FYP Thesis - Recovery of Naphtha From Crude Oil

RECOVERY OF NAPHTHA FROM CRUDE OIL
SESSION: 2010 2014
SUPERVISED BY:
Dr. Shah Muhammad
(Associate Professor)
SUBMITTED BY:
SLAM STUDENTS LIVING A MISSION
2010 CH 63
2010 CH 93*
2010 CH 95
2010 CH 101
2010 CH 125
Rai Mahmood Hussain

Saad Ahmed (Group Leader)
Najeeb ur Rehman
Hafiz Muhammad Zia ul Noor
Sohaib Muhammad Khan
DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE, PAKISTAN
RECOVERY OF NAPHTHA FROM CRUDE OIL
This project is submitted to Department of Chemical Engineering,

University of Engineering & Technology Lahore.
for the partial fulfillment of the requirements for the
BACHELORS DEGREE
in
CHEMICAL ENGINEERING
INTERNAL EXAMINER:
EXTERNAL EXAMINER:
___________________
____________________
Dr. Shah Muhammad
Name: ________________
(Project Supervisor)
DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE, PAKISTAN
In the name of Allah,

the most beneficial & the most merciful
ACKNOWLEDGEMENT | I
ACKNOWLEDGEMENT
All praise to ALMIGHTY ALLAH, who provided us with the strength to complete
this final year Plant Design project. All respects are for the Holy Prophet
(PBUH), whose teachings are true source of knowledge & guidance for whole
of the mankind.
Before anybody else we thank our parents who have always been a source of
moral support and driving force behind whatever we do.
The preparation and writing of this report faced many challenges, as we have
tried to cover complete Crude Distillation Process [Refining] of a refinery in
this project. The project could not have been researched, compiled and written
in these circumstances without the support of our Project Advisor.
We are highly indebted to our project advisor Dr. Shah Muhammad
(Associate Professor, UET Lahore) for his encouragement, technical
discussions, inspiring guidance, remarkable suggestions, keen interest,
constructive criticism & friendly discussions which enabled us to complete this
report. He spared a lot of precious time in advising & helping us in writing this
report.
We are thankful to our respected Chairman, Dr. Nadeem Feroze & honorable
teachers. We are also thankful to librarians of National Library of Engineering
Sciences, & Chemical Engineering Departmental Library for their cooperation
in search of design material.
We assure the reader that this may be our first project of its own kind, but at
least for a while, we have put a bit of "heart and soul" into it! Therefore, we
hope that you will find this report immensely educative & informative.
Authors
RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM
PROJECT MOTIVATION | II
PROJECT MOTIVATION
As students of Chemical Engineering we have always been interested in Oil
Refineries and petroleum industry. There is no doubted the fact that every
chemical engineer is fascinated by the highest paid industry for Chemical
Engineers, which is Petroleum Industry.
As Refinery is one of the two attractive fields, the other being fertilizer industry,
every Chemical Engineer is interested in making his/her career in, the decision
of taking this project and working on it was both challenging and interesting.
This project for the first time gave us the opportunity to explore the Refining
Process, in detail. Our knowledge of this process at the start of the project was
casual. We knew generally about fractionation, knowing nothing specific about
the process flow circuit and design of a chemical plant, also it would not be an
oversimplification of the facts, if we assert that we knew nothing about a
chemical plant before this project.
The learning curve embarked on was considerably steeper than previous work
we have ever undertaken. Hence, the report constitutes our first ever attempt of
understanding a whole chemical process combined with the process flow
conditions and process selection. Our previous knowledge did not cater for this
scale of work but if we can dream it we can do it was the core motivation
behind this project.
Authors
PREFACE | III
PREFACE
Naphtha is one of the most important hydrocarbon fuels currently used in
industry today. Its importance becomes even more pronounced for a growing
economy, because in addition to being deployed in the automobile industry, it
has also become a driving force behind industrial operation.
This report certainly cannot reflect all the efforts behind its compilation because
a lot of things, either of very basic concepts or considered irrelevant for this
report, have been omitted. Hence our emphasis has been on quality of the
report, not on the quantity.
As the art and science of design is a matter of handful experience, supported by
sound theoretical background. So due to the lack of experience, certain aspects
might have been incomplete in this work. But overall design procedures,
significant modification and assumptions strongly justified by logical and
theoretical ground give this work a status of a valuable concise report on the
recovery of naphtha.
To recover naphtha from crude oil, first of all, mass and energy balance was
carried out over the whole system, including equipments like de-salter, crude
tower, stabilizer etc. This forms the basis for our design, where the design specs
are set in order to meet the ranges specified by the rules of thumb or in
accordance with the International Design Standards like TEMA etc.
For the stability, optimization, and reduction of the effect of external forces,
instrumentation of the stabilizer is a necessary action performed after equipment
design completion. After that, HAZOP study gives an accurate idea about the
effect of changing variables on equipment strength and on how far we can push
the process variables. Owing to the global environmental consensus and the
growing need to preserve our planet, Environmental Impact Assessment or EIA
is considered an integral part of any industrial scale project. Our report,
therefore, has a page or two reserved for EIA.
I hope this report will be helpful in understanding the Crude Distillation
Process.
Authors
CONTENTS | IV
TABLE OF CONTENTS
ACKNOWLEDGEMENT .......................................................................................................................................I
PROJECT MOTIVATION ....................................................................................................................................II
PREFACE .........................................................................................................................................................III
TABLE OF CONTENTS...................................................................................................................................... IV
LIST OF TABLES ................................................................................................................................................X
LIST OF FIGURES..............................................................................................................................................XI
1. INTRODUCTION............................................................................................................................................1
1.1 CRUDE OIL ................................................................................................................................................ 1
Crude Bitumen:...................................................................................................................................................2
1.2 CRUDE OIL FORMATION ............................................................................................................................... 3

1.3 CRUDE OIL EXTRACTION ............................................................................................................................... 3
1.4 OIL SANDS ................................................................................................................................................ 3
1.5 WORLDWIDE OIL PRODUCTION ...................................................................................................................... 3
2. PROCESS DESCRIPTION ................................................................................................................................6
2.1 CRUDE OIL FLOW ........................................................................................................................................ 6
2.1.1 Heavy Gas Oil Circuit....................................................................................................................... 7
2.1.2 Light Gas Oil Circuit......................................................................................................................... 7
2.1.3 Light Gas Oil Pumparound Circuit .................................................................................................... 7
2.1.4 Light Weight Kerosene Circuit ......................................................................................................... 8
2.1.5 Naphtha Pumparound Circuit .......................................................................................................... 8
2.1.6 Crude Tower Overhead Circuit ......................................................................................................... 8
2.1.6.1 Neutralizing Amines.................................................................................................................................9
2.1.7 Bottom Stripping Section of Crude Tower ...................................................................................... 10

