Introduction
This project involved simulating the process units 100 to 700 of the Nouri Petrochemical Complex, a key and intricate industrial project. These units were modeled using Process Flow Diagrams (PFDs) in Aspen Plus, Version 10. The goal of this simulation and analysis was to enhance operational efficiency and improve the overall performance of the petrochemical systems.
Process Units in Nouri Petrochemical Complex
Unit 100 – Benzene Hydrogenation from Pyrolysis
This unit purifies pyrolysis benzene received from Jam Petrochemical. After passing through catalytic beds to remove nitrogen, sulfur compounds, and olefins, the treated benzene is sent to the reformate and aromatics separation unit.
Unit 200 – Gas Condensate Preparation
Gas condensate, sourced from the South Pars Gas Complex, enters this unit for the separation of light and heavy compounds. The product is then directed to the hydrotreating unit.
Unit 250 – Hydrotreating
Here, the output from Unit 200 undergoes catalytic treatment to remove nitrogen and sulfur compounds before being forwarded to the catalytic reforming unit.
Unit 300 – Catalytic Reforming
This unit converts paraffinic feed into aromatic compounds. The aromatic-rich hydrocarbons produced, along with the output from Unit 100, are directed to the reformate and aromatics separation unit.
Unit 350 – Catalyst Regeneration
Catalysts used in the four reactors of Unit 300 are regenerated here using a continuous moving bed mechanism. Deactivated catalysts from Unit 300 are continuously cycled through Unit 350 for regeneration and returned to the reactors.
Unit 400 – Reformate and Aromatics Separation and Ortho-xylene Production
The feed for this unit includes products from Units 100 and 300. The unit produces intermediate BT (benzene, toluene), xylene mixture, and C9+ products, as well as the final product, ortho-xylene.
Unit 500 – Benzene and Toluene Extraction
This unit extracts benzene, toluene, and non-aromatic hydrocarbons through extractive distillation using morpholine solvent. The aromatic compounds are then sent to Unit 600 for further separation.
Unit 600 – Disproportionation
In this unit, the benzene and toluene mixture is separated, with benzene stored as a primary product. The remaining toluene is converted into benzene and xylene mixtures in the reactor.
Unit 650 – Transalkylation
This unit converts C9 hydrocarbons from Unit 400 into a xylene mixture, which is returned to Unit 400 for separation.
Unit 700 – Para-xylene Separation
This unit isolates para-xylene from the xylene mixture using molecular sieves and para-diethylbenzene solvent. The remaining xylene components are sent to an isomerization unit for further processing.
Simulation and Process Optimization
Simulation of Units 100 to 300
This simulation covers hydrogenation, condensate preparation, hydrotreating, and catalytic reforming processes. It enables engineers to predict process behavior under operational conditions, applying necessary optimizations before implementation.
Simulation of Units 400 to 700
This section includes simulation for reformate and aromatics separation, extraction, and conversion processes, providing precise flow and interaction data for process control and management.
Energy and Exergy Analysis in Nouri Petrochemical Complex
Energy and exergy analyses were conducted across all units to optimize energy consumption and increase process efficiency. Tower optimization was also prioritized, utilizing analysis results to reduce costs and conserve energy resources.
Available Project Files
- Simulation File for Units 100 to 300
- Simulation File for Units 400 to 700
- Process Diagrams for the Petrochemical Complex
- Excel File for Energy and Exergy Analyses
These files are available for purchase and provide further technical details for specialized audiences.