The GaBi Refinery Model - Sphera
The GaBiRefinery ModelFebruary 2019
AuthorDr.-Ing. Oliver Schulleroliver.schuller@thinkstep.comthinkstep AGHauptstr. 111 – 113, 70771 Leinfelden-Echterdingen, GermanyPhone: 49 711 341 817-0 Fax: 49 711 341 tep.com www.gabi-software.com1
ContentsContents.2Nomenclature .31Description of the Refinery Model.32Allocation in the GaBi refinery model .62.1Crude Oil Demand Allocation72.2Thermal Energy Demand Allocation82.3Electricity Demand Allocation82.4Allocation Example and Allocation method choice explanations92.4.1Crude oil demand2.4.2Thermal energy/ steam demand102.4.3Electricity demand11The Backpack Principle112.539Literature .142
ary- Butyl- EtherFCCFluid Catalytic CrackingHCHydro CarbonISOInternational Organization for StandardizationLCALife Cycle AssessmentLCILife Cycle InventoryLPGLiquefied Petroleum GasMTBEMethyl-Tertiary- Butyl- EtherNCVNet Calorific ValueRONResearch Octane Number1 Description of the Refinery ModelCrude oil refineries are complex plants. The combination and sequence of a large number ofprocesses is usually very specific to the characteristics of the crude oil input and the productsto be produced. Additional influencing factors are the market demand for the products, theavailable crude oil quality and certain requirements of the petroleum products set by authoritiesdetermining the configuration and complexity of a refinery.Simple Hydro-skimming refineries can process only a few crude oil qualities and produce fewhigh-quality products. Complex refineries with many conversion plants can process differentcrude oil types and produce different product slates.Crude oil refinery activities begin with the input of crude oil. After desalting, the crude oil is fedto the distillation column for atmospheric distillation (fractionation of the crude oil by separationaccording to density/ boiling/condensation areas). The light ends (gases) go up to the head ofthe column and are dispatched to the liquid gas system to recover methane and ethane for useas refinery fuel and LPG (propane and butane) as marketable products. This light productseparation occurs in almost every refinery. These gases can also be used in a steam-reformingprocess to produce hydrogen, which is necessary for the desulfurization processes, the hydrocracking and, to a lesser extent, the isomerization unit.3
The straight-run naphtha of the atmospheric distillation, which is taken in the upper trays of thecolumn are divided and fed to three different processes. The light naphtha fraction is introducedto the chemical sweetening process in some refineries. Some sweetened naphtha is directlyblended to the gasoline. The main fraction is sent to the isomerization unit where the aliphaticparaffins are converted into iso-paraffins with a high octane value. Often there is a deisopentanizer (distillation) downstream to increase the acquisition of iso-components. These isoparaffins are very valuable components for gasoline production with high RON content.After desulfurization, the heavy naphtha fractions are sent to the reformer for catalytictransformation from aliphatic paraffins to iso-paraffins and from cyclo-paraffins to aromaticcompounds, with a reduction of the net calorific value. The specific feature of this process is theproduction of hydrogen (the only hydrogen producer besides additional plants, like steamreforming). The outputs of the isomerization (often including a de-isopentanizer) and catalyticreforming go to the gasoline blending system and premium or regular gasoline follows as aproduct.Kerosene is directly obtained from the atmospheric distillation and is separately treated from therest of the middle distillates fraction. The main portion of the middle distillates produced in theatmospheric distillation is deployed into the hydrofiner (for desulfurization). The desulfurizedproduct is fed to the middle distillate blender. The residue from the atmospheric distillation isintroduced to the vacuum distillation. Here, distillation occurs in light vacuum gas oil, vacuumgas oil (wax distillate) and vacuum residue.A portion of the atmospheric residue is fed into the visbreaker (mild thermal cracking). Smallamounts are sometimes introduced directly into the heavy fuel oil blending system and theasphalt-blowing process. The light gas oil, as a product of the vacuum distillation, goes to thehydrofiner, is desulfurized, and employed to the middle distillate blender. Some of the vacuumdistillate, which has been taken from the middle trays of the vacuum distillation, is introduced tothe base oil production of lubricants and waxes (paraffins). Most of it is fed either to a catalyticcracker (often first desulfurized) or a hydrocracker, where the feeds are converted into shorterchains by molecule restructuring. The products are gases, gasoline, middle distillates and heavycycle gas oils (components of the heavy fuel oil). The gases of the catalytic cracking are treatedin an alkylation and polymerization unit to manufacture additional valuable gasolinecomponents. These processes are used to combine small petroleum molecules into larger ones.Butylene of the catalytic cracker is further used together with external supplied methanol toproduce Methyl-Tertiary- Butyl- Ether (MTBE), a product used as octane booster. Externallypurchased (bio-)ethanol is also often used in the esterification instead of Methanol. In this case4