2.1.8 Un-stabilized Naphtha Circuit........................................................................................................ 10
2.2 PROCESS FLOW DIAGRAM ........................................................................................................................... 12
3. CAPACITY SELECTION ................................................................................................................................. 14
4. MATERIAL BALANCE................................................................................................................................... 17
4.1 INTRODUCTION......................................................................................................................................... 17
4.2 MATERIAL BALANCE ACROSS DESALTER V-306................................................................................................. 18
4.3 MATERIAL BALANCE ACROSS V-401 STABILIZER ............................................................................................... 20
4.4 MATERIAL BALANCE ACROSS V-301 CRUDE TOWER .......................................................................................... 21
4.5 MATERIAL BALANCE ACROSS V-302 LWK STRIPPER .......................................................................................... 22
4.6 MATERIAL BALANCE ACROSS V-303 LGO STRIPPER .......................................................................................... 24
4.7 MATERIAL BALANCE ACROSS V-304 HGO STRIPPER.......................................................................................... 25
4.8 MATERIAL BALANCE ACROSS V-305 OVERHEAD ACCUMULATOR .......................................................................... 26
4.9 MATERIAL BALANCE ACROSS V-301 CRUDE TOWER (CONTINUED) ........................................................................ 27
5. ENERGY BALANCE ...................................................................................................................................... 29
5.1 ENERGY BALANCE ACROSS E-301 CRUDE/LWK EXCHANGER ............................................................................... 29
5.2 ENERGY BALANCE ACROSS E-302 CRUDE/LGO (COLD) EXCHANGER ...................................................................... 30
5.3 ENERGY BALANCE ACROSS E-304 CRUDE/HGO EXCHANGER ............................................................................... 31
CONTENTS | V
5.4 ENERGY BALANCE ACROSS E-305 CRUDE/FFO (COLD) EXCHANGER ...................................................................... 32
5.5 ENERGY BALANCE ACROSS E-306 CRUDE/LGO (HOT) EXCHANGER ....................................................................... 33
5.6 ENERGY BALANCE ACROSS E-308 CRUDE/FFO (HOT) EXCHANGER ........................................................................ 34
5.7 ENERGY BALANCE ACROSS E-310 LWK TRIM COOLER ....................................................................................... 35
5.8 ENERGY BALANCE ACROSS ALL EXCHANGERS ................................................................................................... 36
5.9 ENERGY BALANCE ACROSS V-301 CRUDE TOWER ............................................................................................. 36
5.9.1 Enthalpy of Steam Entering in V-301, V-302, V-303, V-304............................................................. 36
6. EQUIPMENT DESIGN .................................................................................................................................. 39
6.1 SHELL & TUBE HEAT EXCHANGER E-301 LWK/CRUDE.................................................................................... 39
6.1.1 Heat Exchanger?........................................................................................................................... 39
6.1.1.1 Heat Exchanger as Heat Recovery Equipment ......................................................................................... 39
6.1.1.2 Uses of Heat Exchangers ........................................................................................................................ 39
6.1.1.3 Classification of Heat Exchanger............................................................................................................. 39
6.1.1.4 Heat Exchanger Selection Criteria........................................................................................................... 40
6.1.2 Shell and Tube Heat Exchanger ..................................................................................................... 40

Advantages of Shell and Tube Exchanger over Other Exchangers........................................................................ 41
Tube Side & Shell Side Fluid Allocation .............................................................................................................. 41
Main Parts of Shell And Tube Heat Exchanger .................................................................................................... 41
Introduction to Thermal Design of Shell-and-Tube Heat Exchanger .................................................................... 41
Design Methods ................................................................................................................................................ 42
6.1.3 Nomenclature ............................................................................................................................... 42

6.1.4 Heat Duty ..................................................................................................................................... 43
6.1.5 Design Steps, Procedure & Calculations ......................................................................................... 43
6.1.5.1: Thermo-Physical Properties .................................................................................................................. 43
6.1.5.2: Log Mean Temperature Difference........................................................................................................ 45
6.1.5.3: Heat Transfer Area ............................................................................................................................... 45
6.1.5.4: Correction Factor.................................................................................................................................. 45
6.1.5.5: Design Specifications ............................................................................................................................ 45
6.1.5.5: Outer Surface Area of Tube [Single Tube] .............................................................................................. 46
6.1.5.6: Theoretical Number of Tubes................................................................................................................ 46
6.1.5.7: Number of Tubes per Pass .................................................................................................................... 46
6.1.5.8: Equivalent Diameter ............................................................................................................................. 46
6.1.5.9: Flow Area ............................................................................................................................................. 46
6.1.5.10: Linear Velocity of Tube [inside] ........................................................................................................... 46
6.1.5.11: Mass Velocity ..................................................................................................................................... 47
6.1.5.12: Reynolds Number .............................................................................................................................. 47
6.1.5.13: Prandtls Number ............................................................................................................................... 47
6.1.5.14: Nusselts Number ............................................................................................................................... 47
6.1.5.15: Film Co-efficient ................................................................................................................................. 48
6.1.5.16: Dirty Overall Heat Transfer Co-Efficient ............................................................................................... 48
6.1.5.17: Pressure Drop Calculations.................................................................................................................. 48
6.2 FIRED HEATER H 301 CRUDE CHARGE HEATER .............................................................................................. 49

6.2.1 Fired heater .................................................................................................................................. 49
6.2.2 Furnaces Used in Petroleum Industries .......................................................................................... 49
6.2.3 Selection Criteria........................................................................................................................... 51
6.2.3.1 Selected furnace.................................................................................................................................... 51
6.2.4 Nomenclature ............................................................................................................................... 52

6.2.5 Heat Duty ..................................................................................................................................... 53
6.2.5.1 Composition of Natural Gas: .................................................................................................................. 53
6.2.5.2 Number of Moles of Fuel Used............................................................................................................... 53
6.2.6 Air to Fuel Ratio ............................................................................................................................ 53
CONTENTS | VI
6.2.6.1 Combustion Reactions ........................................................................................................................... 53
6.2.7 Design Steps in Radiant Section ..................................................................................................... 55

6.2.7.1: Calculation of . ................................................................................................................. 55
6.2.7.2: Calculation of Gas Temperature at Bridge Wall ...................................................................................... 55
6.2.7.3: Heat Balance to Find the Radiant Heat Duty .......................................................................................... 55
6.2.7.4: No. of Tubes in Radiant Section............................................................................................................. 56
6.2.7.5: Calculation of Beam Length................................................................................................................... 56
6.2.7.6: Dimensions of Radiant Section .............................................................................................................. 57
6.2.7.7: Verification of Overall Heat Exchange Factor ......................................................................................... 57
6.2.7.8: Verification of Gas Temperature ........................................................................................................... 58
6.2.7.9: Verification of Radiant Heat Duty .......................................................................................................... 58
6.2.7.10: Verification of Assumed Flux ............................................................................................................... 58
6.2.7.11: Volume of Radiant Section .................................................................................................................. 58
6.2.8 Design Steps in Convection Section ................................................................................................ 59

6.2.8.1: Calculation of Convection Section Duty ................................................................................................. 59
6.2.8.2: Calculation of Overall Convective Heat Transfer Surface ........................................................................ 59
6.2.8.3: Calculation of Number of tubes in Convective Section ........................................................................... 60
6.2.8.4: Calculation of Volume of Convective Section ......................................................................................... 60
6.2.8.5: Calculation of Volume of Furnace.......................................................................................................... 61
6.2.9 Specification Sheet........................................................................................................................ 61

6.3 FRACTIONATING TOWER V-301 CRUDE TOWER ............................................................................................. 62
6.3.1.1: Vaporization Curve ............................................................................................................................... 63
6.3.1.2: Vaporizer Temperature......................................................................................................................... 64
6.3.1.3: Tower Temperatures ............................................................................................................................ 65
6.3.1.4: Bottom Temperature ............................................................................................................................ 66
6.3.1.5: Heat Balance of Tower to Top Plate....................................................................................................... 66
6.3.1.6: Liquid Density at Top Plate.................................................................................................................... 67
6.3.1.7: Vapor Density at Top Plate.................................................................................................................... 67
6.3.1.8: Allowable Vapor Flow Rate of Tower ..................................................................................................... 68
6.3.1.9: Cross-sectional Area of Tower ............................................................................................................... 68
6.3.1.10: Diameter of Tower.............................................................................................................................. 68
6.3.1.11: Linear Velocity .................................................................................................................................... 69
6.3.1.12: Number of Stages ............................................................................................................................... 69
6.3.1.13: Height of Tower .................................................................................................................................. 69
6.3.1.14: L/D Ratio ............................................................................................................................................ 69
6.4 SHELL & TUBE CONDENSER E-309 OVERHEAD VAPORS/WATER ........................................................................ 70

