Heat Balance Calculations

Problem Statement: Operating temperatures, flow rates, flue gas

analysis and feed properties are provided for Refinery A.

Perform heat balance and estimate the following:

Argon corrected flue gas analysis

Dry air to Regenerator

Flue gas flow rate

Coke make

H2 in coke

Air to coke ratio

Catalyst circulation rate

Cat / Oil ratio

Delta coke

Heat of Reaction

6-1 UOP - CONFIDENTIAL

 Operating Data

Base Data:
Parameter Value UOM
Combined Feed Temperature 375 F
Lift Gas Temperature 100 F
Steam Temperature 380 F
Reactor Temperature 970 F
Regenerated Catalyst Temperature 1371 F
Ave. Hottest Regen Temperature 1375 F
Air to Regenerator (MAB Discharge) 399 F
Ambient Temperature 62 F
Ambient Relative Humidity 97 %

6-2 UOP - CONFIDENTIAL

 Operating Data (continued)

Parameter Value UOM

Fresh Feed Rate (30,565 BPD) 412,923 lb/hr
Fresh Feed Gravity at base temperature 21.3 API
Fresh Feed UOP K 11.8
MCB Recycle Flow to Riser 0 lb/hr
Lift Gas Rate (Sponge Gas) 3,250 lb/hr
Lift Steam Flow Rate 12,900 lb/hr
Feed Steam Flow Rate 1,800 lb/hr
Stripping Steam Flow Rate 5,000 lb/hr
Air to Regenerator Flow Rate 380,200 lb/hr

6-3 UOP - CONFIDENTIAL

 Flue Gas Analysis

Flue Gas Composition (Mole % by GC)

CO 0
CO2 15.50
O2 + Ar 3.47
N2 81.03
SOx 0
NOx 0

6-4 UOP - CONFIDENTIAL

 Step 1 : Argon correction

Adjust Flue Gas Composition & correct for Argon,

if necessary:
Component GC, Mol% Argon correction Ar Corrected
GC, mol%
CO 0 0
CO2 15.50 15.50
O2 + Ar 3.47 [O2 - (0.012)x(N2)] 2.50
N2 81.03 [N2 + O2 - O2Corrected] 82.00
SOx 0 0
NOx 0 0
Total 100.00 100.00

Note: Correction required for GC flue gas analyses, flue gas

analyses by Orsat are correct, i.e. N2+Ar.
6-5 UOP - CONFIDENTIAL
 Step 2: Correct Air to dry basis

Estimate Moisture content of Air - Antoines equation

a = Ambient Temperature = 62 F

b = Relative Humidity = 97 %
3165.36
6 .40375-
a + 392 .595
c = Saturated Vapor Pressure = 10
3165 .36
6 .40375 -
= 10 62 + 392 .595 = 0.2756 psia

Moisture content of ambient air =

[0.00622 b c ]
(14.696 [0.01 b c])
= [0.00622 97 0.2756] = 0.0115 lbwater/lbdry air
(14.696 [0.01 97 0.2756])
6-6 UOP - CONFIDENTIAL
 Step 2: Correct Air to dry basis (continued)

Total Air to Regenerator = 380,200 lb/hr

Total Airlb/hr
Dry Air to Regenerator =
[ ]
1 + (lb H 2O lbdry air )
380,200
= = 375,870 lb/hr
[1 + 0.0115]

H2O vapor in Air

(Total Air - Dry Air) = (380,200-375,870) = 4,330 lb/hr

6-7 UOP - CONFIDENTIAL

 Step 3: Calculate flue gas rate

Flue gas rate is not measured by a flow meter,

so we need to calculate it
Nitrogen stays constant, so we use it to find
the flue gas rate

N2 + Ar (in air) = N2 + Ar (in flue gas)

lb
375,870 hr
Dry Air, mol/hr = = 12,976 lbmol/hr
28.966
(MW air)

6-8 UOP - CONFIDENTIAL

 Step 3: Calculate flue gas rate (continued)

Estimate number of moles of N2 + Ar in Air

N2 + Ar (in air) = 12,976 lbmol/hrdry air x 79%(N2 + Ar in air)
= 10,251 lbmol/hr

The moles of N2 + Ar in Air and flue gas stay constant

N2 + Ar (in flue gas) = n lbmol/hrflue gas x 82%(N2 + Ar in flue gas)
Flue gas rate, n lbmol/hrflue gas = 10,251 / 82%