the product is called ETBE. The naphtha of the FCC has to be treated in a special desulfurizationprocess to reduce the high sulfur content. The vacuum residues go into the coking process,which produces gases, gasoline, middle distillates and heavy fuel oil. A further product ispetroleum coke, which is then purified. The vacuum residue, like some of the atmosphericresidue, is also used as feed for the visbreaking, which also produces gases, naphtha, middledistillates and heavy fuel oil. The extracted hydrogen sulfides of all desulfurization processesare fed to a sulfur recovery unit to recover elemental sulfur.The energy generation (heat, steam and electricity) requires a large amount of fuels. The fuelburned in refineries power plants and incinerators may be refinery gas, light fuel oil, heavy fueloil (residual oil), petrol coke and sometimes LPG. In addition, purchased natural gas andelectricity is also employed.The main material and energy flows (input- output) are shown in the following graph “SystemBoundary of a Refinery”.System boundaryCrude oilProductsNatural gasGaBiRefining modelElectricityMethanol / EthanolEmissionsWaterWaste waterHydrogenFigure 1-1:System Boundary of a RefineryA simplified flow chart is shown below. The arrangement of these processes varies among refineriesand few, if any, employ all of these processes.5
Figure 1-2:Refinery Flow Chart2 Allocation in the GaBi refinery modelAlmost all refinery operations are multifunctional processes. Multifunctional processes createtwo or more simultaneous products (co-products). The challenge is to allocate the individualloads of the material and energetic input as well as the emissions released by the process toeach product. ISO standards 14040 and 14044 define allocation as “partitioning the input oroutput flows of a process or a product system between the product system under study and oneor more other product systems.”The inputs of nearly each of the refinery unit processes are thermal energy, steam (both fromnow on called simply “energy”), electricity and crude oil (crude oil only fed in the atmosphericdistillation, the other refinery processes only has a corresponding crude oil consumption). Theenvironmental burdens associated with the provision of these energy and material inputs, e.g.emissions from the steam generation or the upstream emissions of the crude oil supply, mustbe allocated according to the relationship of the different products. This association is doneusing a distribution tool called allocation factors.6
Furthermore, it is assumed that all emissions caused within the refinery (from thermal energy,steam, and electricity production as well as single processes and losses) arise in the refinerypower plant and are allocated to the refinery products with the help of the amount of energyinput of each unit process. This assumption is validated by the fact that nearly all emissions( 95%) are released by the energy supply and in particular by the on-site power plant.Therefore, the environmental burdens of the following “processes” listed below must beallocated to the refinery products. These include: The emissions of the refinery power plant (incl. the power plant itself, converting plants,decentralized boilers, storage, losses) The impact of the crude oil supply (crude oil mix) The impacts of the electricity supply (purchased electricity which is used in addition tothe one produced in the power plant; electricity mix) The impacts of the natural gas supply (if natural gas is used; natural gas mix) The impacts of the methanol/ ethanol supply (if MTBE/ETBE is produced) The impacts of the hydrogen supply (if hydrogen from external sources is used)An appropriate allocation factor must be chosen and its suitability must be justified.The emissions caused by refining are allocated similarly to the impacts of the upstream chainsexternal electricity and natural gas following a mass allocation. The impacts related to the crudeoil supply are allocated by energy content to the products. Impacts from methanol/ethanol andhydrogen supply are assigned directly to the applicable products, e.g. the methanol and ethanolemissions to the produced gasoline.In the next paragraph, the choice of the allocation method is described theoretically and in thefollowing further explained by applying to an example.In general, the allocation condition must be fulfilled, i.e. the inputs and outputs which have beenallocated in a unit process must add up to the inputs and outputs before the allocation wereperformed.2.1 Crude Oil Demand AllocationCrude oil demand is how much crude oil is received by the refinery. This crude oil is processedto refinery products like diesel, gasoline, etc. Processing crude oil determines emissions in thecrude oil supply (crude oil production and crude oil transport), which then must be attributed(called: allocated) to each product of the refinery.7
