(569x) Fast Tracking Process Development Life Cycle Based on State-of-the-Art Process Simulation Models

Abstract

The ability to fast track the process of the development life cycle by effectively utilizing state-of-the-art process simulation models is described in this article. The process development life cycle, encompassing various stages, such as research stage, process development stage and technology deployment stage, depends heavily on validated process models to enable researchers to reduce excessive and unnecessary research spending by efficiently optimizing the process schemes and process parameters. Recently, this novel approach of integrating process simulation efforts into process technology development throughout its life cycle has been successfully implemented for the development of Butenes to Butanols process technology at Saudi Aramco. Motivated by the opportunity to develop technologies to valorize undervalued streams and toward capturing refinery petrochemical integration benefits, researchers at Saudi Aramco invented a distinctive one-step process to convert mixture of Butenes into mixed Butanols liquid without the need for separation of the isomers. The mixed Butanols with high octane rating and energy content can be used as valuable oxygenates for clean fuel combustion and octane enhancers.

Preliminary simulation models developed during the research stage revealed significant issues associated with the Azeotropic nature of the mixed Butanol product, which aided researchers during the scale-up process to incorporate necessary process changes to the pilot plant. Validated simulation models based on pilot plant data were key in developing a comprehensive large scale integrated pilot plant with associated recycle loops and distillation columns that not only predicted optimized process schemes but also aided the researchers to foresee potential technical difficulties associated with product extraction and separation and to devise an action plan to successfully demonstrate the technology at a 60 kg/day capacity unit. In addition, process models are further modified and utilized to depict an 80 KTA commercial Butanol plant towards the development of a comprehensive feasibility study that enables the modelers and researchers to conduct rigorous process economics for potential technology deployment and licensing.

Authors:

Kadhim A MOHAMMED, kadhim.mohammed@aramco.com

Engineering Specialist

Process & Control Systems Department

Saudi Aramco

Dhahran 31311 SAUDI ARABIA

Kareemuddin M SHAIK, kareemuddin.shaik@aramco.com

Research Specialist

Research & Development Center

Saudi Aramco

Dhahran 31311 SAUDI ARABIA

Hiren SHETHNA, hiren.shethna@aramco.com

Engineering Specialist

Process & Control Systems Department

Saudi Aramco

Dhahran 31311 SAUDI ARABIA