03 Crude Units

CrudeDistillation
Chapter4
JohnJechura jjechura@mines.edu
Updated:August19,2015
Gases
Polymerization
Sulfur
Plant
Gas
Butanes
Alkyl
Feed
Gas
Separation &
Stabilizer
Fuel Gas
LPG
Alkylation
Polymerization
Naphtha
Isomerization
Light Naphtha
Alkylate
Isomerate
Aviation
Gasoline
Automotive
Gasoline
Reformate
Naphtha
Hydrotreating
Heavy
Naphtha
Sulfur
LPG
Sat Gas
Plant
Naphtha
Reforming
Solvents
Naphtha
Atmospheric
Distillation
Crude
Oil
Jet Fuels
Kerosene
Kerosene
Desalter
Distillate
Hydrocracking
AGO
LVGO
Vacuum
Distillation
Gas Oil
Hydrotreating
Fluidized
Catalytic
Cracking
Cat
Naphtha
Solvents
Distillate
Hydrotreating
Cat
Distillates
Treating &
Blending
Heating Oils
Diesel
Fuel Oil
HVGO
Cycle Oils
Residual
Fuel Oils
DAO
Solvent
Deasphalting
Visbreaking
Vacuum
Residuum
Coker
Naphtha
Heavy
Coker
Gas
Oil
SDA
Bottoms
Asphalts
Naphtha
Distillates
Fuel Oil
Bottoms
Lube Oil
Lubricant
Greases
Solvent
Dewaxing
Waxes
Waxes
Coking
Light Coker
Gas Oil
Coke
U.S.RefineryImplementation
EIA,Jan.1,2015database,publishedJune2015
http://www.eia.gov/petroleum/refinerycapacity/
Page3
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F
ProductYieldCurves CutPoint,Overlap,&Tails
Atmospheric&VacuumTowerComplex
Atmospheric&VacuumTowerComplex
KochGlitsch BulletinKGSS1,Rev.32010,
http://www.kochglitsch.com/Document%20Library/KGSS.pdf
AtmosphericColumnw/oPreflash
Basedonfigurefrom
RefiningOverview PetroleumProcesses&Products,
byFreemanSelf,EdEkholm,&KeithBowers,AIChE CDROM,2000
AtmosphericColumnwithPreflash
Increasingdistillateproductionatleastcapitalcost,Musumeci,Stupin,Olson,&Wendler,PTQ,Q22015
10
FeedPreheatTrain&Desalter
FeedPreheatTrain
Initialheatexchangewithstreamsfrom
withinthetower
Heatrecoveryimportanttodistillation
economics!
o
o
Firstabsorbpartoftheoverhead
condensationload
Exchangewithoneormoreofthe
liquidsidesstreams,beginningwith
thetop(coldest)sidestream
Requireflexibility
o
o
o
Changesincrudeslate
Temperatureatdesalter
Limitsontwophaseflowthrough
network
Finalheatinginadirectfiredheater
Heatenoughtovaporizelightportions
ofthecrudebuttemperaturekeptlow
tominimizethermalcracking
o
o
Inlettypically550F
Outlet600to750F.
Heaviercrudescannotbeheated
tothehighertemperatures
Desalter
Temperaturecarefullyselected donotlet
watervaporize
Lightercrudes(>40API)@250F
Heaviercrudes(<30API)@300F
Allcrudescontainsalts(NaCl,MgCl,)
Saltpresentintheemulsifiedwater
Treatedinthefieldwithheat&chemicalsto
breakoilwateremulsions.
Saltcancausedamagetoequipment
o
o
o
Scaleinheatexchangers
HCl formationcanleadtocorrosion
Metalscanpoisonrefinerycatalysts
Removesalts&dissolvedmetals&dirt
Oilmixedwithfreshwashwater&demulsifiers.