The crude oil demand COi,Process (expressed in mass), required for the production of product i,(product i defined by its mass mi and its net calorific value of NCVi) of a certain unit process iscalculated proportionately to mass, mi, and the average net calorific value, NCVavg, of allproducts produced in the refinery process. The mass, mi, is calculated with the weightpercentage, mpi, of the total mass of all products produced within this unit process and the crudeoil input of the refinery �𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑝𝑝𝑝𝑝 𝑚𝑚𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑂𝑂𝑂𝑂𝑂𝑂 𝑎𝑎𝑎𝑎 𝑖𝑖𝑛𝑛 1 𝑝𝑝𝑝𝑝 𝑁𝑁𝑁𝑁𝑁𝑁𝑖𝑖100%(2)The crude oil demand (or better: the burden of crude oil supply) is allocated to the refineryproducts according to the quantity produced in the unit process and its energy content. Hence,crude oil consumption of product i, is allocated according to its net calorific value.2.2 Thermal Energy Demand AllocationThe thermal energy demand, ThEi,Process, needed for the production of product i, with mass, mi,of the unit process is calculated with the total energy demand, �𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 ��𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑖𝑖𝑚𝑚𝑖𝑖𝑛𝑛 1 𝑚𝑚𝑖𝑖𝑚𝑚𝑝𝑝𝑝𝑝 ��𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 100%(3)The energy demand required for the production of a product corresponds to a value that isrelative to its weight percentage of the total mass.Hence, the thermal energy demand is also allocated by mass.2.3 Electricity Demand AllocationThe electricity demand, Eli,Process, required for the production of product i, with mass, mi, of theunit process is calculated in the same way as the thermal energy demand with the total demandof electricity, Eltot,Process:Eli,Process Eltot,Process imin 1 mi Eltot,Process mpi100%(4)8
Hence, the electricity demand is allocated by mass as well.2.4 Allocation Example and Allocation method choice explanationsFigure 2-2 shows the allocation of the atmospheric distillation (example).FuelFinput 0.54 MJSteamStinput 0.028 kg** Converted with 3.05 MJ/kgThermal EnergyThEinput 0.6254 MJCrude oilNCV 42.7 MJ/kg1 kgElectricityElinput 0.005 kWhAtmosphericDistillation0.036 kgGasesNCV 48.7 MJ/kgCrude oil (Gases) 0.04169 kgThermal Energy (Gases) 0.02251 MJElectricity (Gases) 0.00018 kWh0.184 kgGasolineNCV 44.5 MJ/kgCrude oil (Gasoline) 0.1947 kgThermal Energy (Gasoline) 0.1151 MJElectricity (Gasoline) 0.00092 kWh0.337 kgMiddle DistillatesNCV 42.7 MJ/kgCrude oil (MD) 0.3422 kgThermal Energy (MD) 0.2108 MJElectricity (MD) 0.00169 kWh0.443 kgAtmospheric ResidueNCV 40.0 MJ/kgCrude oil (AR) 0.4214 kgThermal Energy (AR) 0.2771 MJElectricity (AR) 0.00222 kWh NCVavg 42.05 MJ/kgAllocation condition InputCrude oil 1 kgThermal Energy (Total) 0.6254 MJElectricity 0.005 kWhfulfilled! OutputCrude oil 1 kgThermal Energy (Total) 0.6254 MJElectricity 0.005 kWhFigure 2-1: Allocation example of the atmospheric distillation2.4.1 Crude oil demandFigure 2-1 demonstrates that products with higher net calorific values than the average (gases,naphtha, middle distillates), result in a higher amount of crude oil demand (consumption)compared with products with a lower net calorific value (atmospheric residue). For example,from 1 kg of crude oil input, 0.036 kg gases are produced. To produce a specific amount ofproduct (in this case 0.036 kg), a corresponding amount of 0.036 kg of crude oil is necessary.Through allocation, the gases are attributed 0.04169 kg of the crude oil demand.The atmospheric residue works contrary to those with high net calorific value. The “real” materialconsumption (corresponding crude oil demand) is 0.443 kg but the allocation attributes only0.4214 kg due to its low net calorific value. Therefore, products with higher net calorific valueare attributed higher input amounts, and therefore higher environmental impacts (associatedwith the crude oil supply), than products with a lower net calorific value. This allocation approachdoes make sense, because lighter fractions are usually the preferred refinery products and a lotof effort is undertaken to produce them. This sort of extra effort is expressed in slightly higher9
