DC SIM+User+Guide

DC-SIM

User Guide

KBC Advanced Technologies, LLC

Ownership of KBC Intellectual Property Rights Software KBC Advanced Technologies plc (“KBC”) is the owner of and has vested in it the copyright and all other intellectual property rights of a similar nature relating to its software, which includes, but is not limited to, KBC’s computer programs, user manuals and all associated documentation, whether in printed or electronic form (the “Software”), which is supplied by KBC or its subsidiaries to their respective customers. No copying or reproduction of the Software shall be permitted without the prior written consent of KBC, save to the extent permitted by law. Portions of this product are based on HYSYS technology ©1998 - 2002 Hyprotech Company. Trademarks

Profimatics™, Petro-SIM™, DC-SIM™, REF-SIM™, HCR-SIM™, VGOHTR-SIM™, RHDS-SIM™, DHTR-SIM™ and FCC-SIM™ are trademarks (“KBC Trademark”) of KBC Advanced Technologies,plc, all rights reserved. The Licensee undertakes not to alter, obscure, remove, conceal, or otherwise interfere with KBC Trademarks or any indications of the source of the Software which may be placed on the Software or its packaging or any part thereof, or use, permit any party to use or authorize the use in any way whatsoever of trademarks that are similar or that may be confused with KBC Trademarks. Microsoft Office, Microsoft Windows, Windows XP, Excel and Visual Basic are registered trademarks of Microsoft Corporation. SentinelPro is a trademark of Rainbow Technologies, Inc. All other company names, products or name brands are trademarks of their respective holders. Use The Licensee shall follow all instructions given to it by KBC from time to time in relation to the use of copyright, the KBC Trademarks, and all similar property rights in the Software. All rights in respect of KBC's Trademarks and all rights in respect of the copyright of the Software are reserved.

© Copyright KBC Advanced Technologies plc 2005. All rights reserved.

Registered Office:

KBC Process Technology Plc. KBC House

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Website www.kbcat.com

DC-SIM User Guide KBC Proprietary Contents • i

Contents Introducing DC-SIM 1-1

Overview................................................................................................................................ 1-2 What’s New in This Release .................................................................................................. 1-3

Optimizer Improvements ......................................................................................... 1-3 New Tuning Factor for Furnace Cracking Temperature.......................................... 1-3 Fractionator Configuration for Extra Low Recycle Operation ................................ 1-4 Predicting Viscosity and Flash Point Product Properties......................................... 1-4 Adjustment of Coker Feed Back End Distillation ................................................... 1-4 Special Once Through Coker Configuration with No HCGO Net Product ............. 1-5 PSV Steam Input to Fractionator ............................................................................. 1-5 Calibration Factors for PONA of Naphtha Range Product ...................................... 1-5 Conversion of Old DC-SIM Workbook to Current Version Workbook.................. 1-5 Inter-conversion of Units of Measurement for Data File During IMPORT............. 1-5 Program Security ..................................................................................................... 1-5 Excel Interface Standardization ............................................................................... 1-6

Delayed Coker Refinery Unit................................................................................................. 1-7 Technical Help and Feedback ................................................................................................ 1-9

A Guide to Problem Solving.................................................................................... 1-9 Help and Error Messages......................................................................................... 1-9 Feedback.................................................................................................................. 1-9

DC-SIM Data Requirements 2-1 How DC-SIM Works ............................................................................................................. 2-3 Test Run Data for Model Calibration..................................................................................... 2-4 Drum Dimension Input Data.................................................................................................. 2-5 Calibration Input Data............................................................................................................ 2-7 How the Calibration Case Works......................................................................................... 2-11

Calibration Case Checklist..................................................................................... 2-12 Configuration Guidelines..................................................................................................... 2-13

Zero Natural Recycle Configuration: Once Through............................................ 2-13 Definition of Combined Feed Ratio (CFR)............................................................ 2-17 Velocity Gas Oil .................................................................................................... 2-17

DC-SIM Calibration Guidelines .......................................................................................... 2-20 Predict Input Data ................................................................................................................ 2-22

Quench................................................................................................................... 2-22 Velocity Gas Oil .................................................................................................... 2-23

ii • Contents KBC Proprietary DC-SIM User Guide

Product Cutpoints Target ....................................................................................... 2-24 Coke Inventory ...................................................................................................... 2-24

How the Predict Case Works ............................................................................................... 2-26 Predict Case Checklist ........................................................................................... 2-26

Product Properties ................................................................................................................ 2-28 Sulfur ..................................................................................................................... 2-28 Nitrogen ................................................................................................................. 2-28 Aniline Point .......................................................................................................... 2-28 Naphtha RON and MON ....................................................................................... 2-28 Diesel Cloud Point, Pour Point and Flash Point .................................................... 2-28 Bromine Number ................................................................................................... 2-28 Naphtha PONA...................................................................................................... 2-29 Viscosity @ 50 C................................................................................................... 2-29 Other Properties ..................................................................................................... 2-29 Coke Volatile Matter (VCM)................................................................................. 2-29 Coke Ash Content .................................................................................................. 2-29 Coke HGI............................................................................................................... 2-29

How the Optimizer Works ................................................................................................... 2-30 Optimizer Run Checklist........................................................................................ 2-30

Installing DC-SIM 3-1 PC System Requirements ....................................................................................................... 3-2

Microsoft References ............................................................................................... 3-2 Installation.............................................................................................................................. 3-3

Program Security ..................................................................................................... 3-3 DC-SIM Model Installation ..................................................................................... 3-3 What Is Installed ...................................................................................................... 3-4 Number and Decimal Regional Settings .................................................................. 3-4

Starting the Program .............................................................................................................. 3-7 Opening DC-SIM with the Start Bar........................................................................ 3-7 Starting with the Data Workbook ............................................................................ 3-7 Setting up a Shortcut................................................................................................ 3-8 Starting DC-SIM...................................................................................................... 3-8 Security Settings and Macros................................................................................... 3-9 Testing the Program Execution.............................................................................. 3-10 Problems When Running the Application.............................................................. 3-11

Using the Spreadsheet Interface 4-1 Microsoft Excel...................................................................................................................... 4-3

Data Flow................................................................................................................. 4-3 Gateway Workbook ............................................................................................................... 4-4 Model Workbook and Model Workbook Template ............................................................... 4-5 Getting Started ....................................................................................................................... 4-6

Available Models ..................................................................................................... 4-6 Proceed Button......................................................................................................... 4-6 Cancel Button .......................................................................................................... 4-7

Customizing the Workbook ................................................................................................... 4-8 Model Workbook ................................................................................................................... 4-9

DC-SIM User Guide KBC Proprietary Contents • iii

Grouping Feature ..................................................................................................... 4-9 Comments.............................................................................................................. 4-10 DC-SIM Menu....................................................................................................... 4-11 DC-SIM Options Item ........................................................................................... 4-11 Navigation Item ..................................................................................................... 4-12 Run Item ................................................................................................................ 4-12 Copy Case Data Item ............................................................................................. 4-13 Clear Case Data Item ............................................................................................. 4-13 Text Files Item....................................................................................................... 4-13 Available Results Item........................................................................................... 4-14 Import Case Data Item........................................................................................... 4-14 Export Case Data Item........................................................................................... 4-14 Transfer Workbook Data ....................................................................................... 4-15 Import from Petro-Sim .......................................................................................... 4-15 Export Calibration to Petro-Sim ............................................................................ 4-15 Links ...................................................................................................................... 4-15

Design Worksheet ................................................................................................................ 4-16 Calibration Input Worksheet ................................................................................................ 4-18

Run Button............................................................................................................. 4-18 Import Button ........................................................................................................ 4-19 Copy Button........................................................................................................... 4-20 Clear Button........................................................................................................... 4-21

Predict Input Worksheet....................................................................................................... 4-23 Run Button............................................................................................................. 4-24 Setup Button .......................................................................................................... 4-24 Copy Button........................................................................................................... 4-25 Import Button ........................................................................................................ 4-25 Clear Button........................................................................................................... 4-25

Optimizer Input Worksheet.................................................................................................. 4-26 Run Button............................................................................................................. 4-27 Setup Button .......................................................................................................... 4-27 VGen: LP Vector Generation Tool ........................................................................ 4-28

Result Worksheets................................................................................................................ 4-29 Comparison Worksheet........................................................................................................ 4-31

CaseGen................................................................................................................. 4-31 Summary Worksheet............................................................................................................ 4-33 Charts ................................................................................................................................... 4-34

Charts Worksheet................................................................................................... 4-34 Charts - 2 Worksheet ............................................................................................. 4-37

Worksheet Comments and Model Help ............................................................................... 4-38 Saving Files and DC-SIM Exit ............................................................................................ 4-39

Appendix A - Calibration Factors A-1 Initialization Factors ............................................................................................................. A-2 DCSIM V2006 Tuning Factors............................................................................................. A-3 DC-SIM V2006 Calibration Factors ..................................................................................... A-6

Index I-1

DC-SIM User Guide KBC Proprietary Introducing DC-SIM • 1 - 1

Introducing DC-SIM

Overview................................................................................................................................ 1-2 What’s New in This Release .................................................................................................. 1-3

Optimizer Improvements ......................................................................................... 1-3 New Tuning Factor for Furnace Cracking Temperature.......................................... 1-3 Fractionator Configuration for Extra Low Recycle Operation ................................ 1-4 Predicting Viscosity and Flash Point Product Properties......................................... 1-4 Adjustment of Coker Feed Back End Distillation ................................................... 1-4 Special Once Through Coker Configuration with No HCGO Net Product ............. 1-5 PSV Steam Input to Fractionator ............................................................................. 1-5 Calibration Factors for PONA of Naphtha Range Product ...................................... 1-5 Conversion of old DC-SIM Workbook to Current Version Workbook................... 1-5 Inter-conversion of Units of Measurement for Data File during IMPORT ............. 1-5 Program Security ..................................................................................................... 1-5 Excel Interface Standardization ............................................................................... 1-5

Delayed Coker Refinery Unit................................................................................................. 1-7 Technical Help and Feedback ................................................................................................ 1-9

A Guide to Problem Solving.................................................................................... 1-9 Help and Error Messages......................................................................................... 1-9 Feedback.................................................................................................................. 1-9

1 - 2 • Introducing DC-SIM KBC Proprietary DC-SIM User Guide

Overview This user guide is for the KBC Profimatics DC-SIM V2006 model for simulating delayed coker units. The guide has five chapters and one appendix.

Chapter 1 – Introducing DC-SIM Chapter 2 – DC-SIM Data Requirements Chapter 3 – Installing DC-SIM Chapter 4 – Using the Spreadsheet Interface Appendix A – Calibration Factors

It guides you through the mechanics of setting up and using the model on a personal computer.


What’s New in This Release These enhancements include:

• You can now specify either a maximization or minimization optimization run. The list of available dependent variables has been expanded.

• New furnace cracking temperature adjust factor to improve furnace cracking calculation during calibration.

• Fractionator Open Wash Zone option to allow simulation of extra low recycle (CFR < 1.05) operation.

• Add Flash Point and Viscosity (@ 50 ºC or 122 ºF) calculation for liquid products. The viscosity of furnace feed is also calculated when fresh feeds viscosities are specified.

• Automatic correction of feed distillation 90% and 99% points to avoid flat pseudocomponent profile on the back end.

• Special coker configuration for simulation of Once Through coker with HGO recycled to extinction.

• Input of PSV steam to the fractionator. • Calibration factors for PONA of naphtha range products. • Conversion of old DC-SIM workbook to current version

workbook. • Inter-conversion of units of measurement for data file during

IMPORT. • New KBC Profimatics security mechanism, which replaces the

old parallel port security dongle with either network or local License file/USB dongle combination.

• Standardization of model Excel interface with other KBC Profimatics SIM models.

Optimizer Improvements The capability to run the Optimizer for objective function minimization has now been added. Additional dependent yields variables are now available to use as objective function or constraints.

New Tuning Factor for Furnace Cracking Temperature During the DC-SIM calibration mode, the cracking temperature inside the furnace is set at 75% of the process fluid temperature rise. With the furnace outlet temperature fixed, the furnace inlet temperature is calculated by heat balance during the calibration convergence loops. The amount of cracking occurring in the furnace tube is based on this furnace cracking temperature.


NOTE: Even though the calibration may have converged, you are cautioned to review some of the calibration parameters to potential problems. Under some situations, the calibration data may result in too high a level of cracking in furnace.

The normal range of furnace cracking should be less the 25%. If the initial calibration results calculate too high a furnace cracking level, you can use this Furnace Cracking T Adjust Factor to shift the furnace cracking temperature to reduce the furnace cracking amount to a more acceptable level.