Separationinelectrostaticsettlingdrum
Washwaterupto10%ofcrudecharge
~90%ofthewatercanberecovered
Effluentwatertreatedforbenzene
11
CrudeElectrostaticDesalting
DrawingbyMiltonBeychok
http://en.citizendium.org/wiki/File:Desalter_Diagram.png
BFDsfrom:
12
ExampleCrudePreheatTrains
Ref:ImproveenergyefficiencyviaHeatIntegration
Rossiter,ChemicalEngineeringProgress,December2010
13
DirectFiredHeater
Ref:Usefultipsforfiredheateroptimisation
Bishop&Hamilton,PetroleumTechnologyQuarterly,Q22012
14
AtmosphericDistillationSummary
Condenser
PartialcondenserifnoStabilizer
Column.
TotalcondenserifStabilizerColumnto
removelightends.
butnoreboiler.
Feedpreheatexchangertrain
Alloftheheattodrivethecolumn
comesfromthehotfeed.
Asmuchas50%oftheincoming
crudemaybeflashed.
Overflash
o
Extraamountofmaterialvaporizedto
ensurerefluxbetweenflashzone&
lowestsidedraw
Typically2vol%offeed
Pumparounds
Movecoolingdowncolumn.
Liquidreturnedabovedrawtray
Sidedraws
Sidestrippers
Cleanupsideproducts
Strippingsteam
Reducehydrocarbonpartialpressure
Condensed&removedasasecond
liquidphase.
Conditionssetsoitdoesnt
condensewithinthecolumn can
leadtofoaming
Mustbetreatedassourwater
15
AtmosphericDistillationSummary
WashZone
SideDraws&Strippers
Coupletraysbetweenflashzone&gasoil
draw.
Sidestrippersremovelightcomponenttail
&returntomaincolumn
Refluxtowashresins&otherheavymaterials
thatmaycontaminatetheproducts.
Steamstripperstraditional
Condenser
Typically0.5to20psig.
Balancingact
Lowpressuresreducecompressionon
overheadsystem
Highpressuresdecreasevaporizationbut
increaseflashzonetemperatures&furnace
duty;affectsyields
Pumparounds
Reducesoverheadcondenserload&achieves
moreuniformtowerloadings
Providesliquidrefluxbelowliquiddraws
Reboiled strippersreduceassociatedsour
water&mayreducesteamusage
Trays&PressureProfile
Typically32traysintower
0.1psipertrayfordesign&targetfor
operation
Mayfindashighas0.2psipertray,but
probablyflooding!
Condenser&accumulator
3to10psiacrosscondenser
Liquidstaticheadinaccumulator
Typically6to16psiacrossentirecolumn.
16
VacuumDistillation
Considerpracticalconditionsforvacuumunitmodeling
R.Yahyaabadi,HydrocarbonProcessing,March2009
17
VacuumDistillationSummary
ColumnConfiguration
Feed
Vacuumconditionstokeepoperating
temperatureslow
Atmosphericresiduum
Largediametercolumn
Allvaporcomesfromtheheatedfeed
Verylowdensitygases
Undervacuum(0.4psi)
Condenseronlyforwatervapor
Separatehigherboilingmaterialsatlower
temperatures
Liquidrefluxfrompumparounds
Noreboiler
Strippingsteammaybeused
Neededfordeepcuts(1100F)
Commonproblem cokinginfired
heater&washzone
Firedheater highlinearvelocitiesto
minimizecokeformation
Washzone sufficientwashoilflowto
keepthemiddleofthepackedbedwet
Minimizethermalcracking
Products
Mayhavemultiplegasoils
UsuallyrecombineddownstreamtoFCCU
afterhydrotreating
Vacuumresid
Blended asphalt,heavyfueloil
Furtherprocessing thermal,solvent
o
Dependsonproducts&typesofcrude
18
VacuumDistillationSummary
DrySystem
1050F+cuttemperature&nostripping
steam
Smallertowerdiameters
Reducedsourwaterproduction
Pressureprofile
Flashzone:2025mmHgabs&750to
770F.