6.4.1 Condenser? ................................................................................................................................... 70
6.4.2 Selection Criteria........................................................................................................................... 70
6.4.3 Nomenclature ............................................................................................................................... 71
6.4.4 Heat Duty ..................................................................................................................................... 72
6.4.5.1: Weighted Log Mean Temperature Difference ........................................................................................ 72
6.4.5.2: Correction Factor.................................................................................................................................. 73
6.4.5.5: Number of Tubes .................................................................................................................................. 73
6.4.5.6: Corrected Overall Heat Transfer Coefficient ..................................................................................... 74
6.4.5.8: Flow Area ............................................................................................................................................. 74
6.4.5.9: Mass Velocity ....................................................................................................................................... 74
6.4.5.10: Reynolds Number .............................................................................................................................. 75
6.4.5.11: Heat Transfer Co-efficient De-superheating ...................................................................................... 75
6.4.5.12: Condensation Zone ............................................................................................................................. 75
CONTENTS | VII
6.4.5.13: Weighted Clean Overall Coefficient ..................................................................................................... 76
6.4.5.14: Dirt Factor .......................................................................................................................................... 77
6.4.5.15: Clean Surface Area Required ............................................................................................................... 77
6.4.5.16: Pressure Drop Tube Side .................................................................................................................. 77
6.4.5.17: Return Loss......................................................................................................................................... 77
6.4.5.18: Total Pressure..................................................................................................................................... 77
6.4.5.19: Total Pressure Drop Shell Side .......................................................................................................... 78
6.4.6 Specification Sheet........................................................................................................................ 78

6.5 REBOILER: ............................................................................................................................................... 79
6.5.1 Types of Reboiler: ......................................................................................................................... 79
6.5.1.1 Kettle Reboiler:...................................................................................................................................... 79
6.5.1.2 Vertical Thermosyphon Reboiler: ........................................................................................................... 79
6.5.1.3 Horizontal Thermosyphon Reboiler: ....................................................................................................... 79
6.5.1.4 Internal Reboiler:................................................................................................................................... 80
6.5.2 Choice of Type: ............................................................................................................................. 80

6.5.3 Heat Duty ..................................................................................................................................... 80
6.5.4.1: Thermo-Physical Properties .................................................................................................................. 80
6.5.4.2: Log Mean Temperature Difference........................................................................................................ 81
6.5.4.5: Outer Surface Area of Tube [Single Tube] .............................................................................................. 82
6.5.4.6: Theoretical Number of Tubes................................................................................................................ 82
6.5.4.7: Number of Tubes per Pass .................................................................................................................... 82
6.5.4.9: Flow Area ............................................................................................................................................. 82
6.5.4.10: Linear Velocity of Tube [inside] ........................................................................................................... 82
6.5.4.11: Overall Heat Transfer Co-Efficient ....................................................................................................... 82
7. INSTRUMENTATION & CONTROL ............................................................................................................... 85

7.1 INTRODUCTION......................................................................................................................................... 85
7.1.1 Instrument.................................................................................................................................... 85
7.1.2 Control ......................................................................................................................................... 85
7.1.3 Incentives of Control ..................................................................................................................... 86
7.2 OBJECTIVES ............................................................................................................................................. 86
7.2.1 Safe Plant Operation ..................................................................................................................... 86
7.2.2 Production Rate ............................................................................................................................ 86
7.2.3 Production Quality ........................................................................................................................ 86
7.2.4 Cost .............................................................................................................................................. 86
7.3 COMPONENTS OF THE CONTROL SYSTEM ........................................................................................................ 86
7.3.1 Process ......................................................................................................................................... 86
7.3.2 Measuring Means ......................................................................................................................... 86
7.3.3 Main Process Variables & Their Control ......................................................................................... 87
7.3.3.1 Temperature Measurement & Control ................................................................................................... 87
7.3.3.2 Pressure Measurement & Control .......................................................................................................... 87
7.3.3.3 Level Measurement & Control ............................................................................................................... 87
7.3.4 Controller ..................................................................................................................................... 87

7.3.5 Final Control Element .................................................................................................................... 88
7.4 CLASSIFICATION OF CONTROLLER .................................................................................................................. 88
7.4.1 Modes of Control .......................................................................................................................... 88
7.5 TYPES OF CONTROL ................................................................................................................................... 88
7.5.1 Feedback Control Loop .................................................................................................................. 88
CONTENTS | VIII
7.5.2 Feed Forward Control Loop ........................................................................................................... 89
7.6 CONTROL SCHEME OF V- 401 STABILIZER ....................................................................................................... 89
7.6.1 Objective ...................................................................................................................................... 89
7.6.2 Manipulated Variables.................................................................................................................. 89
7.6.3 Loads / Disturbances..................................................................................................................... 89
7.6.4 Controller ..................................................................................................................................... 89
7.6.5 Final Control Element .................................................................................................................... 89
8. HAZARD OPERABILITY ................................................................................................................................ 92
8.1 HISTORY & APPLICATION ............................................................................................................................ 92
8.2 INTRODUCTION......................................................................................................................................... 92
8.2.1 Hazard.......................................................................................................................................... 92
8.2.2 Operability.................................................................................................................................... 92
8.2.3 Types of HAZOP ............................................................................................................................ 92
8.2.4 The Reasons for such Widespread Use of HAZOPs.......................................................................... 93
8.2.5 When to perform a HAZOP? .......................................................................................................... 93
8.2.6 Success or failure of the HAZOP ..................................................................................................... 94
8.3 OBJECTIVES OF HAZOP STUDY .................................................................................................................... 94
8.4 FEATURES OF HAZOP STUDY ....................................................................................................................... 94
8.5 HAZOP STUDY METHODOLOGY ................................................................................................................... 95
8.5.1 Specify the purpose, objective, and scope of the study. .................................................................. 95
8.5.2 Select the HAZOP study team ........................................................................................................ 95
8.5.3 Collect data. ................................................................................................................................. 96
8.5.4 Conduct the study ......................................................................................................................... 96
Primary Key Words: .......................................................................................................................................... 97
Secondary Key Words: ...................................................................................................................................... 97
Guide Words According to Parameter:............................................................................................................... 98
8.5.5 Write the report. ........................................................................................................................... 98

8.5.6 HAZOP Method Flow Diagram....................................................................................................... 99
Deviation ........................................................................................................................................................ 100
Cause ............................................................................................................................................................. 101
Consequences................................................................................................................................................. 101
Safeguards...................................................................................................................................................... 101
Action............................................................................................................................................................. 101
8.6 CONCLUSIONS ........................................................................................................................................ 102