Fractionator Configuration for Extra Low Recycle Operation For operation at extra low recycle ratio operation (CFR < 1.05), setting HGO draw tray as either tray 4 (default) or tray 3, will likely result in column simulation failure. There is often insufficient liquid traffic in the wash zone trays. By specifying the HGO draw tray to be tray 2, the fractionator is configured as open wash zone, so that the column model will solve even at extra low recycle operation. For this configuration, feed 4 and feed 5 are no longer allowed as there are no intermediate wash zone trays for those feeds.

Predicting Viscosity and Flash Point Product Properties For liquid products, the viscosity (at 50 ºC or 122 ºF) and flash point properties are now calculated by the model using API procedures. If the fresh feeds viscosities are specified on the input sheets, the model will calculate the furnace feed viscosity, blending from fresh feeds and recycle streams. The furnace feed viscosity is required data for the Petro-SIM furnace model. If the gasoil range products have calibration flash point input specified, calibration factors will be calculated comparing the prediction from API procedure vs plant data. The API flash point procedure requires the product stream D86 10% point to be > 150 F.

Adjustment of Coker Feed Back End Distillation The lab measurement of coker feed distillation goes up to about 700 ºC (1300 ºF). This covers about 70% of the feed materials. DC-SIM requires entry of 7 distillation points including the 90% and 99% points. The backend distillation is normally extrapolated from the other distillation points. However, the extrapolated backend distillation, in conjunction with the feed gravity, may result in a flat pseudo-component profile tail. This could cause non-smooth responses in predict case parametric studies. The model now adjusts the 90% and 99% feed distillation points automatically when it came up with a flat pseudo-component profile tail.


Special Once Through Coker Configuration with No HCGO Net Product DC-SIM has been adapted to simulate a coker in Once Through mode but with normal HCGO range product recycled to extinction. This type of coker is constrained by the lack of downstream HCGO processing capability such as FCC unit. To simulate this operation, enter the HCGO yields as 0.0001 wt% in the calibration. The HCGO product quality information is provided in the calibration as this stream is still present in the unit as recycles.

PSV Steam Input to Fractionator In some coker units, PSV steam are present in the fractionator. Entry of this PSV steam to DC-SIM lets you study its impact on the tower vapor liquid equilibrium.

Calibration Factors for PONA of Naphtha Range Product On the Calibration Input worksheet, you can enter the plant test data for olefin, naphthenes, and aromatics vol% content in naphtha range products. The paraffins are calculated by difference. These factors allow better matching between calculated PONA values from correlations and the measured PONA data. In Predict cases, these calibration factors are applied to each of these naphtha components.

Conversion of Old DC-SIM Workbook to Current Version Workbook A new utility has been added to the DC-SIM Tool menu to let you read in an older version DC-SIM workbook which is automatically converted to the current version workbook format.

Inter-conversion of Units of Measurement for Data File During IMPORT During the IMPORT data file process, an option is now available to convert the data to a different set of units of measurement. This tool will help you evaluate data from different sources.

Program Security A new security system has been implemented. This system lets you attach a security key to your USB port, the parallel port, or network system. Contact KBC for details.

Excel Interface Standardization As part of the interface standardization effort for KBC Profimatics SIM models, some changes have been made to DC-SIM Excel interface. The


old Profdc.xls gateway file has been replaced with a SIM universal gateway DLL. While the appearances on some of the worksheets have been modified or improved, the basic functionalities are maintained.


Delayed Coker Refinery Unit Delayed coking is an established and widely used bottoms upgrading process. It uses severe thermal cracking in a low space velocity vessel in which the feedstock is allowed to soak at high temperature. The combination of time and temperature promotes thermal cracking reactions. A key design parameter of the delayed coking process is how to “delay” the formation of coke in the charge furnace and to concentrate the thermal reactions in the coke drum in such a way as to maximize liquid product conversion. The feed to delayed cokers is traditionally a vacuum residue, but petrochemical byproduct tars and catalytic cracker decanted or clarified oil can also be processed. Delayed coking rejects carbon from the residual oil leaving cracked products that are somewhat more enriched in hydrogen and significantly lower in average molecular weight. However, because the feedstock is highly hydrogen deficient to begin with, and some of that hydrogen is lost to H2S or gas, the raw coker liquid products tend to be olefinic and aromatic. Coker products are typically treated chemically to be stabilized or sent to hydroprocessing units to further increase the hydrogen content. Cokers are often built in conjunction with Fluid Catalytic Crackers (FCCUs), which are sized and designed to handle the converted coker products. Traditional delayed coke comes in at least two quality grades (anode or fuel), and several recognizable compositional forms (needle, sponge, or shot), each with a different end use, market value, physical property set, and handling requirements. The coke type is largely predetermined by the properties of the feedstock. For example, the coke produced by nonresidual stocks is more crystalline and less amorphous than typical vacuum resid feed coke. Coker operations have only a limited or marginal effect on what type of coke is produced. DC-SIM focuses on predicting the yield and property shifts from changes in process conditions and from changes in feedstock within a class of feeds. DC SIM is not designed to predict behavior of coke quality across different classes of feeds. However, it can directionally indicate where certain key properties, like sulfur, nitrogen and metals, are likely to go with an entirely different feedstock. DC-SIM is based on a standard representation of a typical fuel or anode grade delayed coker unit as shown in the following figure.



Technical Help and Feedback

A Guide to Problem Solving The SIM Series of models provides assistance in a variety of ways.

• This document includes information on the DC SIM V2006 model covering Excel interface topics, as well as specific DC-SIM model operation.

• Excel Comments on each worksheet provide valuable information on the cell in which they are located.

• Model help and error messages are reported in the DC SIM message log.

If you need additional assistance in using the process modeling software, please contact your KBC modeling specialist.

Help and Error Messages Help and error messages are available to provide guidance. The error messages are reported in the DCMSG.OUT file. To view these messages:

1. Select DC-SIM on the toolbar. 2. Click Text Files to open the View Text Files view. 3. Select Messages 4. Select OK to exit.

Error messages are numbered for easier identification, and provide hints on error cause or correction guidelines, where appropriate.

Feedback KBC Advanced Technologies, Inc. is constantly upgrading and enhancing its software. Your feedback is important to this process. You can contact KBC directly through your modeling specialist or local account representative. Alternately, you can contact KBC Profimatics Software Support (email: [email protected]) or through your regional office.


DC-SIM User Guide KBC Proprietary DC-SIM Data Requirements • 2 - 1

DC-SIM Data Requirements

How DC-SIM Works ............................................................................................................. 2-3 Test Run Data for Model Calibration..................................................................................... 2-4 Drum Dimension Input Data.................................................................................................. 2-5 Calibration Input Data............................................................................................................ 2-7 How the Calibration Case Works......................................................................................... 2-11

Calibration Case Checklist..................................................................................... 2-12 Configuration Guidelines..................................................................................................... 2-13

Zero Natural Recycle Configuration: Once Through............................................ 2-13 Calibration as a Once Through Unit........................................................ 2-13 Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit...................................................................... 2-15

Definition of Combined Feed Ratio (CFR)............................................................ 2-16 Conventional Recycle Coker ................................................................... 2-16 Once Through Coker ............................................................................... 2-16

Velocity Gas Oil .................................................................................................... 2-16 DC-SIM Calibration Guidelines .......................................................................................... 2-19 Predict Input Data ................................................................................................................ 2-21

Quench................................................................................................................... 2-21 Velocity Gas Oil .................................................................................................... 2-22 Product Cutpoints Target ....................................................................................... 2-22 Coke Inventory ...................................................................................................... 2-23

How the Predict Case Works ............................................................................................... 2-25 Predict Case Checklist ........................................................................................... 2-25

Product Properties ................................................................................................................ 2-26 Sulfur ..................................................................................................................... 2-26 Nitrogen ................................................................................................................. 2-26 Aniline Point.......................................................................................................... 2-26 Naphtha RON and MON ....................................................................................... 2-26 Diesel Cloud Point, Pour Point and Flash Point .................................................... 2-26 Bromine Number ................................................................................................... 2-26 Naphtha PONA...................................................................................................... 2-27 Viscosity @ 50 C................................................................................................... 2-27 Other Properties ..................................................................................................... 2-27 Coke Volatile Matter (VCM)................................................................................. 2-27

2 - 2 • DC-SIM Data Requirements KBC Proprietary DC-SIM User Guide

Coke Ash Content .................................................................................................. 2-27 Coke HGI............................................................................................................... 2-27

How the Optimizer Works ................................................................................................... 2-28 Optimizer Run Checklist........................................................................................ 2-28


How DC-SIM Works DC-SIM is a generalized kinetic model that is tuned to an actual unit to model its behavior. Following this tuning, or calibration, the model can be used to predict unit behavior. The model can also predict the specific optimum for a given unit. The three models, called modes, that DC-SIM runs are:

• Calibration mode • Predict mode • Optimization mode

The model is tuned by making a run in Calibration mode. In this run, plant data from a delayed coker unit test run is entered into the model. The model forces a fit between the theoretical model and the real-world unit, automatically calculating a series of parameters called Calibration factors. Kinetic rate constants for the key reactions of cracking and polymerization are calculated during the Calibration procedure. Once the model is calibrated, it can be run in Predict mode. This mode lets you predict model behavior. Calibration factors determined from the Calibration runs are used as inputs to Predict mode. For Predict runs, input the feed rates and qualities and unit operating conditions. You can vary any of a number of process variables, including:

• Feed rates (including adding a new feed or feeds) • Feed qualities • Combined feed ratio (furnace feed/fresh feed) • Furnace outlet temperature • Drum pressure • Product fractionation cut-points

Given these inputs, the model predicts how the unit will behave. Results include:

• Yields • Product properties • Drum fill time • Quench rates


Test Run Data for Model Calibration The suggested general procedure for gathering and organizing calibration data for a delayed coker is based on the following.

• The best interval of time for establishing a mass balance is one complete drum cycle. This is from drum swing to the next drum swing, normally a period of between twelve to twenty-four hours, depending on local operating procedures.

• The model is calibrated as a steady state operation taken at the mid-point of the drum cycle. The coke inventory is set to 50% of the final inventory or just 50% of maximum if the final outage is not available.

• The mass balance is closed around the fractionator tower and includes all residue feeds, light slops, external quenches, and the recovered products from these feeds. It should not include any internal slops, blowdown oils or quench which is taken from tower product streams. Any rich oils or commingled naphthas, light ends, or gases that pass through the coker tower overhead or gas plant should be backed out of the balance.

• The measured flows should be averaged and validated on a consistent basis.

• If the crude slate that generated the coker feed is known and laboratory data is incomplete or unavailable, residue feed distillations and properties can be generated using a Crude Assay Library tool such as KBC’s Crude Assay Management System (CAMS).

• Light ends and naphtha should be adjusted for C4- in naphtha and C5+ in butane. DC-SIM is calibrated using the mass flows of the gases, light ends and liquid product streams. If necessary, the lightest liquid stream gravity should be adjusted for the C4/C5 transfers. However, if the amount of C4- in the naphtha remains about the same in most operations, this C4- adjustment may be skipped. DC-SIM assumes the reported C4- yields do not include the amount included in the naphtha.

• Coke yield is calculated by DC-SIM as the difference between the sum of the feed weights and the sum of the product weights.


Drum Dimension Input Data DC-SIM processes certain drum dimensions so the coke inventory can be translated to an outage value.

The premises of the model are:

• Outage is measured from the top head flange. • The total volume of the drum includes:

• The bottom cone • The cylindrical portion • The top head volume to the flange. Drum outages are estimated subtracting out the top head volume and referencing coke level in the drum to the top tangent line (with appropriate offsets and adjustments).

• Coke inventory is tracked in the model in terms of percent of maximum volume where maximum volume is defined by the coke level at minimum outage. Knowing the volume of coke in inventory, the weight accumulation rate of new coke, the run time interval, and the density of the coke, it is possible to profile the accumulation of coke and the outage level through a drum cycle.

• The model assumes a uniform diameter over the entire vertical range of the drum cylinder (from top tangent line to bottom tangent line). The bottom cone area is represented as a “virtual” cylinder having the same diameter as the main drum and the actual volume of the cone area to the bottom head. This should be kept in mind when analyzing outage estimates in the first few percent of the drum cycle.

• Many cokers consist of multiple trains, or cells, made up of a furnace and drum pair running in parallel looping from and back to a single fractionator. In these cases we aggregate the drums into a conceptual drum made up of the individual drums stacked


on top of each other and a combined furnace. The drum diameter is kept the same as the physical diameter of the drums (which assumes they are all the same). This allows for outage and coke accumulation calculations, which are a simple multiple of the number of cells.


Calibration Input Data

c = Required; blank = optional Note: Input data will be shown as screen captures from the

actual model. The units shown are British/USA; you can select metric units on the Design worksheet. The operating conditions entered represent the average conditions in effect consistent with the material and property balance data.


c = Required; c* = Conditional on presence of stream selection on design

worksheet; blank = Optional

The coker unit product yields are entered as mass flow or weight percent.