Topoftower:10mmHgabs
SteamEjectors&VacuumPumps
Vacuummaintainedontoweroverhead
Steamsystemsconsideredmorereliable
Wastesteamissour&mustbetreated
Combinationssystems Laststeam
stagereplacedwithavacuumpump
DeepCutSystem
1100F+cuttemperature&stripping
steam
Steamreduceshydrocarbonpartial
pressures
Pressureprofile
Flashzone:30mmHgabs
HCpartialpressure1015mmHgabs
Topoftower:15mmHgabs
Drawingfromhttp://www.enotes.com/topic/Injector
19
TypicalCutPointDefinitions
Cut
TBPIBP(oF)
TBPEP(oF)
LightNaphtha
(LSRGasoline)
80to90
180to220
HeavyNaphtha
180to220
330to380
MiddleDistillate
(Kerosene)
330to380
420to520
AGO
(AtmGasOil)
420to520
650
LVGO
(LightVacGasOil)
650
800
HVGO
(HeavyVacGasOil)
800
950to1100
VacuumResid
950to1100
21
ProductYieldCurves CutPoint,Overlap,&Tails
Industrialdistillationcolumnsdonotprovideperfectlysharpseparations
Initialcalculationsusingcrudeoilassaysassumethatallmaterialsatacertainboilingpoint
goestooneproductoranother
Imperfectseparationsresultinlightends&heavyendstailsinadjacentproducts
Presenceoftailscomplicatethedefinitionofcutpoint
Analysis
Scaledistillationcurvestorepresentthevolumeremoved
CutpointtemperaturerepresentsthefeedsTBPcorrespondingthecumulativevolume
removed
Tailrepresentsthelightfractionsamountabovethecutpoint&theheavyfractions
amountbelowthecutpoint
Overlaprepresentstherangebetweenlightfractionsendpoint&theheavyfractionsinitial
point
Endpointmayberepresentedby99%
Initialpointmayberepresentedby1%
22
Example AtmosphericTowerProducts
23
ScaletoFractionofCrudeCharge
24
CutPoint,Overlap,&Tails
Ref:R.N.Watkins,PetroleumRefineryDistillation,2nd ed.,1979
25
CutPoints&OverlapsforExample
26
BoilingPointRangesforExample
27
Summary
Reportedrefinerycapacitytiedtochargetocrudedistillationcomplex
IncreasecapacitywithPreflashcolumn
Complexcolumnconfigurations
Noreboilers,heatfromfeedfurnaces
Reuseheatviaheatexchangebetweenfeed&internalcolumnstreams
Sidedraws,pumparounds,sidestrippers
Pumparounds required toensureliquidrefluxwithinthecolumn
Strippingsteam
3phasecondensers
Condensedwaterwillhavehydrocarbons&dissolvedacidgases
Preheattrainrecyclesheat
Products&internalstreamsheatthefeed
Feedcoolstheinternalstreams&products
Vacuumcolumntoincreasetheeffectivecutpoints
Vacuumcolumnslargediametertokeepvaporvelocitieslow
Vacuumgasoilsrecombined onlyseparatedforoperatingconsiderations
Pressuredropsareimportant,especially inthevacuumcolumn
Steamstrippingaidsinseparationwithoutcracking
Metalsareundesirable.Canremovesome metalsviadesalters.
28
SupplementalSlides
Crudedistillationunitcosts
Crudedistillationtechnologyproviders
Typicaldistillationcolumnconfiguration
Fractionationcolumns&trays
Fractionationtraytypes
Trays&packing
Typicaltrayefficiencies
Vacuumtowertransferlines
Page30
30
CrudeDistillationUnitCosts
Atmosphericcolumnincludes
Sidecutswithstrippers
Allbatterylimitsprocessfacilities
Heatexchangetocoolproductsto
ambienttemperature
Centralcontrolsystem
PetroleumRefiningTechnology&Economics,5th ed.
Gary,Handwerk,&Kaiser
CRCPress,2007
Page31
31
CrudeDistillationUnitCosts
Vacuumcolumnincludes
Facilitiesforsinglevacuumgasoil
3stagevacuumjetsystemat30
40mmHg
HeatexchangetocoolVGOto
ambienttemperature
PetroleumRefiningTechnology&Economics,5th ed.