8.7 ADVANTAGES ......................................................................................................................................... 102
8.8 LIMITATION OF THE HAZOP TECHNIQUE ...................................................................................................... 102
8.8.1 Requires a Well-Defined System or Activity.................................................................................. 102
8.8.2 Time Consuming ......................................................................................................................... 102
8.8.3 Focuses on One-Event Causes of Deviations................................................................................. 103
8.9 HAZOP STUDY OF SHELL & TUBE HEAT EXCHANGER ....................................................................................... 103
8.10 HAZOP STUDY OF RAW CRUDE OIL STORAGE TANK ..................................................................................... 104
9. ENVIRONMENTAL IMPACT ASSESSMENT ................................................................................................. 108
9.1 HYDROGEN SULFIDE ................................................................................................................................ 108
9.1.1 NPI Rank: .................................................................................................................................... 108
9.2 SYMPTOMS OF HYDROGEN SULFIDE POISONING ............................................................................................. 109
9.3 TREATMENT OF ACUTE HYDROGEN SULFIDE POISONING ................................................................................... 109
9.4 TREATMENT OF SUB-ACUTE HYDROGEN SULFIDE POISONING ............................................................................. 111
9.5 PREVENTION OF HYDROGEN SULFIDE POISONING ............................................................................................ 111
CONTENTS | IX
10. COST ESTIMATION ................................................................................................................................. 114
10.1 PLANT COST ESTIMATION ........................................................................................................................ 114
10.2 CAPITAL INVESTMENT............................................................................................................................. 114
10.2.1 Fixed-Capital Investment........................................................................................................... 115
10.3 WORKING CAPITAL ................................................................................................................................ 115
10.4 METHODS FOR ESTIMATING CAPITAL INVESTMENT ........................................................................................ 115
10.4.1 Percentage of Delivered - Equipment Cost ................................................................................. 116
10.5 COST ................................................................................................................................................. 116
10.5.1 Indirect Cost.............................................................................................................................. 117
10.5.2 Direct Cost ................................................................................................................................ 117
10.6 FIXED CAPITAL INVESTMENT .................................................................................................................... 118
10.7 ESTIMATION OF TOTAL PRODUCT COST ...................................................................................................... 119
10.7.1 Fixed charges: ........................................................................................................................... 119
10.7.2 Variable Production Cost ........................................................................................................... 119
10.7.3 Plant Overhead Cost ................................................................................................................. 120
10.8 GENERAL EXPENSES ............................................................................................................................... 120
10.9 TOTAL PRODUCTION COST ...................................................................................................................... 120
10.10 GROSS EARNINGS ................................................................................................................................ 120
REFERENCES................................................................................................................................................. 121
LIST OF TABLES | X
LIST OF TABLES
TABLE 1 - MAJOR CLASSES OF HYDROCARBONS IN CRUDE OIL ......................................................................... 1
TABLE 2 - CRUDE OIL PRODUCT YEILD ANALYSIS OF ARL .............................................................................. 17
TABLE 3- ARL DESIGN CONDITIONS ......................................................................................................... 18
TABLE 4- MATERIAL BALANCE ACROSS V-301............................................................................................ 27
TABLE 5 ENERGY BALANCE ACROSS ALL EXCHANGERS................................................................................ 36
TABLE 6 - ENERGY BALANCE ACROSS CRUDE TOWER ................................................................................... 37
TABLE 7 - THERMOPHYSICAL PROPERTIES FOR E-301 .................................................................................. 44
TABLE 8 - STOICHIOMETRIC CALCULATIONS OF H-301 HEATER...................................................................... 54
TABLE 9 - SPEC SHEET OF HEATER ........................................................................................................... 61
TABLE 10 - EXTRACTED DATA FOR CRUDE TOWER DESIGN............................................................................ 65
TABLE 11 - HEAT BALANCE OF TOWER TOP PLATE ..................................................................................... 67
TABLE 12 - NO OF MOLES CALCULATIONS................................................................................................. 68
TABLE 13 - NUMBER OF STAGES ESTIMATION IN CRUDE TOWER .................................................................... 69
TABLE 14 - THERMOPHYSICAL PROPERTIES FOR REBOILER ............................................................................ 81
TABLE 15 - FEATURES OF HAZOP ........................................................................................................... 95
LIST OF FIGURES | XI
LIST OF FIGURES
FIGURE 1 - PROCESS FLOW DIAGRAM ...................................................................................................... 12
FIGURE 2 - MATERIAL BALANCE ACROSS DESALTER ..................................................................................... 20
FIGURE 3 - MATERIAL BALANCE ACROSS STABILIZER .................................................................................... 21
FIGURE 4 - MATERIAL BALANCE ACROSS LWK STRIPPER............................................................................... 23
FIGURE 5 - MATERIAL BALANCE ACROSS LGO STRIPPER ............................................................................... 24
FIGURE 6 - MATERIAL BALANCE ACROSS HGO STRIPPER .............................................................................. 25
FIGURE 7 MATERIAL BALANCE ACROSS V-305 ACCUMULATOR ................................................................... 26
FIGURE 8 - SCHEMATIC DIAGRAM OF SHELL & TUBE HEAT EXCHANGERS ......................................................... 40
FIGURE 9 - LABELLED DIAGRAM OF FIRED TUBE HEATER............................................................................... 49
FIGURE 10 - TYPES OF FURNACES USED IN PETROLEUM INDUSTRIES ............................................................... 50
FIGURE 11 - ENERGY BALANCE BOUNDARY ............................................................................................... 62
FIGURE 12 - FLASH VAPORIZATION CURVE OF CRUDE DISTILLATION................................................................ 63
FIGURE 13 - RELATIONSHIP BETWEEN THE SLOPES OF DISTILLATION CURVES...................................................... 63
FIGURE 14 - RELATIONSHIP BETWEEN DISTILLATION TEMPERATURES ............................................................... 64
FIGURE 15 - SPEC SHEET OF CONDENSER .................................................................................................. 78
FIGURE 16 - CONTROL SCHEME OF V-401 STABILIZER ................................................................................. 90
CHAPTER # 1
INTRODUCTION
INTRODUCTION | 1
1. INTRODUCTION
1.1 CRUDE OIL
Crude oil is the term for "unprocessed" oil, the stuff that comes out of the ground. Crude oil
is a fossil fuel, meaning that it was made naturally from decaying plants and animals living in
ancient seas millions of years ago most places you can find crude oil were once sea beds.
Crude oils are such a useful starting point for so many different substances because they
contain hydrocarbons, which are molecules containing hydrogen and carbon and come in
various lengths and structures, from straight chains to branching chains to rings.
There are two things that make hydrocarbons exciting to chemists:
1. Hydrocarbons contain a lot of energy. Many of the things derived from crude oil like
gasoline, diesel fuel, paraffin wax and so on take advantage of this energy.
2. Hydrocarbons can take on many different forms. The smallest hydrocarbon is methane
(CH4), which is a gas that is a lighter than air. Longer chains with 5 Cs are liquids.
Very long chains are solids like wax. Hydrocarbon chains are very versatile!
The major classes of hydrocarbons in crude oils include:
Class
Paraffins
Aromatics
Napthenes
or
Cycloalkanes
Alkenes
Alkynes
n
Y
Formula
Short Description / Example
CnH2n+2
straight- or branched-chain molecules

can be gasses or liquids depending upon the molecule
Examples: methane, ethane, propane, butane, isobutene etc.
C6H5 Y
ringed structures with one or more rings rings contain six

carbon atoms, with alternating double and single bonds
between the carbons
Examples: benzene, naphthalene
CnH2n
ringed structures with one or more rings rings contain only

single bonds between the carbon atoms
typically liquids at room temperature
Examples: cyclohexane, methyl cyclopentane
CnH2n
linear or branched chain molecules containing one carboncarbon double-bond, can be liquid or gas
Examples: ethylene, butene, isobutene Dienes
CnH2n-2
linear or branched chain molecules containing two carboncarbon double-bonds

can be liquid or gas
Examples: acetylene, butadiene
is a whole number, usually from 1 to 20

is a longer, straight molecule that connects to the benzene ring
Table 1 - Major Classes of Hydrocarbons in Crude Oil
INTRODUCTION | 2
In crude oils,
half of the hydrocarbons are Naphthenes,