The initialization factors can normally be left blank initially. The two Distribution Factors and the Converge Tolerance Initial Factors can be used during Calibration in accordance with “DC-SIM Calibration Guidelines” on page 2-19. Liquid Stream properties are shown below. Even though product sulfur, nitrogen and metals are not required input, that information is used to calculate their distribution in the Predict cases.






Economic prices and costs can be assigned for a net profit calculation. All economic entries are optional.


How the Calibration Case Works The general sequence of Calibration Case calculations is:

1. Feeds are identified and broken up into volatile oil pseudocomponents and a non-volatile back-end defined as the weight % concarbon residue.

2. The mass yield and gravity data are interpreted to establish the calibration basis for product streams. This sets the weight and volume targets against which the reaction equations are calibrated.

3. The liquid product TBP distillations are interpreted to calculate volume-weighted cutpoints. Distillation overlaps and offsets are calculated and stored as Calibration factors. The cutpoints are stored as Calibration references.

4. Sulfur and nitrogen are balanced based on distributions to gas, liquid products, and coke.

5. The fractionation tower is initialized to provide an initial estimate of the furnace feed composition.

6. The furnace, drum and quench operations are simulated and iterated until the weight yield of gas, liquid products, and coke is converged at the measured process conditions by manipulating the yield and distribution Calibration factors.

7. The fractionator tower is re-calculated with the equilibrium drum vapor to separate the heavy gas oil and lighter from the recycle. The furnace feed is recalculated and step 6 repeated until all sections are converged.

8. Having established the back-end of heavy gas oil in step 7, the front-end cutpoint is manipulated until the heavy gas oil weight is converged with the measured calibration weight within the rigorous fractionation procedure. The tower is resolved and all steps from step 6 are repeated.

9. The remaining tower liquid streams are distributed by weight using a simple column TBP procedure.

10. Each of the liquid stream volumes are adjusted to the measured target volume by adjusting the K-Factors of the pseudocomponents until both the weights and volumes agree. The K-Factor shift from feed to products is recalculated and the model resolved from step 6 again.

11. The converged model then compares estimated properties against the measured inputs and calculates property Calibration factors, or saves the Calibration gross property values as points of reference.


Calibration Case Checklist While calibrating the model, check the following:

1. Retrieve an existing Calibration Case to load into the Calibration Input Worksheet or enter the required data manually.

2. Check that the model configuration and static data on the Design Worksheet are correct and consistent with the Calibration Input Worksheet data.

3. Run the model using the Run button on the Calibration Input Worksheet or the DC-SIM menu.

4. If the model fails, an error message appears above the case that failed on the Calibration Result worksheet. You are prompted to go to the Message Log Report. The cause of the failure is listed at the bottom of the file and will provide information for you to correct the problem. After correcting, run the model again.

5. If the model runs successfully, then the Model Messages should be checked to ensure there are no abnormal warnings. The results will be loaded into the Calibration Result Worksheet.

6. View output files using the Text Files selection on the DC-SIM menu.

7. Review the Summary Worksheet to check Calibration Case data quality.

8. Review the Charts – 2 Worksheet to inspect the feed and product breakups and distillations.


Configuration Guidelines

Zero Natural Recycle Configuration: Once Through Conventional coker technology mixes the bubble tower bottom with fresh feeds to add recycle to the furnace. While this recycle helps the resid flow through furnace, it also contributes to additional coke yields. In recent years, a different coker configuration has been implemented at some refinery. The fresh feeds are no longer mixed with the tower bottom. Depending on the resid quality, distillates such LGO or HGO are mixed in just before furnace inlet to provide the dilution needed. To differentiate this zero natural recycle technology from the conventional recycle mode, this alternative is labeled as Once Through Configuration. Selection of the Once Through Configuration removes the fresh feeds from the tower bottom. The fresh feeds are sent directly to the furnace bypassing the fractionator bottom. In this configuration, there is no natural recycle where the feed is not picking up any recycle from the tower bottom tray. It is still feasible to send Distillate recycle by taking a tower product stream (such as LGO or HGO) and mixing that with the fresh feed just before furnace inlet using the Velocity Gas Oil slot. The Once Through Configuration can be applied in two types of situations:

• Calibration as a Once Through Unit • Prediction of Once Through Unit performance using a

calibrated Conventional Recycle Unit

Calibration as a Once Through Unit A standard Calibration run can be performed by specifying the Once Through option in the Configuration menu on the Design sheet.

In the Once Through configuration, only fresh feeds 1 to 3 are available as furnace feed. Feeds 4 and 5 are not applicable in this mode.


In addition to the product streams present in the conventional recycle coker, a sixth product, Flash Zone Gas Oil (FZGO), is produced from the tower bottom. For the Velocity Gas Oil option, it is also possible to use FZGO as part of the velocity gas oil. This can be done is two ways. FZGO (Flash Zone Gas Oil) used as velocity gas

OR Both HGO and FZGO mixed together to be used as velocity gas

Refer to Velocity Gas Oil for the flow rates of the new Velocity Gas Oil. When HGO + FZGO mixture is used, both Recycle Gas Oil Volume Rate and Recycle FZGO Oil Volume Rate are required (Calibration or Predict input worksheet rows 235 through 238.)


In DC-SIM V2006, a special Once Through configuration where there is no net HGO product streams can be simulated by setting the HGO yields to be .0001 wt% on the Calibration Input worksheet. The Converge Tolerance Initial Factor in row 291 should be specified as 0.005 or less in order to converge on the near zero yields target used for HGO. If the default kinetics can not converge on the yields profile you want, you can enable the special modified kinetics by setting the Cracking Rate Factor (row 458 of Calibration Input) to 1.01. Before running the model, you should also set the Once Through flag for the selected case. (Calibration Input worksheet row 490; Predict Input worksheet rows 345.)

Predict runs of the Once Through configuration can be done either as Primed Predict or Cold Predict.

Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit You can calibrate as a conventional recycle unit, and then switch to a Once Through configuration for Predict mode. This allows a conventional recycle coker to simulate coker performance, if the tower bottom is modified to separate the fresh feeds from the tower bottom liquids. To simulate the Once Through configuration, perform the calibration of the Conventional Recycle base case with Open Wash Zone configuration. As described above in the section about the new Open Wash Zone configuration, this allows simulation of extra low recycle operation. By setting the CFR to 1.001 in the Predict mode, the operation is now a Once Through operation. The yields, including coke yields, would now reflect what one would get in Once Through operation. There is one missing piece of information in this type of simulation. The program is going to predict a combined HGO and FZGO product stream since the configuration is kept as Conventional Recycle. You can use a flowsheet such as Petro-SIM to simulate the coker fractionator. By recombining the products predicted by DC-SIM into a column feed stream, you can get the individual product separation expected. Using this technique, the HGO and FZGO products can be obtained as separate product streams. By using the approach described above (i.e. running at CFR of 1.001), you can identify the benefits of converting from a conventional recycle unit to Once Through operation.

DC-SIM is not configured to perform conventional recycle Predict from the Once Through Calibrated case.


Definition of Combined Feed Ratio (CFR) Various definitions of combined feed ratio (CFR) are used by the model.

Conventional Recycle Coker Type Definition

CFR (Tower Bottoms Volume + Velocity Gas Oil) / Sum of Feeds 1 to 5.

CFR Natural (CFRN) Tower Bottoms Volume / Sum of Feeds 1 to 5.

CFR Distillate (CFRD) (Sum of Feeds 1 to 5 + Velocity Gas Oil) / Sum of Feeds 1 to 5.

Once Through Coker Type Definition

CFR (Sum of Feeds 1 to 3 + Velocity Gas Oil) / Sum of Feeds 1 to 3.

CFR Natural (CFRN) (Sum of Feeds 1 to 3 + FZGO recycle as Velocity Gas Oil) / Sum of Feeds 1 to 3.

CFR Distillate (CFRD) (Sum of Feeds 1 to 3 + Distillate Velocity Gas Oil (non-FZGO)) / Sum of Feeds 1 to 3.

Velocity Gas Oil Velocity gas oil is defined as a stream that is added to the furnace feed to increase the velocity in the furnace. This stream can be either external to the unit or a recycled oil within the coker system.

It is expected that where a fractionator stream is recycled for use as drum quench, that same stream will be used as furnace Velocity Gas Oil. Although you can configure the model to put, for instance, heavy coker gas oil into the drum overhead and light coker gas oil into the furnace feed, this configuration has not been validated and the results may be unreliable.

The velocity gas oil can be formulated with several schemes: 1. Flow Control

You can specify a fixed volume of velocity gas oil. For external feeds, the volume is entered as the feed rate for Feed Number 7 in the Feedstock section of the Input worksheet. For recycled feeds the volume is specified in the Operating Conditions section under Furnace as Recycle Gas Oil Volume Rate.

2. Ratio Control in Predict Cases At the bottom of the Furnace section on the Predict Input worksheet is a target entry that lets you specify a volume percentage of total furnace feed. If this is left blank, the model uses the flows specified above. If it contains a value, it overrides either the external Feed Number 7 rate or the recycle volume rate, whichever is active.


3. Ratio Control Defaults There is a complex system of defaults, allowing quick setup of Predict case studies and optimization runs. The scheme logic is shown below. This lets you set up a Calibration Case and go directly to a Predict case study without any additional set-up of inputs or controls on gas oil to furnace feed. When calibrating with either recycle or external gas oil to the furnace, the model saves the percent of total furnace feed (based on the CFR as defined above) as a Calibration Factor. If you go directly to a Predict Back case without any other inputs, the calibration volume will be passed through and used in the Predict series until it is changed. If you expect to change the fresh feed rate and want to maintain the furnace feed gas oil ratio, enter a zero (0) into the Predict Input “Recycle Gas Oil Volume Rate”. It will then follow the default logic and use the calibration ratio to set gas oil volume. You can change this ratio by putting any sensible number into the “% Furn Feed Target” cell. The model determines the mode of operation (external or recycle) from the selector list box on the design sheet.

A consequence of this scheme is that if you set recycle feed rate and the % target to zero, the model will default to the calibration ratio. There is no way to turn the recycled Velocity Gas Oil completely off with this scheme. External feed can be shut off by simply setting the Feed Number 7 rate to zero.

The default logic for setting Velocity Gas Oil rate and ratio is shown in the following diagram.


Create XKUP (108)= 100*VelGO/

(CFR*Feeds 1-5)

CalibrationCase?

Recycle On?

No Input?

Target > 0? Recycle On?

Set % Target =XKUP (108)

Set Recycle GOfrom Target

Use User Inputsfor Feed #7 orRecycle GO

Set Feed #7 fromTarget

Yes

No

Yes

Yes

Yes

Yes

No

No No

No

VelGO = Calibration Volume Rateof Gas Oil to Furnace Feed


DC-SIM Calibration Guidelines The following guidelines apply to typical delayed coker units. However for special feeds or unit operations, the guidelines may not all apply:

1. If the model does not solve: • Check all temperature and pressure profile numbers. • Check that the amount of quench is consistent with the

recycle rate (CFR). Too much quench relative to CFR can cause the wash zone to become infeasible.

• Check that the feed distillation is reasonable and that the K-Factor is consistent with the products. When the data is uncertain make sure that the feed 50% point is set to yield a K-Factor approximately equal to (or slightly greater than) the K-Factor of the heavy gas oil stream.

• The Converge Tolerance Initial Factor on row 291 of Calibration Input can be used to loosen or tighten the target convergence errors on the internal iteration loops.

2. When the model solves: • Check the H2S and NH3 yields on Calibration Result. If it

is off, use the Distribution Factors on Calibration Input rows 287-288 to adjust and re-run Calibration

• Check the Coking Calibration factor XKUP(03). It should be approximately 1.0. The normal range is 0.6 to 1.2. Values at the extremes of this range or outside of it indicate an unusual coking pattern relative to the ConCarbon of the feed. If the number is low, the input ConCarbon value of the feed may be high (relatively more coke from ConCarbon means that the coke from polymerization requirement to close the coke balance is less). If it is high, the ConCarbon may be low. Also, any error in recovered product yields shows up in coke yield and that, in turn, can impact this Calibration factor.

• Look at the Heat of Cracking Calibration factor XKUP(102). It should be approximately 15 to 25. Above that range indicates that the drum delta temperature is low for the amount of cracking going on in the drum. Low values indicate the opposite. This may create a problem in Predict runs.

• Check the overall cracking profile (found at the bottom of the Summary sheet and the fraction of volatile oil cracked in the furnace (found in the Operating Conditions – Furnace section of the Calibration Results sheet). There should be a reasonable balance between the various cracking modes. There is no typical profile, but a rough guideline is that the


fraction cracked in the furnace should be between 0.05 and 0.25. The tuning factor, Furnace Cracking T Factor, can be used to shift some of the cracking from furnace to the drum.

