Evaluation of the Effect of Tank Temperature on Transport of RAT (Atmospheric Distillation Residue) for the Potiguar Refinery Clara Camarão (RPCC)

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1 Evaluation of the Effect of Tank Temperature on Transport of RAT (Atmospheric Distillation Residue) for the Potiguar Refinery Clara Camarão (RPCC) Gildson Bastos Félix Chemtech Rodrigo Peralta Muniz Moreira ESSS Jairo Zago de Souza ESSS João Aguirre Oliveira Jr. ESSS José Harlen Albino Dantas Petrobras Laerte de Medeiros Barros Jr. Petrobras Waldir Pedro Martignoni Petrobras

2 PRESENTATION TOPICS Company Overview (2-3 minutes); Problem Description; Goals; Methodology; Results; Conclusion.

3 Company Overview The RPCC refinery is located in Guamaré City, 170 km from Natal. It was built in October 1st 2009.

4 Problem Description The refinery needs to improve its products portfolio and to reach this goal is necessary to sell the RAT as MF-380. However, we need to analyze the RAT flow conditions to avoid the paraffins deposition and to ensure the product expedition.

5 Goals Develop a numerical model to simulate pipeline transportation of paraffin; Complexity: Non-Newtonian fluid with a very complex rheology (shear-thinning and thixotropic); Evaluate RAT tank temperature effect in flow rate transportation; Using System Simulation tools: Flowmaster ; Identify possible critical conditions; Evaluate RAT temperature inside tank during the filling and emptying process with two operational condition: with and without insulation; Using CFD tools: ANSYS FLUENT Evaluate influence of tank insulation;

6 Methodology System Simulation Modeling tool: Flowmaster 1D fluid systems simulation software Mathematical model: Incompressible fluid Heat transfer calculation Viscosity calculation (shear-thinning) Flowmaster components to control the Viscosity vs Temperature curve Components controlled by routines Script inputs: temperature and flow rate Script outputs: dynamic viscosity vs. temperature curve

7 Methodology System Simulation a RAT Tank Ship Pipeline Land pipeline Marine pipeline Offshore and subsea pipeline was divided into several pieces to allow manipulating the curve of dynamic viscosity vs temperature, due to non-newtonian behavior of the fluid.

8 Temperature [ C] Dynamic viscosity [Pa.s] Flow rate [m³/h] Results System Simulation Tank Temperature [ºC] Flow rate [m³/h] Minimum Temperature [ºC] 2500 Flow rate , , , ,3 Next to critical temperature Tank Temperature [ºC] 80 Temperature 1,6 Dynamic Viscosity 75 1, ºC 50 ºC 60 ºC 80 ºC 1,2 1 0,8 0,6 40 ºC 50 ºC 60 ºC 80 ºC ,4 35 0, Length [m] RAT transportation from tank to final destination is feasible for all tank temperature simulations!! Length [m]

9 Methodology CFD Simulation CFD: Tank filling and emptying process Two geometric domain Fluid Domain (blue): Moving domain (floating roof) Solid Domain (grey): Static domain Fluid domain: Moves in vertical direction while tank fills or empts Dynamic mesh method: layering

10 Methodology CFD Simulation Software: ANSYS Fluent Transient; Single phase flow (floating roof tank); Turbulence: k-epsilon; Fluid with density as a temperature function; Natural convection effects; Non newtonian fluid Power law model; Boundary conditions: Non slip walls Hexaedrical mesh with initially 300 thousand of elements Heat transfer coefficients Couple walls in interface zone (fluid-solid) Velocity inlet for filling and emptying steps

11 Methodology CFD Simulation Dynamic Process: Filling, resting and emptying Process Filling Fake resting (relative to multiphase step) Time [hours] 14,8 Single phase filling 253,2 Resting 360,0 Emptying Dependent of flow rate of final of resting process (final temperature) Two case studies: Non insulated tank Insulated tank

12 Results Filling Process Non-insulated Tank Insulated Tank

13 Results Filling Process Similar temperature profile Main difference: solid temperature

14 Results Filling Process Non Insulated Tank Homogeneous temperature inside tank; Greater reliability in temperature measurements. Regions of lower temperature in tank film of liquid on the walls due to fluid cooling

15 Results Filling Process Insulated Tank Homogeneous temperature inside tank; Thermal resistance in side wall Regions of lower temperature in tank film of liquid on the walls due to fluid cooling For this case, there isn t so much thermal resistance on the side wall due to greater resistance in solid insulation

16 Problem Description Velocity profile Time: end of filling process Natural convection effect Low velocities Greater velocities in region of action of natural convection due to RAT inlet

17 Results Filling + Resting process

18 Results Resting process Low velocities (fluid ~ stagnant), high viscosity and low temperatures Large heat transfer resistance High velocities for insulated tank case, due to higher temperature in this case lower fluid viscosity

19 Results Resting process Temperature inside tank after resting: Non Insulated tank case: 56,3 ºC Insulated tank case: 61,3 ºC Tank temperature Flow rate 56,3 ºC 1958,4 m³/h 61,3 ºC 2098,4 m³/h Flow rate ~7% higher for insulated tank case

20 Results Emptying process

21 Conclusion Successful modeling of complex rheology fluids using 1D, systems focused tool. Model developed allowed Petrobras s engineers to identify critical conditions of operation Good approach to propose what-if scenarios of pump operation under several operation or environment conditions; CFD tank simulation allowed to predict what temperatures fluid could reach during filling and emptying process; Flow rate during emptying process for insulated tank was predicted as 7% greater than non insulated tank

22 Thank you

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