= 12,501 lbmol/hr

6-9 UOP - CONFIDENTIAL

 Step 4 : Estimate Carbon Content of Coke

C + O2 + H2 + S + N  CO + CO2 + H2O + O2 + SOX + NOX

If 1 mole of C burns for each mole of CO or CO2

produced, then:

No. of moles of carbon burnt,

(Mol%CO + Mol%CO2 )
Clbmol/hr = lbmol hr flue gas
100
(0 + 15.50) = 1,938 lbmol/hr
Clbmol/hr = 12,501
100

6-10 UOP - CONFIDENTIAL

 Step 5: Perform Oxygen balance

C + O2 + H2 + S + N  CO + CO2 + H2O + O2 + SOX + NOX

Calculate H2O formed due to combustion by O2 balance
O2 in air = (O2 in flue gas) + (O2 in CO) + (O2 in CO2) + (O2 in H2O)
O2 in air = 12,976 lbmol/hrdry airx 21% = 2,725 lbmol/hr
O2 in flue gas = 12,501 lbmol/hrflue gas x 2.5% = 312 lbmol/hr
O2 in CO = 12,501 x 0% x (0.5 lbmol O2/lbmol CO) = 0 lbmol/hr
O2 in CO2 = 12,501 x 15.5% = 1,938 lbmol/hr
O2 in SO2 = 12,501 x 0% = 0 lbmol/hr
O2 in NO2 = 12,501 x 0% = 0 lbmol/hr
O2 in H2O = 2,725 - 312 - 0 - 1,938 - 0 - 0 = 475 lbmol/hr
Calculate the H2 burnt to H2O
H2 burned to H2O = 2 lbmolH2/lbmolO2 x 475 lbmol/hrO2 = 950 lbmol/hr
6-11 UOP - CONFIDENTIAL
 Step 6: Estimate Coke Yield

Calculate Coke from C and H2

Clb/hr = lbmol hrC MWC = 1,938 x 12.01 = 23,275 lb/hr

H 2 (lb/hr) = lbmol hrH 2 MWH 2 = 950 x 2.016 = 1,915 lb/hr

Coke Ratelb/hr = C + H2 = 23,275 + 1,915 = 25,190 lb/hr

Coke hrlb
Coke Yieldwt% FF = 100
lb
Fresh Feed hr

= 25,190 / 412,923 x 100 = 6.10 wt% of Fresh Feed

6-12 UOP - CONFIDENTIAL

 Step 7: Calculate Hydrogen in Coke

H 2 hrlb
H2 in Cokewt% = 100
lb
Coke hr

= 1,915 / 25,190 x 100 = 7.60 wt%

Dry Air hrlb

Air to Cokelb/lb =
Coke hrlb

= 375,870 / 25,190 = 14.92 lbair/lbcoke

6-13 UOP - CONFIDENTIAL

 Step 8: Correct HC for Regen temperature

Basis: 1 lb of Coke

Average hottest regenerator temperature = 1,375 F

Correct HC for operating temperature:

HC (CO) = 46,216 + (1.47 x 1375F) = 48,237 Btu/lbmol

HC (CO2) = 169,135 + (0.500 x 1375F) = 169,822 Btu/lbmol

HC (H2O) = 104,546 + (1.586 x 1375F) = 106,725 Btu/lbmol

Heat of combustion, BTU/lbmol @ 25C

Note: The HC for various compounds in reference handbooks is provided at 25C (77F). These heat of combustions must
be corrected for the operating temperature of regenerator.
6-14 UOP - CONFIDENTIAL
 Step 9: Convert HC of compounds to Btu/hr

Since: C + O2 + H2  CO + CO2 + H2O + O2

Convert HC of compounds to Btu/hr

HC (CO2) = HC (CO2)Btu/lbmol x C in Cokelbmol/hr

= 169,822 x 1,938 = 329,100,000 Btu/hr

HC (H2O) = HC (H2O)Btu/lbmol x H2O in Cokelbmol/hr

= 106,725 x 950 = 101,400,000 Btu/hr

6-15 UOP - CONFIDENTIAL

 Step 10: Calculate gross heat of combustion

The gross heat of combustion of coke in Btu/lb of coke is

sum of heat of combustions of CO, CO2 and H2O divided by
total coke make in lb/hr.
i.e.
HComb = [HC (CO2) + HC (H2O)]Btu/hr/Cokelb/hr)
= [329,100,000 + 101,400,000]/25,190
= 17,090 Btu/lb Coke