• Check the Notional Depth of Drum Liquid Holdup found on the Operating Conditions – Drum section of the Calibration Results should be a reasonable number. Again, there is no typical number, but it usually falls between 1-4 feet (0.3 to 1.3 meters).

• Check the Tower Temperature Profile for reasonableness. Check that Calibration factors XKUP(118) and (119). XKUP(118) are completely data driven and indicate the measured difference between the front end of the heavy gas oil distillation and the heavy gas oil process temperature. The bigger this number is the worse the fractionation or the more suspect one or more of the data points. XKUP(119) is a measure of the internal adjustments needed to be made by the model to bring the pseudocomponent bubble points into balance with the measured temperatures. As this number grows, it indicates that the model has to make a larger correction. As the value exceeds 50, it indicates possible problems with the process data or yield data.

• Check the K-Factor profile for reasonableness. Typically, the K-Factor of the light and heavy gas oil will be approximately the same as the feed, the distillate will be somewhat lower, and the light naphtha will trend upward. A typical profile of product K-Factor vs. TBP (in deg F) looks like:

9

9.5

10

10.5

11

11.5

12

12.5

0 500 1000 1500 2000


Predict Input Data Predict cases require many of the same inputs as the Calibration case for feed and operating conditions. Yield information is not required, since it will be calculated by the program.

Quench When external source quench is encountered in the Predict mode, DC-SIM always requires the presence of a Temperature Control Quench stream to adjust the amount of quench needed to achieve the drum vapor quenched delta temperature target. If only external Flow Control Quench is used during Calibration, DC-SIM assumes the same quality external quench will be used to satisfy the Temperature Control Quench during Predict, unless you specify a separate external Temperature Control quench stream (row 200 on Predict Input worksheet). When calibrated with only external Flow Control quench in Predict mode, reduce the Predict Input Flow Control quench input (Predict Input row 176) by at least 10% from the Calibration value. This amount is then used as the initial value for the Predict Input Temperature Control quench (Predict Input row 200). In this situation, both the Flow Control and Temp Control quench streams are the same external quench stream. This gives the model flexibility of adjusting the total external quench flow needed to meet the specified Predict drum vapor quenched delta temperature target. This approach is required in situations when less total quench flow is needed to meet the delta temperature target. This can happen when the drum vapor quench delta enthalpy requirement is less than that used during Calibration due to either lower delta temperature target or less drum vapor enthalpy. The total external quench flow is reported on line 471 of the Results worksheet.


When LGO or HGO is used as recycle quench, the amount required is calculated by the model in the Predict cases. The quench target can be specified in two ways. In the Quench Targets section, on row 253, there is a Quench Delta T Override Selector. When this is set to 0, the Quench Delta T Override Value on row 254 is used by the model as the quench delta T target for the drum vapor. When the Quench Delta T Override Selector is set to 1, then the Drum Vapor Inlet Temperature to Fractionator is used as the target for how much the drum vapor should be quenched.

Velocity Gas Oil In the Furnace section, the recycle Velocity Gas Oil (for example, LGO or HGO used as velocity gas oil) can be specified in several different schemes. A detailed discussion of how velocity gas oil are handled in the Predict cases can be found in the Velocity Gas Oil section.

Product Cutpoints Target For the naphtha range products (product streams 1 to 3), use D86 values for cutpoint specification by entering a new value in the Alternative Cut Point Spec section. Any value entered here will override the value in the corresponding TBP cutpoint.


Coke Inventory In the Predict mode, DC-SIM can be set up to predict a history of coke buildup in the drum during a cycle. There are two approaches to keeping track of coke inventory. In the first method, you specify a Run Time Interval in row 247.

The model calculates the amount of coke made in that time interval starting at the Calibration case or first Cold Predict case drum coke level conditions. Each Predict case is a separate run that is not affected by the other Predict cases in the stack.

In the second method, you set up a series of Predict cases and set the Coke Inventory Sequence in Feature Selections section to 1.

Each of the Predict cases will calculate the amount of coke made in the specified Run Time Interval (row 247) starting with the existing drum coke inventory established in the previous Predict case. In this manner, the drum coke inventory history during a cycle can be viewed on the Predict Results worksheet.



How the Predict Case Works The Predict Case works as follows:

1. Feeds are identified and broken up the same as in the Calibration case.

2. The fractionator is initialized at the specified recycle (CFR) and product distillation cutpoints. If no distillation cutpoints are supplied, the model will default to the calibration reference.

3. The furnace, drum, and quench sections are solved based on the Calibration factors, independent variables, and any quench temperature targets.

4. The fractionator tower is re-calculated with the equilibrium drum vapor as in the Calibration case. The furnace feed is recalculated and step 3 repeated until all sections are converged.

5. The converged model then estimates properties for the liquid product streams and sulfur, nitrogen, and metals distributions across all products based on Calibration factors.

Predict Case Checklist Before running a model Predict Case, check the following items:

1. Select the Predict Input worksheet. 2. Select the run mode, primed or cold. If running a primed mode

case, select a Calibration case to start the model from. If running a cold Predict, make sure that a Calibration factor set has been copied into the Predict case column from the Calibration Result Worksheet. If necessary, set the quench temperature target mode and setpoint.

3. If desired, set product stream cutpoints. 4. Set other independent variables. If running a cold Predict, all

required data must have a value. In a primed case, no independent variable entries are required. Any blank entries will cause the model to use the value supplied in the Calibration case. Change tuning factors and other selection items as desired.

5. Run the model using the Run button. 6. If the model does not run because of a fatal error, the error will

be reported. All messages are stored in the Message Log. The information provided in the message should be enough to troubleshoot the problem. Once the problem has been fixed, rerun the program.

7. When the model runs successfully, please view Messages to ensure that there are no serious non-fatal run errors.


Product Properties The product properties in Calibration cases are based either on your input or correlations. When user-supplied product properties are available from Calibration runs, this information is taken into account during Predict runs to adjust calculated product properties from correlations.

Sulfur In a Calibration case, you enter the sulfur content of feed and product streams. The distribution of sulfur to liquid products is based on a correlation between sulfur concentration and API gravity of the streams, calibrated to the measured sulfur distribution.

Nitrogen Nitrogen is distributed using the same procedure as sulfur.

Aniline Point Aniline points are calculated and compared to the measured input in the Calibration case. The Calibration factor for aniline point is represented by an additive correction term, which is applied to the calculated value in Predict runs.

Naphtha RON and MON Octanes (RON and MON) are predicted for the coker naphtha range products. RON and MON predictions require plant measured RON and MON values to be specified during Calibration. The calibrated value is then adjusted during Predict mode to reflect changes in cracked product properties.

Diesel Cloud Point, Pour Point and Flash Point Cloud Point, Pour Point and Flash Point properties are calculated for gas oil and diesel range products. These properties are calculated using API procedures, and are based on the product stream average boiling point and specific gravity. The flash point procedure requires the stream D86 10% point to be > 150 F. If Cloud Point, Pour Point or Flash Point data is available in the Calibration run, Calibration factors are calculated comparing the laboratory data to calculated values. These Calibration factors are then applied to the calculated values in the Predict runs.

Bromine Number Bromine numbers are input to the model and saved as reference calibration data. In Predict runs, the reference Bromine Numbers are adjusted for feed K-Factor and product stream cutpoint to estimate the


Predict case value. Olefins Content is calculated from the Bromine Number for each stream. Calibration Bromine value is required for Naphtha range products in order to predict PONA.

Naphtha PONA PONA properties for naphtha range products are predicted from coker naphtha data, using the TBP midpoints, bromine number and API.

Viscosity @ 50 C The viscosities at 50 C are calculated for the liquid product streams

Other Properties Olefins content, refractive index, cetane index, and molecular weight are estimated by defined correlations, based on various forms of distillation and gravity.

Coke Volatile Matter (VCM) The VCM of the coke is based on the amount of liquid holdup in the drum. Liquid holdup is affected by changes in operating conditions, primarily drum temperature and cycle length, coke VCM responds accordingly.

Coke Ash Content Since a significant portion of the ash in coke consists of metals, the ash content of coke is assumed to be proportional to the metal content. An ash/metals weight ratio is calculated from the data you supply in the Calibration case. This factor is used to estimate ash content in subsequent Predict cases.

Coke HGI The Hardgrove Grindability Index (HGI) property for coke is estimated in DC-SIM. HGI is a measurement of the propensity of the coke to break into fines, which may cause problems during coke cutting calcinations or other final use. This coke hardness is likely to be related to the level of asphaltenes in the coker feed. Feed alphaltenes level is not routinely measured in the refinery. However, the coke sulfur is usually proportional to the asphaltene level. DC-SIM calculates the HGI using a correlation to coke sulfur. If the coke HGI is specified in calibration input, this lab HGI value is compared to the calculated value from correlation to obtain a Calibration factor. If no calibration HGI is specified, this Calibration factor is set to 1. In the Predict mode, the newly calculated coke HGI from correlation is adjusted by this Calibration factor to arrive at the predicted coke HGI.


How the Optimizer Works The Optimizer works as follows:

• The Optimizer maximizes or minimizes a variable you select producing the Objective Function. Profit, product yield, or fresh feeds are examples of variables that can be maximized or minimized.

• Up to eight constraints with minimum/maximum limits can be defined. These are typically furnace duty and a fractionator tower constraint.

• Up to nine manipulated (independent) variables with minimum/maximum limits can be defined. The Optimizer manipulates these to maximize/minimize the desired function while staying inside constraint limits. Typically, these include furnace coil outlet temperature, feed rate, recycle rate (CFR), etc. Enter maximum step sizes for each manipulated variable. These keep the Optimizer from moving too far in one step.

• The Optimizer starts by running the selected Predict case. This is the initial case for the Optimization run. If the initial case is outside of constraint limits, the Optimizer will force the model to be inside of the constraint limits. If the initial case is too far outside of the constraint limits, the model will abort.

• The Optimizer maximizes/minimizes the objective by moving the manipulated variables. Each move will be limited by maximum step sizes.

• The Optimizer stops when the objective moves by less than 0.1% (default value) from case to case.

Optimizer Run Checklist An Optimizer run is a series of Predict cases. This checklist highlights items specific to the optimizer. Before running the model optimizer, check the following items.

1. Select the Optimizer Input Worksheet. 2. Check that the model contains the results of an earlier Predict

Case run. Processing of the optimization case does not start until the Calibration Case used to prime the Predict Cases and all the Predict Cases with a non-blank Run Status are run. Select an optimizer starting point by using the Reference Case Number spinner. By setting up the Predict Cases appropriately, you control the initial starting point of the optimizer.

3. Choose Maximize or Minimize mode on the Setup dialog box using the Minimization Option selection.

4. Use default tolerances that are displayed on the Settings dialog box. Typically, no inputs are required for tolerances.


5. Select up to nine independent variables. The Optimizer will manipulate these to maximize or minimize the Objective Function.

6. Select the variable that will be maximized or minimized (the Objective Function) with an “x”.

7. Use a non-x, non-blank character to select up to eight constraints with minimum and maximum limits on the dependents variable list.

8. Run the Optimizer using the Run button on the worksheet. 9. If the model does not run because of a fatal error, the error will

be reported in the Optimizer Log or the Message Log. The message should provide enough information for you to fix the problem. Once the problem is fixed, run the program again.

10. If the model runs successfully, scan the messages in the Optimizer Log to ensure there are no serious non-fatal run errors. The independent and dependent variable results from the final Optimization run are displayed in the Optimized Value column on the Optimizer Input Worksheet

To be thorough, also review the Predict Case checklist.


DC-SIM User Guide KBC Proprietary Installing DC-SIM • 3 - 1

Installing DC-SIM

PC System Requirements....................................................................................................... 3-2 Microsoft References............................................................................................... 3-2

Installation.............................................................................................................................. 3-3 Program Security ..................................................................................................... 3-3 DC-SIM Model Installation ..................................................................................... 3-3 What Is Installed ...................................................................................................... 3-4 Number and Decimal Regional Settings.................................................................. 3-4

Starting the Program .............................................................................................................. 3-7 Opening DC-SIM with the Start Bar ....................................................................... 3-7 Starting with the Data Workbook ............................................................................ 3-7 Setting up a Shortcut................................................................................................ 3-8 Starting DC-SIM...................................................................................................... 3-8 Security Settings and Macros .................................................................................. 3-9 Testing the Program Execution.............................................................................. 3-10 Problems When Running the Application ............................................................. 3-11

3 - 2 • Installing DC-SIM KBC Proprietary DC-SIM User Guide

PC System Requirements Minimum system configurations required to run DC-SIM are

• Microsoft Excel 97 or Excel 2000 • Intel Pentium processor or better • Microsoft Windows XP, Windows 97, Windows 98, Windows

2000 or Windows NT • CD-ROM drive, to load the installation CD • USB port to attach a software security key or network

connection to use network version of software security system

Microsoft References The software package provided by KBC uses many Microsoft products to perform user interface, file editing and file management tasks. This approach was taken to make the model as open and universally portable as possible. However, it is your responsibility to have and maintain valid licenses for any Microsoft application needed to operate this model.