one-third are paraffins,
one-sixth are aromatics,
and the rest are asphalt.
The color can range from pure black or dark brown to greenish or yellowish, and in viscosity,
from water to almost solid depending on the composition.
Crude oil is considered light if the level of hydrocarbons relative to organics and metals is
high, making its density low, and it is considered heavy if the level of hydrocarbons relative
to organics and metals is low, making its density as high.
Additionally, crude oil is classified as sweet if it has very little sulfur in it, and is classified as
sour if it has a great deal of sulfur in it. So a crude oil will usually be called something like a
sweet, light oil, or a sour, heavy oil.
Sweeter oils are more valuable than sour oils, because most countries have sulfur regulations
for environmental reasons, and sweet oils require less treatment to remove the sulfur. Light
oils are more valuable than heavy oils, because more gasoline can be created from a smaller
amount.
Different regions on earth tend to have different types of oil, so crude oil is often classified
based on where it comes from. Certain regions will act as a sample of a broader region, since
they are seen as relatively representative of that broad region. For example,
Dubai-Oman oil is a sour crude oil, and is used to benchmark most sour crude from
the Middle East;
West Texas Intermediate is a sweet, light oil; and
the OPEC Reference Basket is a composite oil sample that averages oils from all over the
Organization of the Petroleum Exporting Countries.
While conventional crude oil is currently the major source of petroleum on the planet, it
actually makes up a minority of crude oil currently in reserve.
A bit less than one-third of the crude oil known on the planet is in conventional form.
Another one-sixth is heavy oil, and
a quarter is extra-heavy oil.
Another one-third, is in the form of oil sands, or crude bitumen.
CRUDE BITUMEN: This is not a liquid form of crude oil, but is mixed with sand into a
somewhat solid form. Huge reserves of bitumen can be found in Venezuela and Canada,
which also contain large amount of extra-heavy oil, making the two countries reserves equal
to about twice the known reserves of conventional oil.
Now that we know what's in crude oil, let's see what we can make from it.
INTRODUCTION | 3
1.2 CRUDE OIL FORMATION

Crude oil is created through the heating and compression of organic materials over a long
period of time. Most of the oil we extract today comes from the remains of prehistoric algae
and zooplankton whose remains settled on the bottom of an Ocean or Lake. Over time this
organic material combined with mud and was then heated to high temperatures from the
pressure created by heavy layers of sediment. This process, known as diagnosis, changes the
chemical composition first into a waxy compound called kerosene and then, with increased
heat, into a liquid through a process called cytogenesis.
1.3 CRUDE OIL EXTRACTION

The most common method of crude oil extraction is drilling. Geologists will first identify a
section of land they believe has oil flowing beneath it. There are a number of ways this can
be accomplished, the most frequently used methods are satellite imagery, gravity meters, and
magnetometers. Once a steady stream of oil is found, underground the drilling can begin
Drilling is not an overly complicated process however a standard method has been developed
to provide maximum efficiency. The first step of the process involves drilling into the ground
in the exact location where the oil is located. Once a steady flow has been identified at a
particular depth beneath the ground a perforating gun is lowered into the well. A perforating
gun has explosive charges within it that allow for oil to flow through holes in the casing.
Once the casing is properly perforated a tube is run into the hole allowing the oil and gas to
flow up the well. To seal the tubing a device called a packer is run along the outside of the
tube. The last step involves the placement of a structure called a Christmas tree which allows
oil workers to control the flow of oil from the well.
1.4 OIL SANDS

Oil can also be extracted from oil sands, often called tar sands. Oils sands are typically sand
or clay mixed with water and a very viscous form of crude oil known as bitumen. The
extraction process for oil sands is quite different from drilling due to the high viscosity of this
extra-heavy oil. Rather than using drills, crude oil is extracted from oil sands through strip
mining or a variety of other techniques used to reduce the viscosity of the oil. This process
can be far more expensive than traditional drilling and is found in high abundance only in
Canada and Venezuela. As oil demand continues to rise, and reserves become depleted, oil
sands could provide one of the last viable methods for extracting crude oil from the Earth.
1.5 WORLDWIDE OIL PRODUCTION

While just about every country in the world depends on oil, not all countries produce it. The
top five oil producing countries are: Saudi Arabia, Russia, United States, Iran, and China. It is
important to note that the term production here refers to crude oil extracted from oil reserves.
The top five oil consuming countries are: United States, China, Japan, Russia, and Germany.
INTRODUCTION | 4
At the current rate of consumption it is estimated that worldwide reserves will become
extinguished by 2039. Scientists and engineers are working hard to find ways of more
efficiently extracting and processing crude oil to delay what could become a global energy
crisis.
CHAPTER # 2
PROCESS DESCRIPTION
PROCESS DESCRIPTION | 6
2. PROCESS DESCRIPTION
2.1 CRUDE OIL FLOW
The following process description can best be understood by referring to the Process Flow
Diagram in next Section. All references to operating conditions reflect the operation when
processing Sweet Crude Oil (API = 44.28).
Crude oil flows into the suction of the Crude Charge Pump, P-301 A or B, from crude
storage. This pump provides part of the necessary head required to move the crude oil
through the crude charge system. The crude oil is pumped through the
Kerosene Crude Exchanger, E-301,

Light Gas Oil (cold) Crude Exchanger, E-302,
Naphtha Pumparound Crude Exchanger, E-303,
and into the De-salter, V-306 (operated at approximately 119C)
Water is added in the Crude Stream before flowing into Desalter. Water may also be injected
at intermediate positions, if desired
upstream of the Crude Charge Pump, P-301 A or B,
upstream of the Kerosene Crude Exchanger, E-301
The normal De-salter water addition rate is 3 volume percent of the crude charge. In the
Desalter, water droplets are electrostatically coalesced and collected water exits the vessel on
tri-cork level control. The desalting system is designed for processing Crudes with salt
contents up to 16 kg / 159 m3 (35 lbs. /1000 bbl.). Normal De-salter pressure should be
maintained at approximately 140 psig (965 kPa) in order to always maintain hydraulic
pressure on this vessel and prevent any possible vaporization.
From the De-salter, crude oil flows into the suction of the Crude Booster Pump, P-313 A or
B. This pump provides the remainder of the necessary head required to move the crude oil
through the
Heavy Gas Oil Crude Exchanger, E-304,

Furnace Fuel Oil (cold) Crude Exchanger, E-305,
Light Gas Oil (hot) Crude Exchanger, E-306,
Light Gas Oil Pumparound Crude Exchanger, E-307,
Furnace Fuel Oil (hot) Crude Exchanger, E-308,
Into the convection section of the Charge Heater, H-301.
At this point an optional recirculating residue or bottoms stream (FFO) joins the fresh crude
charge stream on flow control. The purpose of this recirculating stream is to continually
maintain a satisfactory flow of liquid at the heater outlet and prevent excessive vaporization
and possible tube coking.
About 15 % of the fresh crude charge rate in the form of residue will be re-circulated when
processing Sweet crude. If crude oils, containing as much as 25 volume percent residue, are
processed no recirculation will be required.
The preheated charge and recycle stream enters the convection section of a Direct Fired
Charge Heater H-301, from which the additional feed heat requirement is satisfied. The
charge heater is supplied with a dual fuel burner system so that either fuel (Natural Gas in our
project) or refinery fuel gas may be used as a combustion medium.
The crude charge enters the flash zone of the Crude Tower, V-301, from the Fired Heater, H301. Sufficient over-flash (3% in our project) must be maintained to ensure ample reflux on
the trays immediately above the flash zone. The vaporized distillates and some over-flashed
material passes up the tower and the residue (FFO), passes to the stripping section beneath
the flash zone (feed point). It is expected that a heater outlet temperature of approximately
324C will be required at design plant yields.
2.1.1 HEAVY GAS OIL CIRCUIT