Gary,Handwerk,&Kaiser
CRCPress,2007
Page32
32
CrudeDistillationTechnologies
Provider
Foster Wheeler
Shell Global Solutions
TECHNIP
Uhde GmbH
Features
Complex of atmospheric & vacuum distilation for
initial separation of crude oil. May include preflash
column.
Vaccum distillation
33
TypicalDistillationColumn
Topofcolumn condensertoremoveheat
Providesliquidrefluxthroughtopofcolumn
Partialcondensermayhavevaporbutnoliquiddistallate product
Coldesttemperature coolingmediamustbeevencolder
Lowestpressure
Topsectionstripsheavycomponentsfromtherisingvapors
Feed
Vapor,liquid,orintermediatequality
Introducedinvaporspacebetweentrays
Internals
Traystocontactrisingvaporswithfallingliquids
Pressuredropacrosstrays overcomestaticheadofliquidontray,
Bottomofcolumn reboiler toaddheat

Providesvaportrafficinbottomofcolumn
Highesttemperature heatingmediamustbeevenhotter
Highestpressure
Bottomsectionstripslightcomponentsfromthefallingliquid
DrawingbyHenryPadleckas &modifed byMiltonBeychok:
http://en.wikipedia.org/wiki/File:Continuous_Binary_Fractional_Distillation.PNG
34
FractionationColumns&Trays
DrawingsbyHenryPadleckas
http://en.wikipedia.org/wiki/Fractionating_column
35
FractionationTrayTypes
http://www.termoconsult.com/empresas/acs/fractionation_trays.htm
36
Trays&Packing
http://www.ec21.com/product-details/Tower-Internals--3942077.html
37
TypicalOverallEfficiencies
ColumnService
SimpleAbsorber/Stripper
SteamSideStripper
ReboiledSideStripper
ReboiledAbsorber
Deethanizer
Depropanizer
Debutanizer
AlkyDeiC4(reflux)
AlkyDeiC4(noreflux)
NaphthaSplitter
C2Splitter
C3Splitter
C4Splitter
AmineContactor
AmineStripper
CrudeDistillation
StrippingZone
st
FlashZone1 draw
TypicalNo.of
ActualTrays
2030
57
710
2040
2535
3540
3845
7590
5570
2535
110130
200250
7080
2024
2024
3550
57
Typical TypicalNo.of
Theoretical
Overall
Trays
Efficiency
2030
2
34
4050
6575
7080
8590
8590
5565
7075
95100
95100
8590
45
4555
912
5060
2030
30
2
37
30
1 Draw2 Draw
710
4550
35
2ndDraw3rdDraw
TopDrawReflux
VacuumColumn(G.O.Operation)
Stripping
FlashZoneHGODraw
HGOSection
LGOSection
FCCMainFractionator
QuenchZone
QuenchHGODraw
HGOLCGO
LCGOTop
710
1012
5055
6070
35
68
5060
1
12
2
2
1317
2
23
35
57
st
nd
24
23
35
35
2435
57
35
68
710
Viscosity
Maxwell
cP
AveViscosityof
liquidonplates
0.05
0.10
0.15
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.50
1.70
104
86
76
63
56
50
46
43
40
38
36
30
28
Drickamer&
Bradfordin
Ludwig
MolalAve
Viscosityof
Feed
98
79
70
60
50
42
36
31
27
23
19
17
7
5
RulesofThumbforChemicalEngineers,4thed.
CarlBranan,GulfProfessionalPublishing,2005
EngineeringDataBook,12thed.
GasProcessorsAssociation,2004
12
RefineryProcessModeling
GeraldKaes,AthensPrintingCompany,2000,pg.32
38
VacuumTowerTransferLines
Masstransfereffectsinthetransferlinecomplicatetheeffectsatthebottomof
theVacuumTower
Mythofhighcutpoint indryvacuumunits,S.Golden,T.Barletta,&S.White,PTQ,Q22014
39

03 Crude Units

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Bottomofcolumn reboiler toaddheat

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