Installation A single model installation package for one standalone PC is contained on the CD provided in the installation package. To install DC-SIM:

1. Place the CD in the disc drive, select Setup to bring up the installation screen.

2. Follow the instructions. Before installing the DC-SIM software, follow the procedures in the stand-alone or network Security Key Installation Instruction documents to install the license file (delivered separately via email) on your PC.

Program Security DC-SIM operates with a security scheme based on either a network license or local PC license. A software security key (dongle) is used to protect against unauthorized use of the model. This security key is a small device with USB connector on one end. It contains a custom microprocessor, nonvolatile memory, and other support circuitry. The security key must be connected to the USB port either locally or on a network server for the model to run. The instructions for network license users are provided in a separate documentation on network license. With network license, you can run DC-SIM whenever you are connected to your network. For local PC licenses, place the KBC license file, License.kbclic, in the C:\Program Files\Common Files\KBC folder. A USB dongle specific to that license file should be attached to the USB port of that PC. Each license file is set up to run only with its own specific USB key. Presently, KBC Profimatics SIM Series models use a security key manufactured by Rainbow Technologies, called SuperSentinelPro.

The parallel port dongle used with Version 96 to Version 2003.2 is not compatible with this version of the model. That dongle can be used only to run those older versions.

Refer to the “Model Installation Instructions Single User” manual if you are using a stand-alone PC or “Network Security Key Installation Instructions” manual if you are running DC-SIM on a network.

DC-SIM Model Installation The model is loaded using InstallShield, which creates program folders and loads program files into those folders. InstallShield guides you through the installation process. Program Folder or Directory Selection: The default program folder or directory into which InstallShield places its files is C:\Program Files\KBC Profimatics\SIM Suite 3.0\Profsim. It can be placed either as


the root directory or as the subdirectory of a user-defined directory. It can also be placed on any of your local drives. The only restriction is that the DC-SIM directory must be a subdirectory of PROFSIM. Windows NT Users: To successfully install the model, the person performing the installation (the person logged on as the current user) must have Supervisor/Administrator privileges. This is necessary because the procedure includes installation of the dongle driver software and registration of the model DLL.

What Is Installed The files programs loaded onto the PC hard disk during the model installation are:

Program Folders Description

\Program Files\KBC Profimatics\SIM Suite 3.0\Profsim

Version Definition \SIMSUITE.INI

DCSIM Executable

\DCSIM.EXE

SIM Interface Executable \KBCProfSIMGATEWAY.DLL

\KBC_Gateway.EXE

..\Profsim\DCSIM

Variables mapping table

\DCUnitsConversin.xls

\DCMAP.xls

Help files

..\Profsim\DCDATA Model Workbook Template \DCSIMV2006MASTER.XLS

Example Case Data \TEST_DCSIM.XLS

Example Case Test Data \*.DAT

\Program Files\Common Files\KBC

License File

\LICENSE.KBCLIC

Number and Decimal Regional Settings Both the DC-SIM core code and the Excel user interface are configured to accept and report numbers in a standard format. When running DC-SIM adjust your Windows operating system settings.

1. Select Control Panel from the Start menu. 2. Select Regional and Language Settings. The following Dialog

box appears.


3. Click Customize.

4. Set Decimal symbol to: . (decimal period) 5. Set Digit grouping symbol to: , (comma) 6. Set List separator to: , (comma) 7. Click on the Currency tab


8. Set Decimal symbol to: (decimal period) 9. Set Digit grouping symbol to: , (comma) 10. Click OK.

You may need to adjust other settings, depending on local conditions.


Starting the Program After DC-SIM V2006 has been installed, KBC recommends that you start the program and run the example problem to test it. You can start the program in several ways. You can use the Start bar, open the gateway workbook file, or create a shortcut for your desktop.

Opening DC-SIM with the Start Bar To begin with the Start bar, select KBC Profimatics as shown:

Starting with the Data Workbook In the past, the Gateway Workbook, Profdc.xls, is required to be active before opening the data workbook. In DC-SIM V2006, this is now replaced with a Gateway executable. You can also select the data workbook from Windows Explorer to start the DC-SIM model. The interface executables are now automatically initialized when the data workbook is opened.


Setting up a Shortcut You can set up a shortcut to KBC_Gateway.exe in the C:\Program Files\KBC Profimatics\Sim Suite 3.0\Profsim directory using standard Microsoft methods.

Starting DC-SIM When you start DC-SIM through the Gateway executable, the KBC Profimatics Simulation window appears:

Select Proceed. This dialogue box opens so you can select the Excel data file you want.


To test the installation, select TEST_DCSIM.XLS. To create a new DC-SIM workbook, open the template file, DCSIMV2006Master.xls. Next this dialogue box appears.

This dialogue box refers to the macros in the applications. To continue with the start up, select Enable Macros.

Security Settings and Macros The Gateway contains macro files that are used to run the program. Depending upon your security settings in Excel, you may get a warning message regarding macros.

• If your security message is set to Medium (which is the most typical) you will see the message shown in “Starting DC-SIM” on page 8:

• If your Excel security is set to Low, you will not get a message. • If your security setting is High, you will get the following

message:

Change the security setting to Medium to use DC-SIM. To set or change your Excel security:

11. Open the Tools menu. 12. Select Macros and then select Security.

When the Security window opens, select the setting you want.


Testing the Program Execution To test the running of the program, go to the DC-SIM menu, and select Run for one of the cases, as shown:

When the program runs, it searches for the security key or dongle that needs to be attached to your USB port. If you are using network security, then you must connect through your network to a server with the license file and network security key installed. It then executes the program. If the security key is found, the spreadsheet opens with DC-SIM active.


Problems When Running the Application If the dongle is not attached or the license file not found, this message appears:

After you press the Enter key, you return to the program. A message appears asking you to load the results. This opens a message stating that the results are not available:


If you get this message, first check that the dongle is connected to the USB port or the license file is in the correct folder. If the program still does not run properly, follow the procedure in the Security Key Installation manual to identify the problem. If DC-SIM still does not work, contact KBC additional assistance.

DC-SIM User Guide KBC Proprietary Using the Spreadsheet Interface • 4 - 1

Using the Spreadsheet Interface

Microsoft Excel...................................................................................................................... 4-3 Data Flow ................................................................................................................ 4-3

Gateway Workbook ............................................................................................................... 4-4 Model Workbook and Model Workbook Template ............................................................... 4-5 Getting Started ....................................................................................................................... 4-6

Available Models..................................................................................................... 4-6 Proceed Button......................................................................................................... 4-6 Cancel Button .......................................................................................................... 4-7

Customizing the Workbook ................................................................................................... 4-8 Model Workbook ................................................................................................................... 4-9

Grouping Feature ..................................................................................................... 4-9 Comments.............................................................................................................. 4-10 DC-SIM Menu....................................................................................................... 4-11 DC-SIM Options Item ........................................................................................... 4-11 Navigation Item ..................................................................................................... 4-12 Run Item ................................................................................................................ 4-12 Copy Case Data Item ............................................................................................. 4-13 Clear Case Data Item ............................................................................................. 4-13 Text Files Item....................................................................................................... 4-13 Available Results Item........................................................................................... 4-14 Import Case Data Item........................................................................................... 4-14 Export Case Data Item........................................................................................... 4-14 Transfer Workbook Data ....................................................................................... 4-15 Import from Petro-Sim .......................................................................................... 4-15 Export Calibration to Petro-Sim ............................................................................ 4-15 Links ...................................................................................................................... 4-15

Design Worksheet ................................................................................................................ 4-16 Calibration Input Worksheet ................................................................................................ 4-18

Run Button............................................................................................................. 4-18 Import Button ........................................................................................................ 4-19 Copy Button........................................................................................................... 4-20 Clear Button........................................................................................................... 4-21

Predict Input Worksheet....................................................................................................... 4-22 Run Button............................................................................................................. 4-23

4 - 2 • Using the Spreadsheet Interface KBC Proprietary DC-SIM User Guide

Setup Button .......................................................................................................... 4-23 Copy Button........................................................................................................... 4-23 Import Button......................................................................................................... 4-24 Clear Button........................................................................................................... 4-24

Optimizer Input Worksheet.................................................................................................. 4-25 Run Button............................................................................................................. 4-26 Setup Button .......................................................................................................... 4-26 VGen: LP Vector Generation Tool ........................................................................ 4-27

Result Worksheets................................................................................................................ 4-28 Comparison Worksheet ........................................................................................................ 4-30

CaseGen................................................................................................................. 4-30 Summary Worksheet ............................................................................................................ 4-32 Charts ................................................................................................................................... 4-33

Charts Worksheet................................................................................................... 4-33 Setup Button ............................................................................................ 4-33 Update Button.......................................................................................... 4-34 Select Button .......................................................................................... 4-34 Series /X Variable.................................................................................... 4-35 Save ......................................................................................................... 4-35 Load......................................................................................................... 4-36

Charts - 2 Worksheet ............................................................................................. 4-36 Worksheet Comments and Model Help ............................................................................... 4-37 Saving Files and DC-SIM Exit............................................................................................. 4-38


Microsoft Excel The spreadsheet environment provides one of the most flexible, powerful and easy-to-use engineering application interfaces available. Microsoft Excel includes Visual Basic, a sophisticated high level programming language. Visual Basic has been used extensively to enhance Excel’s functionality to support the specific tasks needed to operate DC-SIM.

Data Flow When you run DC-SIM, you remain in the Excel workbook while the application runs. Information flows between the Excel worksheets and the model executable as follows:

ExcelInput

Worksheet

ModelExecution

ExcelResults

Worksheet

DC.DAT DCSIM.CSV

When running the model from Excel, the file DC.DAT is created in the default directory from the data entered in the Excel Input worksheets. This text file includes all the input data necessary for the model to run. If multiple cases are being run, then the data for each case are appended to the DC.DAT file. The model executable, DCSIM.exe, is run in a batch mode loading the DC.DAT file and processing each case sequentially. Once the model has processed all the cases, it generates a text file containing the results, called DCSIM.CSV. The output data in the DCSIM.CSV file is then loaded into the Result worksheet. If one of the model cases fails, processing is stopped and those cases successfully completed are loaded into the Result worksheet and the “Error” flag is displayed at the top of the failed case. Model messages are logged in a Message file that you view from the Model Workbook using a menu item.


Gateway Workbook The traditional Gateway Workbook, Profdc.xls, in the earlier versions of DC-SIM is now being replaced by the KBC Profimatics Simulation Gateway. This Gateway is used to open all Sim Suite 3.0 versions of SIM models. It contains most of the Visual Basic code used to initialize and support the DC-SIM Excel interface. You can now access the DC-SIM data workbooks in two ways.

1. Start/Programs/KBC Profimatics/SIM Suite 3.0/DC-SIM. This would open the KBC Profimatics Simulation Gateway. Select DC-SIM from the dropdown menu, then select Proceed to open the data model workbook.

2. Select the data model workbook in Windows Explorer.


Model Workbook and Model Workbook Template The Model Workbook file is where you enter model input data, executing the model in Calibration, Predict or Optimization Modes, or viewing the results. An example Workbook file is included. A Model Workbook Template is loaded on your PC at installation time, and is named DCSIMV2006Master.xls. The default location is the Program Files\KBC Profimatics\Sim Suite 3.0\Profsim\Dcdata\ directory. The template file is the base format for all DC-SIM Excel files. It is write-protected.

The templates file is write-protected and should not be altered or over-written. If this happens, DC-SIM must be reinstalled.

The DC-SM Workbook is created by taking the template file and using it for a specific coker unit, and then saving the new file.

Never delete or insert rows or columns into the worksheets. All the worksheets have hidden columns and rows that may be corrupted if columns or rows are inserted or deleted. In addition, the interface code in some cases relies on data being in specific locations which could also be corrupted. The result would be unreliable model runs.

Be careful when copying or moving data around the worksheets. It is safer and more convenient to use the Copy function provided with the interface. For manual copying we recommend using the Paste Special – Values function, to avoid unintended propagation of formulas and formats.


Getting Started Once DC-SIM has been installed, start the program. The following entry window opens.

Available Models Select DC-SIM from the dropdown box.

Proceed Button Use Proceed to open a dialog box where you select a Model Workbook to be opened by Excel.


Cancel Button Selecting Cancel stops the loading process and closes the Prodc.xls workbook.


Customizing the Workbook With the standardization of the KBC Simulation Gateway, DC-SIM users are now limited in customization of the working environment. This is done with the DC-SIM Tool Menu/DC-SIM Options. Selecting this item lets you choose whether or not the results Load Confirmation Dialogs popup window should be present after each DC-SIM model run.