associated burdens. For instance, a lot of processing steps are involved in converting heavyfractions to lighter fractions, ultimately to a higher calorific value. Note, light products have oftena higher market demand and market price. As previously mentioned, all products are consideredto be main products (outputs) and are taken into account in allocation, but there are also mainproducts with a higher complexity than others, resulting from the lighter fractions and requiremore effort in production to obtain the required amount of refinery products in the end. Theallocation of the crude oil input by net calorific value could also be explained from a physicalpoint of view, because the energy content is a representative value relating to the crude oilconsumption of the refinery products. Background is the predominant energetic applications ofthe refinery products, on which representative oil consumption should be based.This method is therefore providing a cause-oriented assignment of environmental impacts. Thephysical factor “net calorific value” as opposed to “market price” is preferred for allocation,because the assessment of plant-internal interim products with “market prices” is simply notpossible as there are no market prices on intermediates. Moreover, economic allocation isalready not the preferred allocation method following ISO 14044. Because there is a correlation(not linear and within limits) between market price and heating value, the conclusion of bothallocation methods should anyway yield similar results.2.4.2 Thermal energy/ steam demandThe first step to find an adequate method for the allocation is to clarify the scope of theparameters (in this case thermal energy and steam) used in the processes. Then a fairassessment must be developed according to the input involved. The preheating phase to heatthe different refinery process input materials to process temperature is the primary energyconsumer in most of the refinery processes.Equation (5) shows that heat, Q, which is the affiliated energy of a medium, depends on thespecific heat capacity, c. The mass is m, and the temperature difference T.𝑄𝑄 𝑚𝑚 𝑐𝑐 𝑇𝑇(5)Based on the aforementioned information the following conclusion can be made: An allocationbased on crude oil demand, similar to that based on “net calorific value,” would increase theenvironmental impact associated with the provision of thermal energy, associated withproducing heavier fractions. Since the heavier fractions have a higher specific heat capacity ccompared to the lighter products, a higher amount of energy is needed to heat them to the sametemperature, resulting in a higher T. For example, for the separation via distillation (higherboiling point) an allocation by mass was chosen for the energy demand. As a result, a10
“preferential treatment” toward the heavier products is avoided (compared to the allocation withnet calorific value).2.4.3 Electricity demandThe allocation by mass can also be used for the electricity demand. The mass of the product isused for the allocation, not because of higher specific heat capacity c, but rather the higherdensity of heavier products. The electricity is primarily used to run the equipment, which includespumps and mixers. The pump performance increases with the density of the medium, soallocation by mass is argued to be sufficiently efficient to demonstrate the higher burden of theheavy fractions.Figure 2-1 shows a fulfilled allocation constraint: The sum of allocated inputs and outputs to aprocess are equal to the sum of inputs and outputs before allocation. This point can be observedat the bottom of Figure 2-1, where a comparison of the sums of the inputs and outputs are made.2.5 The Backpack PrincipleTo quantify and assess the energy and material (crude oil) demand that is essential to producerefinery-finished products, the consideration of the atmospheric distillation process alone is notsufficient. Since most of the products pass through a great number of processes within therefinery, all refinery processes must be considered and allocated to the final products. Morecomplex products (which undergo many more processes), such as fuel, require a higherelectricity and energy demand (and therefore higher environmental loads) compared to productswhich undergo fewer refinery processes, such as vacuum residue which can be used directlyas bitumen.This requirement is achieved through the “Backpack Principle”. Each output of the refinery unitprocesses is assigned a “backpack” of allocated crude oil, energy and electricity demand.Thereby the backpack (crude oil, energy and electricity demand) of the feedstock plus theenergy and electricity demand of the subsequent processes are allocated to the products andhence, the backpack continues to accumulate during subsequent “travel” through the refinery.The formula for the distribution of the feedstock backpack’s content is the same as for the crudeoil, energy and electricity demands of the atmospheric distillation process. In their respectivebackpacks, the products carry a proportionate amount of the feedstock, as well as aproportionate amount that has been redefined in each process stage.11