Heavy Gas Oil is withdrawn from the Crude Tower, V-301, as a side-cut and is admitted to
the Heavy Gas Oil Stripper, V-304, on level control. The Heavy Gas Oil is steam stripped for
flash point correction. Heavy Gas Oil product prior to exiting the unit on flow control at 60C
and 30 psig (207 KPa) flow into
the suction of the Heavy Gas Oil Pump, P-306 A or B, from which it is pumped
through
the Heavy Gas Oil Crude Exchanger , E-304
the Heavy Gas Oil Cooler, E-312
2.1.2 LIGHT GAS OIL CIRCUIT

Light Gas Oil is also withdrawn from the Crude Tower, V-301, as a side-cut and is admitted
to the Light Gas Oil Stripper, V-303, on level control. The Light Gas Oil is steam stripped for
flash point correction. Light Gas Oil product prior to exiting the unit on flow control at 54 C
and 30 psig (207 kPa) flows into
the suction of the Light Gas Oil Pump, P-305 A or B, from which it is pumped
through
the Light Gas Oil (Hot) Crude Exchanger, E-306
the Light Gas Oil (Cold) Crude Exchanger, E-302
the Light Gas Oil Cooler, E-311
2.1.3 LIGHT GAS OIL PUMPAROUND CIRCUIT

Part of the Light Gas Oil withdrawn from the main tower is taken to the Light Gas Oil
Pumparound Pump, P-307 A or B, rather than to Light Gas Oil stripper. This stream is
circulated as a pumparound stream, supplying all of the heat required by the Stabilizer
Reboiler, E-403, and allowing high level heat recovery in the crude preheat train by being
circulated through the Light Gas Oil Pump around Crude Exchanger, E-307. The combined
pumparound stream returns to the main tower on 18th Tray.
This pumparound loop unloads the top section of the crude tower and reduces the load on the
overhead system. Three trays in the main tower serve as the Light Gas Oil pumparound
section.
2.1.4 LIGHT WEIGHT KEROSENE CIRCUIT

Kerosene is also withdrawn from the Crude Tower, V-301, as a side-cut and is admitted to
the Kerosene Stripper, V-302, on level control. The Kerosene is steam stripped for flash point
correction. Kerosene product prior to exiting the unit on flow control at 38C and 100 psig
(690 kPa) flows into
the suction of the Kerosene Pump, P-304 A or B, from which it is pumped through
the Kerosene-Crude Exchanger, E-301
the Kerosene Cooler, E-310
Kerosene product to storage is trim cooled with cooling water since the high ambient air
temperatures prevent utilizing air cooling and achieving required battery limits temperatures.
2.1.5 NAPHTHA PUMPAROUND CIRCUIT

In order to achieve additional heat recovery and minimize the overhead condensing
requirement, Naphtha is withdrawn from the main tower at 38th Tray and circulated as a
pumparound stream. This naphtha flows to
the suction of Naphtha Pumparound Pump, P-312 A/B, which circulates naphtha
through
the Naphtha Pump Around Exchanger, E-303, and
the Pumparound Flow Control Station, FCV-I02
This Naphtha Pump Around stream joins the main tower reflux stream and returned to the
main tower on 40th Tray. Three trays in main tower serve as the Naphtha Pump Around
section.
2.1.6 CRUDE TOWER OVERHEAD CIRCUIT

Crude tower over head vapor passes through the Overhead Condenser E-309, by which the
overhead vapor is essentially totally condensed. Condensed liquid plus any non-condensable
vapors flow into the Overhead Accumulator, V-305. Sufficient pressure is maintained on this
accumulator so that essentially all vapors will be condensed, but not so high as to impose
high flash zone pressures. It is anticipated that the accumulator pressure will be maintained
between 10 and 20 psig (70 and 140 kPa).
The overhead accumulator temperature may be regulated at approximately 60C, for this
sufficient fans, including two-speed motors, and louvers have been provided for the Overhead
Condenser, E-309. This regulation may be required if that naphtha fed to the Stabilizer, V401, is heat exchanged with stabilizer bottoms as a means of heat recovery. If the Overhead
Accumulator, V-305, temperature is allowed to fall too low, sufficient stabilizer feed heat
recovery may not be achieved, imposing greater than design loads on the Stabilizer Reboiler,
E-403.
Condensed naphtha collected in the crude tower overhead accumulator flows into the suction
of the Naphtha Reflux Pump, P-302 A or B. This pump provides the necessary head required
to pump naphtha reflux back into the Crude Tower,
The reflux rate is reset by the crude tower overhead vapor Temperature Controller. A level
controller on the Overhead Accumulator, V-305, and resets the stabilizer feed flow controller,
allowing naphtha to be boosted into the suction of the Stabilizer Feed Pump, P-303 A or B.
This pump provides the necessary head required to move naphtha through
the Stabilizer Feed-Bottoms Exchanger, E-401
into the Naphtha Stabilizer, V-401
2.1.6.1 NEUTRALIZING AMINES

Although a De-salter is provided with this crude unit, the crude charge will contain some salts
downstream of the De-salter. Small amounts of these salts are hydrolyzed to hydrogen
chloride during heating in the crude furnace. Hydrogen chloride is not corrosive at
temperatures above the dew point. As a result, this type of corrosion is confined to the crude
tower overhead equipment where lower temperatures are experienced.
To overcome potential hydrogen chloride corrosion in this plant, the overhead system is
protected by injection of neutralizing and filming amines. These chemicals are mixed with a
small slipstream of naphtha and injected through a spray nozzle immediately downstream of
the first overhead system piping elbow. Dosage rates depend upon the particular types of
neutralizing and filming amines used and the amount and types of salts in the oil; however,
nominal dosage rates based on the total overhead vapor rate may be considered to be in the
order of
3-5 wppm of Neutralizing Amine and
1-6 wppm of Filming Amine
Stripping steam injected into the system (V-301, V-302, V-303, and V-304) and condensed in
the Overhead Condenser is collected as water in the water boot provided on the overhead
accumulator. The water from the Overhead Accumulator boot should be controlled in a pH
range from 5.5 to 6.5 when neutralizing amine is used in conjunction with filming amine,
since best performance of the two amines will be achieved at this condition.
Water from the Overhead Accumulator Boot flows into the suction of the Overhead
Accumulator Water Pump, 309 A or B, which provides the necessary head required to move
the water through the Oily Water Effluent Level Control Valve and on to either disposal or
use as desalting water.
2.1.7 BOTTOM STRIPPING SECTION OF CRUDE TOWER

That portion of the crude tower charge which is not vaporized, plus the condensed over-flash
material, flows downward from the crude tower flash zone across four stripping trays. Steam
is admitted below the bottom tray for flash point correction of the residue or bottoms stream.
Crude tower bottoms flows into the suction of the Atmospheric Residue Pump, P-308 A or B.
This pump provides the necessary head required to move the residue product stream through
the Residue (Hot) Crude Exchanger, E-308,
the Residue (Cold) Crude Exchanger, E-305,
the Residue Cooler, E-313
Since the plant is designed for a wide variance in residue product yield, a residue stream bypass has been provided around the Residue (Hot) Crude Exchanger, E-308, and the Cold
Residue-Crude Exchanger, E-305. These by-passes may be utilized should the residue side
pressure drop become excessive.
The Residue Cooler, E- 313, is adequately designed to handle the additional heat load and
system hydraulics.
2.1.8 UN-STABILIZED NAPHTHA CIRCUIT