Model Workbook An example problem and a template file are provided with the installation of DC-SIM. You may also have a DC-SIM Workbook for your unit created by KBC. These workbooks consist of the following worksheets:

• Design • Calibration Input • Calibration Result • Predict Input • Predict Result • Opt Input • Opt Result • Comparison • Summary • Charts • Charts – 2

Grouping Feature Many of the sheets in the workbook contain a large number of rows. To make these long files manageable, the DC-SIM worksheets make extensive use of the Grouping feature provided with Excel.


Grouping allows sections of worksheet rows and columns to be combined and hidden from view. The plus and minus signs on the left of the worksheets are used to unhide (+) or hide (-) the rows. At the top of the column of + and - are the grouping levels. Clicking on Level 1 hides all the rows. Clicking on Level 2 or Level 3 reveals all the rows in that level. Additionally, individual model cases are grouped in sets of ten. The worksheets using this feature must be unprotected to use the hide/unhide capabilities. They must also have the row and column headings enabled (choose Tools – Options and select the View tab), to see the master grouping levels at the upper left-hand corner of the sheet. For more information, refer to the Excel documentation.

Comments The DC-SIM worksheets provided also use Excel comments to give you valuable information. Comments appear as red triangles on the upper right of an individual cell. To view the text of the comment, put the cursor over the red triangle. When you move your cursor away from the red triangle, the comment box disappears.


DC-SIM Menu When starting a modeling session, a new menu is created called DC-SIM. It is attached to the standard Excel menu bar.

Some of the menu functions are also made available by clicking buttons on the worksheet. Each menu item for the DC-SIM is described below.

DC-SIM Options Item The Options show the selections for customizing the DC-SIM general functions. Currently, you can choose whether or not the program advises you when a model run is completed and ready to be loaded onto the Results worksheet.


Navigation Item The Navigation function lets you navigate among all the worksheets. This could be used instead of directly selecting the Excel Worksheet Tabs. The Navigation secondary menu lists all the available worksheets in the Model Workbook.

Run Item The Run function lets you run any of the model modes. It has the same function as the Run Button provided on each of the Input worksheets. The Run secondary menu lists the three model modes: Calibration, Predict and Optimize.


Copy Case Data Item The Copy Case Data copies certain values from on sheet to another or from one column to another. Its function has the same functionality as the Copy button on Input and Results sheets. (Refer to “Calibration Input Worksheet” on page 4-18 for more details).

Clear Case Data Item The Clear Case Data function clears certain cells. It has the same function as the Clear Button on Input sheets. (Refer to “Calibration Input Worksheet” on page 4-18 for more details). The Clear option can also be used to perform the clear function on Result worksheets.

Text Files Item The Text Files Data function displays a dialog box that gives you access to all the output files produced by DC-SIM. The reports are stored in the default directory and are opened, by default, with Microsoft’s WordPad, or a text editor you specify (see the section on Case Manager Settings).


The advantage of opening the reports with this menu item is that the reports are automatically formatted with page breaks, etc., and for printing in Portrait orientation instead of Landscape. Print Zoom lets you control the size of the report pages printed on each page from Excel. Opening with WordPad is a bit faster and may be better when you only intend to browse rather than print.

Available Results Item The Available Results function is specific to the Charts sheets and has the same function as the Available Results button. (Refer to “Charts” on page 4-33 for more details).

Import Case Data Item The Import Case Data function brings information from test files in .DAT format into Excel. It has the same function as the Import button on the Calibration Input and Predict Input sheets. (Refer to “Calibration Input Worksheet” on page 4-18 for more details).

Export Case Data Item The Export Case Data function creates a DAT text file under the user-specified name that includes all required input data needed to recreate the current worksheet when that DAT file is imported into another workbook. Only the information from the Calibration Input and Predict Input worksheets that have the Run Case selection specified are included on this DAT file. The information from the Optimizer Input worksheet is also included in this exported DAT file.


Transfer Workbook Data This function can be used only when you are in the template DCSIMV2006Master.xls workbook. This tool translates the Design, Calib Input and Predict input worksheets from any old version DC-SIM workbook into the current workbook format.

Import from Petro-Sim This function is not operative in the stand-alone DC-SIM. It is enabled only when the Petro-Sim flowsheet software is also present.

Export Calibration to Petro-Sim This function is not operative in the stand-alone DC-SIM. It is enabled only when the Petro-Sim flowsheet software is also present.

Links This function is not operative in the stand-alone DC-SIM. It is enabled only within the appropriate flowsheet environment.


Design Worksheet The Design worksheet is used to configure unit specific information needed by the model. The schematic is used to set up the unit and model data that applies to all worksheets: Coker unit data included on the diagram consists of:

• Coker Configuration (recycle vs. once through) • Quench Configuration • HGO Tower Draw Stage • Feed Injection Points • Velocity Gas Oil Feed Option • Liquid Products Stream Options

Also included are selections controlling information in the model worksheet:

• Model Title • Engineering Units • Mol. Wt. Method

Note that these setup data are global to the Model Workbook. Each workbook is specific for a given process unit configuration. If a different configuration is required, set up a new Model Workbook.

Below the schematic, you can input unit specific stream names. These stream labels are used throughout the workbook. Further down on the Design worksheet are the required additional unit data inputs representing the unit static coke drum dimensional data.



Calibration Input Worksheet The Calibration Input worksheet is used to enter test run data and run the calibration cases. Each column represents one case. The worksheet can handle up to 60 calibration cases.

Run Button Run executes the model in Calibration mode. The calibration cases processed are those that have a non-blank character in the Run Case row (Row 3). At the start of model execution, a DOS box opens to display processing information. This box automatically closes after model execution has been completed. A message box prompts you to start loading the model results. While the DOS box is open, the model run can be aborted by terminating the operation in any valid manner (i.e., Ctrl-Break). The drop-down box located to the right of the Run button lets you select whether to clear the whole Calibration Result worksheet (Reset All Results) or only the columns corresponding to the cases solved (Spot Load Results), after selecting the Run button.


Import Button You can import text-based input files into the Model Workbook for files that have been stored in the correct text format. The text file extension must be *.DAT and is typically created by the Export function. Import initially opens a file input dialog box that lets you select the text-input file that is to be loaded. The selected text-input file is opened with Excel and a dialog box is displayed showing the Calibration cases (identified with 0) or Predict cases (identified with non-zero number) in text-input file that could be loaded.

To load a single case, select the case to be loaded and its destination case number (i.e., column). Once the Load is initiated, the interface prompts you to confirm:

This is a reiteration of the selection you made and needs to be confirmed by you.


You must confirm the overwriting of the Design and Stream Titles data. The other option is to use Load All to import all the cases in the .DAT file. There is an option at the bottom of the Import Case Data window for you to Convert the data into a different set of units of measurement. In the first step, the selected input data, calibration and/or predict input cases, are converted to the new units of measurement. Next you can opt to keep the existing display of units of measurement on the worksheets by not loading the design data after the input data.

Copy Button Copy lets you copy existing case data to other case columns in either the Calibration or Predict Input worksheets. This lets you transfer data to other case columns for the purpose of:

• Adjusting existing calibration or predict case data or altering tuning constants.

• Creating “cross predicts” i.e., creating a predict run using a calibration data set.

• Predicting using a specific calibration factor set. • Predicting using an average calibration factor set.

Calibration Input Worksheet data copy options include: • 0 – Calibration Inputs to Calibration Inputs • 1 – Calibration Inputs to Predict Inputs


• 2 – Calibration Factors to Predict Factors • 3 – Average Calibration Factors to Predict

Predict Input Worksheet data copy options include: • 0 – Calibration Inputs to Predict Inputs • 1 – Calibration Factors to Predict Factors • 2 – Average Calibration Factors to Predict • 3 – Predict Case to Predict Case

If you select Case at Cursor Position, do not select a case number. The case where the cursor is positioned is selected for copying.

Clear Button The Clear function lets you clear data from any number of columns.

CAUTION:

Be certain of what you are clearing. You cannot recover the data if you inadvertently clear the wrong column.


Predict Input Worksheet The Predict Input worksheet is the main worksheet used to run Predict cases and is also used to enter data for Optimization cases. Each column represents one case. The worksheet can handle up to 60 Predict cases.

The Predict case can be run in either a Primed or Cold predict mode. A Primed case is run stacked behind a Calibration case, which is run to initialize the model. The Cold Predict mode runs just the Predict case, but requires a complete set of input data and Calibration Factors. The Setup button above the Copy button lets you select either Primed Predict or Cold Predict.

In a Primed case, or any case beyond the first case in either mode, any blank entries will cause the model to use the value supplied in the previous selected case.

The drop-down menu located to the right of the Setup button lets you select one of the calibration cases as the Primed case. The selected Calibration case data is displayed in column “J” of the worksheet. The drop-down menu located under the Factors selection options lets you select whether to clear the entire Predict Result worksheet (Reset All Results) or only the columns corresponding to the cases just run before loading the new results (Spot Load Results).


Run Button The Run function executes the model in Predict mode. The Predict cases processed are those that have a non-blank character in the Run Case row.

Setup Button The Setup function lets you select various modes of running the model in the Predict mode.

Primed Predict can be run with these sets of calibration factors:

1. Base calibration factors generated during the calibration run just before running the predict case(s).

2. Set of Average calibration factors from all the calibration cases present on the Calibration Results worksheet.

3. Set of Selected Average calibration factors calculated only from the calibration cases selected for averaging on the Calibration Results worksheet.

When running Cold Predict, the Base calibration factors are the calibration factors present in the first Cold Predict case on the Predict Input worksheet. The Average and Selected Average options are the same as that used for Primed Predict. When using Average or Selected Average options in Cold Predict, it is not necessary to copy the calibration factors into the first Cold Predict case.

Copy Button The Copy function lets you copy existing case data to other case columns in the Calibration Input worksheet or the Predict Input worksheet. The function is identical to that described in the Calibration Input Worksheet section.


Import Button The Import function lets you import previously saved calibration and predict case data from a *.DAT file. The function is identical to that described in the Calibration Input Worksheet section.

Clear Button The Clear function lets you clear data from any number of columns. The function is identical to that described in the Calibration Input Worksheet section.


Optimizer Input Worksheet The Optimizer Input worksheet is used to configure an optimization run which consists of perturbing a series of independent variables to maximize an objective function. The Optimization run is based on what is selected in the Predict Input sheet, plus additional information on the optimization sheet. The available independent and dependent variables are presented on the worksheet.

For each selected independent variable, provide the minimum value, maximum value, and move limit. Select one dependant variable to be maximized or minimized.


For each selected dependent variable, (i.e., constraint) you must add a minimum or maximum value. The Optimizer can handle up to nine independent variables and nine dependent variables including the objective function. The selected variables and ranges are included in the DAT file when Export Case Data is performed.

Run Button The Run function executes the model in Optimizer mode. Note that the cases processed before the start of the Optimizer include the Calibration case used to prime the Predict case and all the Predict cases with the Run Case status ON up to and including the Primed Predict case. To save time, you may want to create a Cold Predict case specific to the optimization and turn off all other Predict cases.

Setup Button The Setup function displays a dialog box where you can change the Optimizer tolerances or configure the Optimizer reporting options. To switch the Optimizer to the Minimize Objective Function mode, check Minimization Option.


To use the Optimizer as the LP Vector Generation Tool, check the Vector Generation Tool option.

VGen: LP Vector Generation Tool On the Optimizer Input worksheet, there is also a utility tool useful for generating vectors for LP models. This tool uses the perturbation information specified on the Optimizer Input worksheet to impose step changes to the model and reports the results in a customized table. Specify this customized table using the same procedure as that described for CaseGen on the Comparison Worksheet section. Refer to “CaseGen” on page 4-30 for more information. The step changes are identified using the same set up procedure for selecting the independent variables and the perturbation step sizes on the Optimizer Input worksheet.

To run the VGen, check the Vector Generation Tool option in the Settings, then click the Run button.


Result Worksheets There are corresponding Result worksheets for each of the model modes.

For consistency, all Result worksheets present the same data in the same format. On the Calibration Result worksheet, the calibration factors can be averaged and the standard deviations calculated. You select the Calibration cases to be included in this averaging by entering non-blank characters in cells on row 4 to the right of the title, Select Calibration Factors for Average.

The averaged Calibration factors and standard deviations are located in columns BG through BI at the right end of the calibration factor section. To use the Average Calibration Factors in Predict cases, use the Setup button on the Predict Input worksheet to choose whether to use Average All or Average (Selected).


The Result worksheets for the Predict and Optimize modes are the same as the Calibration Result except:

• The Predict and Optimize Result worksheets do not have the calibration factor averaging section.

• The Predict Result worksheet contains indices and text material used by the Optimizer Input and various dialog boxes.