6-16 UOP - CONFIDENTIAL

 Step 11: Correction factor for H2 in Coke

Calculate Correction Factor for Hydrogen in Coke

H2 Correction Factor = 1133 - (134.64 x wt% H2 in Coke)
= 1133 - (134.64 x 7.60)
== + 110 Btu/lb Coke

Corrected Gross Heat of Coke Combustion (H

(HCombCoke)
HCombCoke = HComb + H2 Corr Factor = 17,090 + 110
= 17,200 Btu/lb Coke

Note: The base heats of combustion are for the burning of H2, Carbon (graphite), or CO to the combustion products
H2O + CO2. Since Coke is not an ideal compound, it does not behave necessarily like these ideal compounds.

Therefore, an adjustment must be made for the effect of the Hydrogen-Carbon interactions in the coke.
6-17 UOP - CONFIDENTIAL
 Step 12: Heat consumed by streams
Regenerator Heat Balance:
Basis: 1 lb of Coke
Heat consumed to heat up catalyst,
QNet = HCombCoke - HCoke - HAir - HH2O - HRadLoss - HHtRemoval
Also, QNet = mass x CP x T

Heat consumed to heat up coke,

HCoke = (0.4 Btu/lbF) x (TFG-TRx) = 0.4 x (1375 - 970)
= 162 Btu/lb Coke
Heat consumed to heat up Air,
HAir = Air/Cokelb/lb x 0.26 Btu/lbF x (TFG-TMAB)
= 14.92 x 0.26 x (1375 - 399)
= 3,786 Btu/lb Coke

6-18 UOP - CONFIDENTIAL

 Step 12: Heat consumed by streams (contd..)

Heat consumed to heat up water,

HH2O = (H2O in Air)/Cokelb/lbx 0.485 Btu/lbF x (TFG-TMAB)
= (4,330/25,190) x 0.485 x (1375 - 399) = 81 Btu/lb Coke

Radiation losses,
HRadiation Loss = 250 Btu/lb Coke

Heat consumed to generate steam in catalyst cooler,

HHt Removal = Cooler Duty, calc separately = 58,750,000 Btu/hr
= (Cooler DutyBtu/hr)/Cokelb/hr)
= 58,750,000/25,190 = 2,332 Btu/lb Coke

6-19 UOP - CONFIDENTIAL

 Step 13: Net Heat of Combustion

Heat consumed to heat up catalyst,

QNet = HCombCoke - HCoke - HAir - HH2O - HRadLoss -

HHtRemoval

= 17,200 - 162 - 3786 - 81 - 250 - 2,332

= 10,589 Btu/lb Coke

6-20 UOP - CONFIDENTIAL

 Step 14: Catalyst circulation rate

Also, QNet = mass x Cp x T

then mass = QNet / (Cp x T)

Therefore, Catalyst Circulation Rate,

CCR = (Cokelb/hr x Net Regen HeatBtu/lb Coke)

[0.275 Btu/lbF x (TCat-TRx)]

= (25,190 x 10,589)/[0.275 x (1371 - 970)]

= 2,419,000 lb/hr

= 2,419,000lb/hr/ (60 min/hr x 2,000 lb/ton)

= 20.16 ton/min
6-21 UOP - CONFIDENTIAL
 Step 15: Catalyst to oil ratio & Delta coke

Cat/Oil Ratio = Cat Circ lb/hr/FFlb/hr

= 2,419,000 / 412,923

= 5.86 lb/lb

Cokewt% = Cokelb/hr / Cat Circ lb/hr x 100

= 25,190 / 2,419,000 x 100

= 1.04 wt%

6-22 UOP - CONFIDENTIAL

 Reactor Heat Balance

Reactor Heat Balance: Basis: 1.0 lb of Fresh Feed

Reactor Temp (TRx) 970 F
Combined Feed Temp (TCF) 375 F
Fresh Feed Rate (FF) 412,923 lb/hr
Recycle Rate (Recy) 0 lb/hr
FF Enthalpy at TCF (HFFCFT) 252 Btu/lb
FF Enthalpy at TRx (HFFRxT) 760 Btu/lb
Recycle Enthalpy at TCF (HRecyCFT) 0 Btu/lb
Recycle Enthalpy at TRx (HRecyRxT) 0 Btu/lb