Un-stabilized Naphtha, from the Stabilizer Feed-Bottoms Exchanger E-401, flows onto 22nd
Tray of the Naphtha Stabilizer, V-401. In this tower, essentially all of the ethane and propane
and sufficient butanes are fractionated from the Naphtha so as to produce Specification
Stabilized Naphtha. Pentanes are basically fractionated into the bottoms product so that
commercial grade propane-butane mixture may be produced as an overhead liquid product.
Overhead vapors from the stabilizer tower flow through the Stabilizer Overhead Condenser,
E-402, which serves to condense LPG product and provide adequate reflux for the stabilizer
tower. Condensed liquid and non-condensed vapor flows into the Overhead Accumulator, V402, which is pressure controlled at 155 psig (1069 kPa) by controlling the flow of off-gas to
the existing refinery fuel system.
Multiple fans, each with two-speed motors, and louvers have been provided for the Stabilizer
Overhead Condenser, E-402, so that the temperature of the overhead accumulator can be
controlled within a reasonable operating range. At a fixed accumulator pressure, the
temperature may be varied if required to adjust the ethane content of the LPG product. The
main point of temperature control will beat the tower bottoms, and the tower reflux rate may
be adjusted to insure that excess quantities of pentanes are not taken overhead. A small
amount of water will likely collect in the Accumulator Water Boot. The water level in the
boot should be observed periodically and manually drained as necessary.
Naphtha flows from the bottom of the Naphtha Stabilizer, V-401, into the shell side of the
Stabilizer Re-boiler, E-403. Light Gas Oil pumparound flows through the tube side of this
kettle re-boiler. The Re-boiler vapor return temperature to the stabilizer is maintained by
resetting the Light Gas Oil flow rate through the Re-boiler.
The liquid level in the bottom of the stabilizer rises as necessary to provide the head required
to offset the pressure drop through the Re-boiler and associated piping. Stabilized naphtha
flows
from the Stabilizer Re-boiler, E-403,

through the Stabilizer Feed Bottoms Exchanger, E-401
the Naphtha Cooler, E-404, and
the Naphtha Trim Cooler, E-405,
Stabilized naphtha flows to battery limits at38C and 100 psig (690 kPa). A by-pass is
provided around the shell side of the Stabilizer Feed-Bottoms Exchanger, E-401, to allow
control of the Stabilizer feed temperature if required.
2.2 PROCESS FLOW DIAGRAM
Figure 1 - Process Flow Diagram
CHAPTER # 3
CAPACITY SELECTION
CAPACITY SELECTION | 14
3. CAPACITY SELECTION
The capacity for the plant is selected based on the market demand of one of the products of
Crude Oil Distillation. From the data for Pakistan
(2012 13) 3.8 .
Diesel production from refineries = 3 MMTY Approximately. Therefore
(2012 13) 2.8 .
Just to indicate how fast the demand for diesel is growing in country, the statistics show
( 2012 2013) 1
The capacity calculation is based on the gasoline import required for the year 2012-13.
Assuming that Gasoline is produced by fractionation of Crude Oil is by weight 40% of the
feed (Crude Oil). Then to meet the market demand,
= 2.8 0.4 = 7.0
Based on 330 days of plant operation,
= 7.0 106 330 = 21500

In our case the API gravity of Crude Oil is 44.28. So
and
141.5
= 0.805
44.28 + 131.5
= 0.805 1000 = 805 /3
Then the conversion factor for feed VGO is
1 1000 13
1
1 =
= 7.1813 /
1
805 0.15899 3
1 = 7.1813
Hence the required capacity of the unit is
= 21500 7.1813 = 154,398

CAPACITY SELECTION | 15
A distillation unit of this much large capacity is not yet practically possible. The largest such
plant in operation is at (Saudi Arabia) with a capacity of 45,000 BPSD. The largest proposed
crude distillation unit will come up in Korea in 2010 with a capacity of 75,000 BPSD.
Now we turn to the previous installations of distillation units. Attock Refinery Limited has a
unit of 5000 BPSD. Giving an allowance for future expansion, and considering the fact that
the new units are being installed with larger capacities, we select the capacity of the unit to be
5,000 BPSD.
= 5,000
CHAPTER # 4
MATERIAL BALANCE
MATERIAL BALANCE | 17
4. MATERIAL BALANCE
4.1 INTRODUCTION
We would take feed basis for our material balance. Which means we are fixing the refining
capacity of crude oil for our plant. The awesome thing about Crude Oil is that wherever we
get it from, its composition depends on its API gravity which in turn is dependent upon the
specific gravity of crude and characterization factor (UOP K factor) which depends upon the
distillation curve (ASTM D86). Hence if we know the API gravity of crude oil, we know the
mass percentages of products to be separated from crude oil.
See Appendix B of Petroleum Refinery Engineering (Nelson)
We have selected 5000 Barrels per Stream Day BPSD as our plants refining capacity. We
have selected crude oil of 44.28 API gravity. Our plant has five products out of which we are
concerned only with the Naphtha, but for material balance we would take every product in
consideration.
The following table has been extracted from ARLs Howe Baker Units Manual.
(The primary source of our design data is Attock Refinery Limited, Morgah, Rawalpindi)
Volumetric
API
Crude Charged
% age
Flow Rate
BPSD
Mass
Flow Rate
lbs./hr.
44.28
100.0
20000
234640
0.57
114
678
Products
Off Gasses
Liquefied Petroleum Gas
LPG
0.93
186
1500
Naphtha
Nap
60.40
42.5
8500
91492
Light Weight Kerosene
LWK
42.91
20.0
4000
47297
Light Gas Oil
LGO
32.15
21.0
4200
52928
Heavy Gas Oil
HGO
22.27
5.0
1000
13411
Fuel Furnace Oil
FFO
19.50
10.0
2000
27334
Table 2 - Crude Oil Product Yeild Analysis of ARL
Instrument
Tag No.
Volumetric
Service
FRC-103
Crude Charge
FIC-101
BPSD
Mass
% age
Kg/hr.
% age
20,000
100.000
106660
Desalter Water
600
3.000
FR-116
Off-Gasses
114
0.570
308
0.30
FRC-113
LPG to Treating
186
0.930
682
0.64
FR-115
Naphtha to Storage
8500
42.500
41521
38.93
FRC-108
Kerosene Product
4000
20.000
21500
20.16
FRC-110
Light Gas Oil Product
4200
21.000
6101
5.72
FRC-109
Heavy Gas Oil Product
1000
5.000
24063
22.56
FR-114
Residue to Storage
2000
10.000
12416
11.64
FRC-112
Stabilizer Reflux
1104
5.520
4052
3.80
FRC-106
Naphtha Reflux
6317
31.585
30860
28.93
FRC-102
Naphtha Pumparound
15051
75.255
73526
68.93
FRC-105
Light Gas Oil Pumparound
10624
53.120
60858
57.06
FRC-111
Light Gas Oil to Reboiler
11100
55.500
63590
59.62
FI-5
V-301 Stripping Steam
756
0.7088
FI-8
756
0.7088
Fl-7
476
0.4463
FI-6
76
0.07
Table 3- ARL Design Conditions
4.2 MATERIAL BALANCE ACROSS DESALTER V-306