• The Optimizer Result worksheet does not contain output for calibration factors since they are the same for all optimization passes.


Comparison Worksheet The Comparison worksheet lets you compare two cases from any of the three Result worksheets. The absolute delta and percent delta for the case data are calculated automatically and displayed in columns G and H respectively. Empty cells means the two cases have exactly the same value for that variable.

CaseGen A utility tool is available on the Comparison worksheet to create customized comparison table. Select the results to be included in the customized table by entering a number in the index column (column M) on the right side of the worksheet. Using sequence such as 5, 10, 15, lets you insert additional selections at a later time. The table is created using the numerical sequence in this column.

(Hint: Select the section heading when the label in column A does not identify the stream. For example, if the label only states Mass Rate make sure the stream label is also selected.)

The results can be presented either as absolute values or delta from the base case. The display mode is selected in cell on Row 16 with 0=delta and 1=absolute. The base case is the first case selected in column E. All the results cases on the chosen Result worksheet, starting with the case selected in column F, are included in the customized table. Once the table selections have been made, click the CaseGen button on the upper right corner to create the table and save the table to a separate file name.



Summary Worksheet The Summary worksheet displays summary data for a specified case result for quickly reviewing and printing case highlights. Select the case to be displayed using the list box and spinner as shown on the Comparison worksheet.


Charts There are two Charts worksheets.

• Charts is designed to look at one variable at a time across a number of cases.

• Charts-2 looks within a single case at a number of variables in profile.

Charts Worksheet Use Charts worksheet to plot up to ten sets of X-Y charts of data selected from any of the three Result worksheets. For each set, specify one X variable and up to seventeen Y variables. The range of cases to be plotted is from a selected result sheet across a consecutive series of cases identified in the cells labeled First and Last.

Setup Button Setup lets you select which Results worksheet and group of cases are to be plotted. The Available button opens a list of cases present on all three Results worksheets. The numbers displayed are the values in the profit cell for all cases in the three Results worksheets. Those with values indicate that case data exists for that case and are available for plotting.


Update Button Use Update to reset the plots after any change has occurred to the configuration.

Select Button Select lists all the possible variables available for plotting from the Result worksheets. It also lets you select the specific variables and load them into either the X variable slot or one of the seventeen Y variables in Charts 1 through 17.


Series /X Variable Use Series /X Variable to toggle back and forth between X-Y mode and line mode (where the Y data is displayed case by case). When you work with X variables from Results page, Series is offered as the other choice for X-axis. When the charts are shown with the case sequence as the X-axis, X-Variable is offered as the other choice.

Save The X and Y variable indices for each set of 17 charts can be saved with a descriptive title. Ten sets of X, Y indices can be saved for the workbook.


Load Load brings back the desired set of X, Y indices for display on the Charts worksheet. Set 11 to 16 are predefined index sets. At present only set 11 is predefined using CFR as X axis.

Charts - 2 Worksheet The Charts – 2 worksheet displays the profiles shown below.


Worksheet Comments and Model Help The on-line help available with the interface is in the form of Excel comments and a help file available from the DC-SIM menu. To access Comments attached to individual cells, place the mouse pointer over the cell. A red triangle in the upper right hand corner of the cell indicates a comment. Refer to the Excel documentation for more information.


Saving Files and DC-SIM Exit Completed model files should be saved with their own unique names in the default Dcdata directory or custom directory using the Excel Save As option. Maintain the template file DCSIMV2006Master.xls as an empty template from which to start new models. As the inventory of calibration cases grows it may be desirable to save them as *.DAT files as described in the Export Case Data procedure. The easiest way to save data in this format is to select the calibration and predict cases using the Run Case flag (row 3 of Calibration and Predict Input worksheets). Use Export Case Data option from the DC-SIM Tool menu and specify the .DAT file name to save to. To Exit the model, close and exit as you would any Excel session.

DC-SIM User Guide KBC Proprietary Appendix A - Calibration Factors - A • 1

Appendix A - Calibration Factors

Initialization Factors ............................................................................................................. A-2 DCSIM V2006 Tuning Factors............................................................................................. A-3 DC-SIM V2006 Calibration Factors ..................................................................................... A-6

A • 2 - Appendix A - Calibration Factors KBC Proprietary DC-SIM User Guide

Initialization Factors Initialization Factors

Default Range Type

H2S Calibration Distribution

H2SDR 0.25 >0 fraction of feed S distributed to H2S

NH3 Calibration Distribution

NH3DR 0.13 >0 fraction of feed N distributed to NH3

K Factor Shift Initializer

DUKNI 0.5 >0 Initial shift of cracked pseudo K from uncracked pseudo. Help to get product volumes converge

Furnace Residence Time Factor

TIMNI 0.5 >0 used in cracking rate in furnace

Converge Tolerance Initial Factor

TOLFACI 0.01 >0 Tighter tolerance will improve reproducibility

DC-SIM User Guide KBC Proprietary Appendix A - Calibration Factors • 3

DCSIM V2006 Tuning Factors Tuning Factors

Default Range Type

Drum Temperature Scaling Factor

DRTSF 0.5 0 -1 multiplier multiplier to adjust the Drum T

Furnace Pressure Offset

PRFA2 0.5 >0 offset nominally the furnace to drum pressure drop, main effect of furnace outlet V/L equilibrium

Drum Pressure Offset

PRFA1 0 >0 offset drum pressure tuning factor, affect both drum and furnace V/L equilibrium

Cracking Rate Factor

CRACK 1 >0 multiplier cracking rate factor to tune for liquid yields

Polymerization Rate Factor

COKER 1 >0 multiplier tuning factor for coke make from polymerization

Sulfur/Nitrogen Gravity Intercept

SGI 90 intercept of the sulfur-API correlation. Changing the intercept shifted the curve.

Fuel Oil Equivalent Conversion Constant

FOEFC --- FOE barrel conversion. Default is 6

Furnace Duty Scaling Factor

FFAC 1 > 0 multiplier used to adjust the enthalpy of the furnace outlet stream

Furnace Cracking T Factor

FURCRK 1 0 – 1.32 multiplier Used to shift the equivalent cracking T in the furnace

Kinetics Tuning Flag

IN(16) 0 0 or 1 0 = V2003 Kinetics; 1 = Use V2001 Kinetics

CFR factor on Coke Make

CCFRADJ 1 multiplier multiplier to ratio of recycle ratio to calib tower bottom recycle ratio. Impacts coke make from cracked feed, use 0.0001 for 0

Drum T factor on Coke

COKDTADJ 0 multiplier power factor to ratio calib drum T vs drum T. Multiplied to total coke make


Tuning Factors

Default Range Type

Drum P factor on Coke

COKPADJ 1 multiplier factor based on delta of drum P from calib drum P. Impact total coke make. Use 0.0001 for 0

H2S Sulfur Temperature factor

SULFTH2S 0 multiplier power factor to ratio calib drum T vs drum T. Multiplied H2S level.

H2S Sulfur Pressure factor

SULFPH2S 0 multiplier power factor to ratio drum P vs calib drum P. Multiplied H2S level. More sensitive than T factor.

Coke Sulfur Pressure factor

SULFPFAC 0 multiplier power factor to ratio drum P vs calib drum P. Multiplied coke sulfur level. More sensitive than T factor.

Coke Sulfur Temperature factor

SULFTFAC 0 multiplier power factor to ratio calib drum T vs drum T. Multiplied coke sulfur level.

Advanced Tuning Factors

Default Range Type


Drum P factor unCrack V/L

PFAC1 1 >0 multiplier multiplier factor on the vapor/liquid equilibrium for drum uncracked pseudo components

Drum P factor Crack V/L

PFAC2 1 >0 multiplier multiplier factor on the vapor/liquid equilibrium for drum cracked pseudo components

Crack rate factor for UnCracked comp

CRAFAC1 1 >0 multiplier multiplier to the cracking rate for uncracked pseudo components

Coke rate factor for UnCracked comp

COKFAC1 1 >0 multiplier multiplier to the cracking rate for cracked pseudo components

Crack rate factor for Cracked comp

CRAFAC2 1 >0 multiplier multiplier to the coking rate for uncracked pseudo components

Coke rate factor for Cracked comp

COKFAC2 1 >0 multiplier multiplier to the coking rate for cracked pseudo components



Default Range Type

factor on Kinetic K1 for T effect on Cracking

CKTK 1 >0 multiplier multiplier to the K1 factor in Cracking Arhenius kinetics: K1* exp (-A1/T)

factor on Kinetic Act Eng for T effect on Cracking

CKTA 1 >0 multiplier multiplier to the A1, activation energy, in Cracking Arhenius kinetics: K1* exp (-A1/T)

factor on Kinetic K2 for T effect on Coking

COKTK 1 >0 multiplier multiplier to the K2 factor in Coking Arhenius kinetics: K2* exp (-A2/T)

factor on Kinetic Act Eng for T effect on Coking

COKTA 1 >0 multiplier multiplier to the A2, activation energy, in Coking Arhenius kinetics: K2* exp (-A2/T)


DC-SIM V2006 Calibration Factors Calibration Factors

--- Type

C4- Hydrocarbon XKUP(1) multiplier Gas Yield calibration factor, ratio of actual yield to predicted yield

C4- Mol. Wt. XKUP(2) multiplier Gas MW factor, ratio of actual C4- MW to predicted MW

Coking Rate XKUP(3) multiplier factor based on ratio of actual coke/predicted coke yields from Concarbon in feed

H2S XKUP(4) Fraction Feed Sulfur to H2S

NH3 XKUP(5) Fraction Feed Nitrogen to NH3

Hydrogen (offset) XKUP(6) Offset Factor to adjust mol % distribution used to match predict yield to actual

Methane (offset) XKUP(7) Offset Factor to adjust mol % distribution used to match predict yield to actual

Ethane (offset) XKUP(8) Offset Factor to adjust mol % distribution used to match predict yield to actual

Ethylene (offset) XKUP(9) Offset Factor to adjust mol % distribution used to match predict yield to actual

Propane (offset) XKUP(10) Offset Factor to adjust mol % distribution used to match predict yield to actual

Propylene (offset) XKUP(11) Offset Factor to adjust mol % distribution used to match predict yield to actual

Isobutane (offset) XKUP(12) Offset Factor to adjust mol % distribution used to match predict yield to actual

Normal Butane (offset)

XKUP(13) Offset Factor to adjust mol % distribution used to match predict yield to actual

Butylene (offset) XKUP(14) Offset Factor to adjust mol % distribution used to match predict yield to actual

Stream #1 Sulfur Distr

XKUP(15) multiplier Shift to Sulfur to product 1 distribution factor, multiplier to total liquid sulfur






XKUP(18) multiplier Shift to Sulfur to product LCGO distribution factor, multiplier to total liquid sulfur


XKUP(19) multiplier Shift to Sulfur to product HCGO distribution factor, multiplier to total liquid sulfur


XKUP6(1) multiplier Shift to Sulfur to product FZGO distribution factor, multiplier to total liquid sulfur


Calibration Factors

--- Type

Coke Sulfur Distr XKUP(20) multiplier Sulfur factor for Concarbon coke contribution

Stream #1 Nitrogen Distr

XKUP(21) multiplier Shift to N2 to product 1 distribution factor, multiplier to total liquid N2






XKUP(24) multiplier Shift to N2 to product LCGO distribution factor, multiplier to total liquid N2


XKUP(25) multiplier Shift to N2 to product HCGO distribution factor, multiplier to total liquid N2


XKUP6(2) multiplier Shift to N2 to product FZGO distribution factor, multiplier to total liquid N2

Coke Nitrogen Distr

XKUP(26) N2 factor for Concarbon coke contribution

Stream #1 RON (offset)

XKUP(27) Offset Calibration RON

Stream #1 MON (offset)

XKUP(28) Offset Calibration MON









Stream #2 Aniline Pt(offset)

XKUP(31) Offset Actual-Predicted. If no data, set to XKUP(32)


XKUP(32) Offset Actual-Predicted. If no data, set to XKUP(33)


XKUP(33) Offset Actual-Predicted


XKUP(34) Offset Actual-Predicted


XKUP6(3) Offset Actual-Predicted

Stream #1 Bromine Number

XKUP(35) Offset Calibration Bromine Number








Calibration Factors

--- Type




XKUP6(4) Offset Calibration Bromine Number

Stream #1 K-Factor Shift

XKUP(40) Offset Shift to cracked pseudo K in product 1, based on convergence of predicted vs actual product volume







Stream #5 K-Factor - UK2

XKUP(44) Cracked K factor, UK2

Stream #6 K-Factor - UK2

XKUP6(5) Offset Shift to cracked pseudo K in FZGO

Cutpoint Shift Stream 1-2

XKUP(45) Offset Shift to cutpoint in pseduos to converge product yields








XKUP6(6) Offset Shift to cutpoint in pseduos to converge product yields

Stream 1-2 TBP Cutpoint

XKUP(49) deg F Cutpoint from actual b.p. curves







Stream 5-Recycle Cutpoint


Convergence Tolerance Factor

XKUPN(10) Internal Calibration Iteration Convergence Factor

Stream 1 D86 90% Cutpoint

XKUPC(1) deg F D86 Cutpoint from actual b.p. curves




Calibration Factors

--- Type







Stream 1 D86/TBP Cutpoint Shift

XKUPCS(1) Offset TBP CUTPOINT - D86 CUTPOINT









Stream #1 T00 TBP Shift

XKUP(54) Offset Offset of TBP in actual data from predicted value from cutpoints.






























