(192f) Full Furnace Simulation and Optimization with COILSIM1D

COILSIM1D is the result of more than 40 years of expertise of the Laboratory for Chemical Technology (LCT) in independent research and modeling of thermal cracking reactions. The kinetic model incorporated in COILSIM1D is the broadest and most accurate reaction network for steam cracking of hydrocarbons. The kinetic model has been recently updated and validated based on more than 1000 different pilot plant data points. Among others, the effect of typical oxygenated impurities can be accounted for.

COILSIM1D also comes with a fast feedstock reconstruction method that allows reconstructing the composition of naphtha’s, kerosenes, gasoils and vacuum gasoils based on their commercial indices. The combination of the feedstock reconstruction method with COILSIM1D allows to obtain accurate simulation results and provides a valuable tool to take optimal advantage of feedstock flexibility.

COILSIM1D incorporates a TLE simulation module that enables users to carry out simulations using different boundary conditions:

• Specific mass flow of water

• Specific steam quality

• Full thermosyphon simulation

A specific model for the deposition of condensation coke is implemented for the TLE next to the specific coke deposition models for gaseous and liquid feeds in the reactor section. This provides users with a very accurate tool for the estimation of run length based on their intrinsic fouling tendency.

In its latest release, several essential additions to COILSIM1D have been implemented. It now simulates both the radiant and convection sections of a cracking furnace, allowing users to estimate process parameters of interest:

• Flue gas temperature

• Utility steam production

COILSIM1D supports different tube bundle arrangements in the convection section and allows users to customize the fuel gas composition.

These new additions can further boost the profitability of steam crackers by maximizing yields and optimizing the process, using highly accurate furnace simulations for a broad range of feedstocks, reactor geometries and operating conditions. Results of an extensive evaluation of one of the largest olefin producers using real plant data will be shared to illustrate the performance of COILSIM1D.