FuelFinput 0.246 MJSteamStinput 0.0164 kg** Converted with 3.05 MJ/kgThermal EnergyThEinput 0.29602 MJElectricityElinput 0.00123 kWhBackpack:Crude OilCOAR 0.4214 kgThermal EnergyThEAR 0.2771 MJElARElectricity 0.00222 kWhVaccumDistillation0.027 kgGasoilNCV 40.0 MJ/kgCrude oil (Gasoil) 0.0273 kgThermal Energy (Gasoil) 0.03493 MJElectricity (Gasoil) 0.00021 kWh0.261 kgWax DistillatesNCV 39.0 MJ/kgCrude oil (WD) 0.2571 kgThermal Energy (WD) 0.33766 MJElectricity (WD) 0.00203 kWhVacuum ResidueNCV 35.0 MJ/kgCrude oil (VR) 0.1370 kgThermal Energy (VR) 0.20053 MJElectricity (VR) 0.00121 kWh0.155 kgAtmospheric Residue 0.443 kgNCV 40.0 MJ/kg NCVavg 37.66 MJ/kgAllocation condition InputFigure 2-2:Crude oil 0.4214 kgThermal Energy 0.57312 MJElectricity (Total) 0.00345 kWhfulfilled! OutputCrude oil 0.4214kgThermal Energy (Total) 0.57312 MJElectricity 0.00345 kWhAllocation example of the vacuum distillationTo the three products of the vacuum distillation unit (gas oil, wax distillates and vacuum residue)a share of the crude oil (backpack of raw material), electricity (backpack of electricity andelectricity demand of process) and energy demand (backpack of energy and energy demand ofprocess) is allocated. The allocated crude oil demand of subsequent process inputs in the“downstream processes” is redistributed to the products (“subsequent processes are notallocated crude oil input”), during which the shares of energy and electricity in the backpackincrease according to the energy required at the current process stage.For processes with two or more hydrocarbon inputs, the respective input fractions of thebackpacks are added together.All subsequent processes of the atmospheric distillation consist of five corresponding inputs.Crude oil, energy and electricity of the input backpack, as well as energy and electricity at eachspecific step in the refinery process (in rare cases there are zero inputs, which means noconsumption occurs, or even negative inputs, which means that energy or electricity is producedand hence credited) makes up the five inputs.There are significant differences in the energy and electricity demands of each unit process.There are also differences in the number of processes a finished product undergoes over thecourse of its production route. But the backpack principle guarantees that each finished productis assigned the environmental impact of all processes over the course of its production pathway.12
Gasoline derived from atmospheric distillation, which only undergoes gasoline desulfurizationand passes through the catalytic reformer, has a smaller backpack than gasoline produced viaatmospheric distillation followed by vacuum distillation, vacuum distillate desulfurization, andFCC because more processes are involved. Vacuum residue which can be sold directly asbitumen has a smaller backpack than the finished diesel fuel product.13
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Crude oil demand is how much crude oil is received by the refinery. This crude oil is processed to refinery products like diesel, gasoline, etc. Processing crude oil determines emissions in the crude oil supply (crude oil production and crude oil transport), which then must be attributed (called: allocated) to each product of the refinery.
Due to the interlinkages within refinery, all refinery products and all processes within the refinery a must be considered when analyzing the environmental performance of refinery products. The "GaBi LCA Refinery Model" is a generic, parameterized LCA model which describes the con-version of crude oil into finished refinery products.
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Dr. Sunita Bharatwal** Dr. Pawan Garga*** Abstract Customer satisfaction is derived from thè functionalities and values, a product or Service can provide. The current study aims to segregate thè dimensions of ordine Service quality and gather insights on its impact on web shopping. The trends of purchases have
Operation Guide for the Mercedes-Benz GLA/CLA This is a basic operation guide for those who are driving the Mercedes-Benz GLA/CLA vehicle for the first time. Please read this guide before you leave the rental office if you are not familiar with operation. For more information about the vehicle, please read the instruction manual. Basic Operations to Note Before Driving the Vehicle Starting .