Calibration Factors

--- Type










































XKUP6(10) Offset Offset of TBP in actual data from predicted value from cutpoints.(if no data, use recycle info)




Calibration Factors

--- Type











Calib External Flow Control Quench

XKUP(89) Used with Calib Drum T to determine if too much Flow Control Quench predict input.

Stream 4+ CCN and Metals Weight Reference

XKUP(90) multiplier Wt distribution in Gas Oil and Coke, used for ConCarbon and Metals prediction


XKUP(91) multiplier Wt distribution in Gas Oil and Coke, used for ConCarbon and Metals prediction


XKUP6(9) multiplier Wt distribution in Gas Oil, FZGO, and Coke, used for ConCarbon and Metals prediction

Sulfur in Coke from Con Carbon

XKUP(92) Sulfur in precipitated coke

Nitrogen in Coke from Con Carbon

XKUP(93) N2 in precipitated coke

Coke Ash XKUP(94) Offset factor of coke ash to feed metal ratio

Coke VCM (offset) XKUP(95) Offset wt% VCM correction factor

Coke HGI factor XKUPN(5) multiplier ratio of calibration HGI input to calculated HGI

H2S Sulfur Temperature factor

XKUPN(8) multiplier H2S T response factor from Tuning Factor section

H2S Sulfur Pressure factor

XKUPN(9) multiplier H2S P response factor from Tuning Factor section

Coke Sulfur Temperature factor

XKUPN(6) multiplier Coke Sulfur T response factor from Tuning Factor section

Coke Sulfur Pressure factor

XKUPN(7) multiplier Coke Sulfur P response factor from Tuning Factor section

Stream 4 CCR Distr

XKUP(96) multiplier used in CCR correlation

Stream 5 CCR Distr

XKUP(97) multiplier used in CCR correlation


Calibration Factors

--- Type

Stream 6 CCR Distr

XKUP6(7) multiplier used in CCR correlation

Stream 4 Metals Distr

XKUP(98) multiplier used in Metal correlation


XKUP(99) multiplier used in Metal correlation


XKUP6(8) multiplier used in Metal correlation

DISADJ XKUP(100) multiplier Gas yield factor to converge liquid factor

DUK XKUP(101) offset shift between feed K and recycle (cracked) K

HTCK XKUP(102) multiplier Heat of Cracking factor used to calculate Drum outlet temperature

Flow Control Quench molar Enthalpy Offset

XKUP(103) Offset correction to Flow Control Quench enthalpy, btu/mole

Furnace Duty Factor

XKUP(104) multiplier factor to adjust furnace duty during calibration

Reference CFR XKUP(105) Calibration CFR

Reference CFRD XKUP(106) Calibration CFR using only distillates

Reference CFRN XKUP(107) Calibration CFR (only tower bottom recycle, exclude distillate recycle)

Reference Velocity GO % of Furnace Feed

XKUP(108) Calibration Velocity Gas Oil % of feed

Reference Quench Del T (DTQ)

XKUP(109) deg F Drum vapor delta T due to Quench

Furn to Drum Delta T

XKUP(110) deg F Furnace outlet to Drum Inlet heat loss T

Drum Delta Temperature

XKUP(111) deg F Drum inlet T - Drum outlet T

Quenched Vapor to Frac Delta T

XKUP(112) deg F Heat loss of Quenched Drum Vapor to Frac inlet

T.C. Quench Oil vol Enthalpy Offset

XKUP(113) Offset correction to Temperature Control Quench enthalpy, Btu/bbl

Drum Minus Frac Pressure

XKUP(114) psi delta P between Drum and Fractionator overhead

Frac Minus WGS Suction

XKUP(115) psi delta P between Fractionator overhead and gas compressor suction P

Residence Time Base Volume

XKUP(116) cuft Furnace base flow rate used to adjust furnace residence time

Residence Time Basis

XKUP(117) multiplier Furnace residence time factor for cracking kinetics

HGO Draw Temp - Cutpt Shift

XKUP(118) deg F Shift between HGO draw temperature and HGO cut point


Calibration Factors

--- Type

Tower Temperature Adjustment

XKUP(119) deg F Adjustment to tower temperature profile to match plant data

Calibration FZGO Cut Point

XKUP(120) deg F Calibration FZGO cut point

Stream 3 Cloud Update

XKUPN(3) deg F delta between API predicted vs actual


XKUP(121) deg F delta between API predicted vs actual





Stream 3 Pour Update

XKUPN(4) deg F delta between API predicted vs actual







Calib External Temp Control Quench

XKUP(127) Used with Calib Ext Flow Control Quench to determine if too much Flow Control Quench predict input.

Calibration Drum Pressure

XKUP(128) psi

Calibration Drum Out Temp

XKUP(129) deg F

Calibration Total Feed CCR

XKUPN(11) wt%

Calibration Total Feed API

XKUPN(12)

Product API Adjust Factor for Slurry Oil

XKUPN(13) multiplier Power factor to UK2 ratio used in Predict mode to adjust product API when slurry oil is in feed

Calibration Coke Yield

XKUPN(14) wt%

Furnace Cracking T Tuning Factor

XKUPN(15) multiplier Used to shift the equivalent cracking T in furnace

Calib HGO T50 XKUPN(16)

Calib HGO API XKUPN(17)

FZGO Cracking Factor

XKUPN(18) multiplier Used to adjust FZGO range cracking

FZGO Tail Index XKUPN(19) Used to match plant data FZGO endpoint

TGO Bias XKUPN(20) Offset Tower HGO temperature internal bias


Calibration Factors

--- Type

Release Version XKUPN(21)

Prod 2 Flash Point Update

XKUPN(22) Offset

Prod 3 Flash Point Update

XKUPN(23) Offset

LGO Flash Point Update

XKUPN(24) Offset

HGO Flash Point Update

XKUPN(25) Offset

FZGO Flash Point Update

XKUPN(26) Offset

Release Build XKUPN(27)

Prod 1 Olefins Update

XKUPN(28) Offset

Prod 1 Naphthenes Update

XKUPN(29) Offset

Prod 1 Aromatics Update

XKUPN(30) Offset


XKUPN(31) Offset


XKUPN(32) Offset


XKUPN(33) Offset


XKUPN(34) Offset


XKUPN(35) Offset


XKUPN(36) Offset

Spare XKUPN(37)

Spare XKUPN(38)

Spare XKUPN(39)

Spare XKUPN(40)

Spare XKUPN(41)

Spare XKUPN(42)

Spare XKUPN(43)

Spare XKUPN(44)

Spare XKUPN(45)

VDRUM - Volume XKUP(130) cuft


Calibration Factors

--- Type

DDRUM - Diameter

XKUP(131) ft

HDVOL - Head Volume

XKUP(132) cuft

TLOUT - Top T/L Outage

XKUP(133) ft

CELLS - Number of Cells

XKUP(134)

MNOUT - Minimum Outage

XKUP(135) ft


DC-SIM User Guide KBC Proprietary Index - I • 1

Index

A

A Guide to Problem Solving 1:9 Adjustment of Coker Feed Back End

Distillation 1:4 Aniline Point 2:28 Available Models 4:6 Available Results Button 4:34 Available Results Item 4:14

B

Bromine Number 2:28

C

Calibration as a Once Through Unit 2:13

Calibration Case Checklist 2:12 Calibration Factors for PONA of

Naphtha Range Product 1:5 Calibration Input Data 2:7 Calibration Input Worksheet 4:18 Calibration of Once Through Unit as

a Conventional Recycle Unit 2:15

Cancel Button 4:7 CaseGen 4:31 Charts 4:34 Charts - 2 Worksheet 4:37 Charts Worksheet 4:34 Clear Button 4:21, 4:25 Clear Case Data Item 4:13 Coke Ash Content 2:29 Coke HGI 2:29 Coke Inventory 2:24 Coke Volatile Matter (VCM) 2:29 Comments 4:10 Comparison Worksheet 4:31 Configuration Guidelines 2:13

Constraints 2:30 Conventional Recycle Coker 2:17 Conversion of Old DC-SIM

Workbook to Current Version Workbook 1:5

Copy Button 4:20, 4:24, 4:25 Copy Case Data Item 4:13 Customizing the Workbook 4:8

D

Data Flow 4:3 DC-SIM Calibration Guidelines 2:20 DC-SIM Menu 4:11 DC-SIM Model Installation 3:3 DC-SIM Options Item 4:11 DC-SIM V2006 Calibration Factors

A:6 DCSIM V2006 Tuning Factors A:3 Definition of Combined Feed Ratio

(CFR) 2:17 Delayed Coker Refinery Unit 1:7 Design Worksheet 4:16 Diesel Cloud Point, Pour Point and

Flash Point 2:28 Drum Dimension Input Data 2:5

E

Excel Interface Standardization 1:6 Export Calibration to Petro-Sim 4:15 Export Case Data Item 4:14

F

Feedback 1:9 Fractionator Configuration for Extra

Low Recycle Operation 1:4

G

Gateway Workbook 4:4 Getting Started 4:6 Grouping Feature 4:9

H

Help and Error Messages 1:9 How DC-SIM Works 2:3 How the Calibration Case Works

2:11 How the Optimizer Works 2:30 How the Predict Case Works 2:26

2 • Index KBC Proprietary DC-SIM User Guide

I Import Button 4:19, 4:25 Import Case Data Item 4:14 Import from Petro-Sim 4:15 Initialization Factors A:2 Installation 3:3 Inter-conversion of Units of

Measurement for Data File During IMPORT 1:5

L

Links 4:14, 4:15 Load 4:37

M

Microsoft Excel 4:3 Microsoft References 3:2 Model Workbook 4:9 Model Workbook and Model

Workbook Template 4:5

N

Naphtha PONA 2:29 Naphtha RON and MON 2:28 Navigation Item 4:11, 4:12 New Tuning Factor for Furnace

Cracking Temperature 1:3 Nitrogen 2:28 Number and Decimal Regional

Settings 3:4

O

Once Through Coker 2:17 Opening DC-SIM with the Start Bar

3:7 Optimizer Improvements 1:3 Optimizer Input Worksheet 4:26 Optimizer Log 2:30, 2:31 Optimizer Run Checklist 2:30 Other Properties 2:29 Overview 1:2

P

PC System Requirements 3:2 Predict Case Checklist 2:26 Predict Input Data 2:22 Predict Input Worksheet 4:23

Predicting Viscosity and Flash Point Product Properties 1:4

Prediction of Once Through Unit Performance Using a Calibrated Conventional Recycle Unit 2:15

Problems When Running the Application 3:11

Proceed Button 4:6 Product Cutpoints Target 2:24 Product Properties 2:28 Program Security 1:5, 3:3 PSV Steam Input to Fractionator 1:5

Q

Quench 2:22

R

Reset Button 4:35 Result Worksheets 4:29 Run Button 4:18, 4:24, 4:27 Run Item 4:12 Run the Optimizer using the Run

button on the worksheet. 2:30, 2:31

S

Save 4:36 Saving Files and DC-SIM Exit 4:39 Security Settings and Macros 3:9 Select Button 4:35 Select the Optimizer Input

Worksheet. 2:30 Select Variable Button 4:35 Series /X Variable 4:36 Setting up a Shortcut 3:8 Settings Button 4:27 Setup Button 4:24, 4:27, 4:34 Special Once Through Coker

Configuration with No HCGO Net Product 1:5

Starting DC-SIM 3:8 Starting the Program 3:7 Starting with the Data Workbook 3:7 Sulfur 2:28 Summary Worksheet 4:33

T

Technical Help and Feedback 1:9

DC-SIM User Guide KBC Proprietary Index - I • 3

Test Run Data for Model Calibration 2:4

Testing the Program Execution 3:10 Text Files Item 4:13 Transfer Workbook Data 4:15

U

Update Button 4:35

V

Velocity Gas Oil 2:17, 2:23 VGen

LP Vector Generation Tool 4:28 Viscosity @ 50 C 2:29

W

What Is Installed 3:4 What's New in This Release 1:3 Worksheet Comments and Model

Help 4:38

Z

Zero Natural Recycle Configuration Once Through 2:13

Documents

DC SIM+User+Guide