6-23 UOP - CONFIDENTIAL

 Reactor Heat Balance

Inerts from Regen (assumed) 0.007 lb/lb FF

Inerts Specific Heat (Cp) 0.275 Btu/lbF
Lift Gas Temp (TLG) 100 F
Lift Gas Rate (Sponge Gas) 3,250 lb/hr
Lift Gas Specific Heat (CpLG) 0.5 Btu/lbF
Steam Temp (TStm) 380 F
Steam Specific Heat (CpStm) 0.485 Btu/lbF
Feed Dispersion Steam Rate 1,800 lb/hr
Lift Steam Rate 12,900 lb/hr
Stripping Steam Rate 5,000 lb/hr

6-24 UOP - CONFIDENTIAL

 Entrained Inerts

1 1 Pemulsion MWgas
Inertsmass time = Cat Circ Rate
emulsion skeletal R Tcatalyst

- MWgas 29 for Regen standpipe, 18 for spent standpipe

- emulsion 40 lb/ft
 The standpipe overall density should not be used, as its not indicative
of the gas that is carried with the catalyst)
- skeletal 160 lb/ft (use the catalyst vendors value if available)
- Pemulsion abs. pres. at the lowest point in the standpipe, usually just
upstream of the slide valve

- All catalyst temperatures in R or K

6-25 UOP - CONFIDENTIAL

 Entrained Inerts

1 1 Pemulsion MWgas
Inertsmass time = Cat Circ Rate
emulsion skeletal R Tcatalyst

Regenerated Catalyst
Cat Circ Rate lb/hr PRCSV inlet
Inertslbs/hr = 29
572.352 TRegen cat

Spent Catalyst
Cat Circ Ratelb/hr PSCSV inlet
Inertslbs/hr = 18
572.352 Tspent cat

6-26 UOP - CONFIDENTIAL

 Reactor Heat Demand

Reactor Heat Balance:

Reactor heat demand QRx by rearranging formula (2):

QRx = HFF + HRecy + HLG + HStm + HInerts + HRad Loss + HRx

Also,

QRx = mass x CP x T

6-27 UOP - CONFIDENTIAL

 Step 16: Heat consumed by streams

Heat Consumed by Feed

HFF = HFFRxT-HFFCFT
= 760 - 252 = 508 Btu/lb FF

Heat Consumed by Recycle

HRecy = Recy x (HRecyRxT-HRecyCFT) /FFlb/hr = 0 Btu/lb FF

Heat Consumed by Steam

HStm = Total Stm x CpStm x (TRx-TStm)/FFlb/hr

= (5,000 + 1,800 + 12,900)x 0.485 x (970 - 380) /412,923
= 13.6 Btu/lb FF
6-28 UOP - CONFIDENTIAL
 Step 16: Heat consumed by streams (contd)

Heat Consumed by Lift Gas

HLG = LG x CpLG x (TRx-TLG)/FFlb/hr
= 3,250 x 0.500 x (970 - 100) /412,923 = 3.4 Btu/lb FF
Heat Consumed by Inerts
HInerts = Inerts Rate lb/lb FF x CpInerts x (TRx-TRegen Cat)
= 0.007lb/lb FF x 0.275 x (970 - 1371) = -0.8 Btu/lb FF

Reactor Radiation Losses (typically 2 Btu/lb FF)

HRad Loss = 2 Btu/lb FF

6-29 UOP - CONFIDENTIAL

 Step 17: Calculate Reactor heat demand

Reactor Heat Demand,

QRx= HFF + HRecy + HLG + HStm + HInerts + HRadLoss + HRxn

= (508 + 0 + 3.4 + 13.6 - 0.8 + 2) + HRxn

= 526.2 + HRxn Btu/lbFF

6-30 UOP - CONFIDENTIAL

 Step 18 : Overall Heat Balance

Overall Balance: QNet = QRx

lb Coke
Q net ( BTU lb Coke ) = Q Rx ( BTU lb FF )
lb Fresh Feed
= 526.2 Btu/lbFF + HRxn

10,589 Btu/lbCoke x (25,190 lb Coke / 412,923 lb FF) = 646.0 Btu/lbFF

Heat of Reaction, HRxn = 646.0 - 526.2 = 120 Btu/lb Fresh Feed

Usually 150 to 200 btu/lb

6-31 UOP - CONFIDENTIAL