorous towers including pump-arounds and side strippers
• Simplified Distillation separation based on molecular structure

This session will focus on Fluid Characterization of whole crudes using a molecular structure (PIONA) approach, looking at efficient workflows to create complete slate of components to address separation and reactive processes. Characterization options based on available laboratory analysis are introduced with focus on consistent result across multiple users. Rigorous Distillation separation for crude oil for complex towers and simplified approach based on molecular structure for realistic separation and product property matching are investigated.  

Session 2 – Crude blending Studies

• Multiple crude characterization on single component slate
• Automated adjust of feed properties set up
• Blended product property constraints
• Optimization study set up for crude blending, including simplified economic inputs

This session will focus on Fluid Characterization of various whole crudes using a molecular structure (PIONA) approach looking at efficient workflows to create complete slate of components to address separation and reactive processes. Characterization options based on available laboratory analysis are introduced with multiple crudes characterized on to a single component slate. Blending analysis based on final crude properties and downstream imposed constraints using automated calculations on top of the flowsheet is included. An optimization study using built in optimizer capabilities for best economic performance is shown during the session. 

Session 3 – Intermediate Product Characterization and Hydrotreating (HT+HCC part 1)

• Intermediate product characterization (Heavy Vacuum GasOil) 
• Hydrotreater configuration and catalyst, including multiple beds, service time and intermediate H₂ feed
• Molecular structure reactive engine and reactor tuning introduction 
• Hydrotreater product and profile analysis  
• Reactive unit regression for tuning set up 

This session addresses the modeling of intermediate refinery product characterization based on molecular structure and Hydrotreating process to remove sulfur and nitrogen. Rigorous modeling of the Hydrotreater reactor including multiple bed configuration, catalytic components and H₂ consumption are carried out, with specific attention at product properties and reactive beds variable profiles for validation. It also includes reactive base molecular structure kinetic engine review and tuning of reactive pathways to match product distribution, properties and process profiles, ending up with a regression tool set up for automated fine tuning of the model.

Session 4 – Hydrocracker (HT+HCC part 2)

• Heavy recycle stream property estimation.
• Accounting for process piping
• Hydrocracker configuration, mechanical details and by-functional catalyst set up in Symmetry 
• Molecular Structure based reactivity tuning strategies 
• Prediction reactive effluent characteristics based on final product data 
• H₂ and Unconverted Gas Oil recycle - closing the loop 

The session builds upon the Hydrotreating session adding a Hydrocracker process for converting the feedstock into valuable final products. The sessions focus on Hydrocracker unit operation configuration and catalyst functionality set up, with further analysis of tuning strategies of reactive units based on the molecular structure kinetic engine. Modeling of process pipes to account for facilities configuration is included. Strategies to predict effluent from reactive units for efficient modeling are explored. Finally, closing process loops with Unconverted Gas Oil recycle to the process and H₂ excess usage is investigated.

Session 5 – Fluid Catalytic Cracking (RFCC)

• Molecular characterization of heavy feeds (Vacuum GasOil and Vacuum Residue) and blending 
• Fluid Catalytic cracking configuration and set-up
• Molecular based reactions and tuning, with “Recommended regression” feature  
• Molecular based simplified distillation
• Automatic adjust of flowsheet variables (controller) and flowsheet convergence considerations
• Case study and trend analysis
• Molecular Reduced Order Model (ROM) introduction, with integrated ML models inside unit operations  

This session is dedicated to Fluid Catalytic Cracking modelling, with a rigorous reactive unit including process and utility considerations and dependency - a representation of mechanical unit configuration, including regenerator to obtain a representative model. Feed characterization of heavy fractions in a single component slate and blending for the unit feed are explained. Molecular based simplified distillation is set to represent a complex separation system with automatically controlled flowsheet variables to capture recycle and unit behavior are presented during the session. Case Study utility tool is presented to analyze trends and behaviors. Molecular Reduced Order Model (ROM) technology is introduced for faster solution time models. 

Session 6 – Delayed Coker (DC) and Advanced Modeling Techniques

• Heavy Feed characterization and property estimation 
• Flowsheet (recycle point selection) strategies 
• Preheating cracking furnace model alternatives with Vis-breaker unit operation 
• Delayed Coking Vessel specifications  
• Rigorous fractionation column modeling and initialization 
• Flowsheet convergence - Recycle solution ordering
• Reactor tuning and model regression 
• Molecular Reduced Order Model (ROM) finalization with integrated ML models inside unit operations 

This session is designed for building a Delayed Coker unit, starting with heavy crude oil fraction characterization and property estimation based on molecular structure. Rigorous representation of Delayed Coking vessels and process are addressed together with the main fractionation column. Strategies around recycle point set up, selection and ordering are explored with analysis on the impact on model solution time and robustness. It also includes the learning of reactive base molecular structure kinetic engine and tuning of reactive pathways to match product distribution and properties, ending up with a regression tool set up for automated fine tuning. Molecular Reduced Order Model (ROM) technology is reviewed for faster solution time models.