Crude Oil has some salts, which need to be removed before entering into the fractionating
tower (V-301 Crude Tower). Salts in average crude oil are less than 1%.To accomplish
desalting, the crude is first preheated to 120-150 with heat exchangers in order to reach the
required viscosity level normally in the range of 5-15 centi-stoke. About 2-6% wash water is
added ahead of the Desalter as an extraction agent in addition to emulsifying agents to help
dissolve salts and sediments.
We have selected 3 volumetric % water injection rate and a brine removal rate of 3.1%
(Using VSEP to Treat Desalter Effluent).
The density of brine in water is 973.7 kg/m3 extracted from A Technical Data book for
Geothermal Energy Utilization (Phillips)
CRUDE (SPECIFIC GRAVITY = 0.805)

159
1 3
1 1000
3
= 5000
=
33.125
24
= 0.805 1000
33.125
= 26665.625
3
WATER (SPECIFIC GRAVITY = 1)

= . = 0.03 33.125
= 1 1000
3
3
= 0.99
0.99
= 990
3
BRINE REMOVAL (DENSITY = 973.7 KG/M3)

=
33.125
3
3
. = 1.03
= @ 120
= 1.03
973.7 3 = 1002.91
DESALTED CRUDE

306
= 306
+ = +
26665.625
+ 990
= 1002.91
+
= .
Figure 2 - Material Balance across Desalter
4.3 MATERIAL BALANCE ACROSS V-401 STABILIZER

OFF GASES
= %
= 0.003 26665.625
= 80
V-401 PRODUCT - LPG

= %
= 0.0064 26665.625
= 170.66
V-401 PRODUCT - NAPHTHA

= 60.40 =
141.5
131.5
.
. = 0.7374
= % = 0.425 33.125
= 14.07813
= 0.7374 1000
V-401 FEED OF STABILIZER
14.07813
= 10381.21
3
401 = + +
401 = 80
+ 170.66
+ 10381.21
401 = 10631.87
Figure 3 - Material Balance across Stabilizer
4.4 MATERIAL BALANCE ACROSS V-301 CRUDE TOWER

V-301 STEAM
301 = % 301
301 = . 26665.625
= 189.01
NAPHTHA REFLUX
= %
= . 26665.625
NAPHTHA PUMPAROUND
= 7714.37
= %
= . 26665.625
NAPHTHA RETURN
= 18380.62
= +
= 7714.37
LGO TO REBOILER
+ 18380.62
= 26094.99
= %
= . 26665.625
LGO PUMPAROUND
= 15898.05
= %
= . 26665.625
LGO RETURN
= 15215.41
= +
= 15898.05
+ 15215.41
= 31113.46
4.5 MATERIAL BALANCE ACROSS V-302 LWK STRIPPER

V-302 PRODUCT - LWK
= . =
141.5
131.5
.
. = 0.8113
= % = . 33.125

3
3
= 6.625
= 0.8113 1000 3 6.625

= 5374.86
V-302 FEED LWK DRAW OFF

302 = %
302 =
5374.86
0.92
= 5842.24
V-302 STEAM
302 = % 302
302 = . 26665.625
= 189.01
V-302 LWK STRIP ENDS

302 + 302 = + 302
5842.24
+ 189.01
= 5374.86
+ 302
302 = 656.39
Figure 4 - Material Balance across LWK Stripper
4.6 MATERIAL BALANCE ACROSS V-303 LGO STRIPPER

V-303 PRODUCT - LGO
= . =
141.5
131.5
.
. = 0.8647
= % = . 33.125
= 0.8647 1000
V-303 FEED LGO DRAW OFF
6.95625
= 6015.07
3
303 = %
303 =
V-303 STEAM
3
3
= 6.95625
6015.07
0.95
= 6331.65
303 = % 303
303 = . 26665.625
V-303 LGO STRIP ENDS
= 119.01
303 + 303 = + 303

6331.65
+ 119.01
= 6015.07
+ 303
303 = 435.59
Figure 5 - Material Balance across LGO Stripper
4.7 MATERIAL BALANCE ACROSS V-304 HGO STRIPPER

V-304 PRODUCT - HGO
= . =
141.5
131.5
.
. = 0.9202
= % = . 33.125
= 0.9202 1000
V-304 FEED HGO DRAW OFF
1.65625
= 1524.08
3
304 = %
304 =
V-304 STEAM
3
3
= 1.65625
1524.08
0.96
= 1587.58
304 = % 304
304 = . 26665.625
V-304 HGO STRIP ENDS
= 19.01
304 + 304 = + 304

1587.58
+ 19.01
= 1524.08
+ 304
304 = .
Figure 6 - Material Balance across HGO Stripper
4.8 MATERIAL BALANCE ACROSS V-305 OVERHEAD ACCUMULATOR

DOWNSTREAM OF V-305 OVERHEAD ACCUMULATOR
305 = 401 +
305 = 10631.87
+ 7714.37
= 18346.24
BOOT OF V-305 OVERHEAD ACCUMULATOR

305 = 301 + 302 + 303 + 304
305 = 189.01
V-301 OVERHEAD
+ 189.01
+ 119.01
+ 19.01
305 = 516.04
301 = 305 + 305

301 = 18346.24
+ 516.04
= 18862.28
Figure 7 Material Balance across V-305 Accumulator
4.9 MATERIAL BALANCE ACROSS V-301 CRUDE TOWER (CONTINUED)

V-301 PRODUCT - FFO
= . =
141.5
131.5
.
. = 0.9371
= % = . 33.125
= 0.9371 1000
3.3125
= 3104.14
3
MATERIAL IN
Stream
Desalted Crude
3
3
= 3.3125
MATERIAL OUT
Kg/hr.
26652.715
Stream
V-301 Overhead
Kg/hr.
18802.87
V-302 LWK Strip Ends
656.39
LWK Draw Off
5842.24
V-303 LGO Strip Ends
435.59
LGO Draw Off
6331.65
V-304 HGO Strip Ends
82.51
HGO Draw Off
1587.58
189.01
FFO Draw Off
3104.14
Steam V-301
Naphtha Reflux
Material In to V-301
7654.95
35671.17
Material Out of V-301
35668.48
Table 4- Material Balance across V-301
CHAPTER # 5
ENERGY BALANCE
ENERGY BALANCE | 29
5. ENERGY BALANCE
5.1 ENERGY BALANCE ACROSS E-301 CRUDE/LWK EXCHANGER
E-301 SHELL SIDE LWK
= 5374.86
E-301 TUBE SIDE CRUDE
= 26665.625
301 = 336 F 135 F = 201 F
301 =
301 = 130 F 85 F = 45 F
336 F + 135 F
= 235.5 F
2
For Cp value at 42.91o API, interpolate between 40

and 50o API at Avg. T using Fig 5.1 (Nelson)
Cp @40 o API = 0.55
=
Cp @50 o API = 0.58
50 42.91
42.91 40
(0.58)
(0.55) +
50 40
50 40
= 0.5587 = 2.339
301 = 301
301 = 5374.86
201
2.339
1.8
301 = 1403850.73
301 = 389.9585
301 =
130 F + 85 F
= 107.5 F
2

and 50o API at Avg.. T using Fig 5.1 (Nelson)
Cp @40 o API = 0.49
=
Cp @50 o API = 0.52
50 44.28
44.28 40
(0.52)
(0.49) +
50 40
50 40
= 0.5028 = 2.105
301 = 301
301 = 26665.625
45
2.105
1.8
301 = 1403278.52
301 = 389.7996
ENERGY BALANCE | 30
5.2 ENERGY BALANCE ACROSS E-302 CRUDE/LGO (COLD) EXCHANGER

E-302 SHELL SIDE LGO COLD
= 6015.07
= 26665.625
302 = 325 F 180 F = 145 F
302 =
302 = 160 F 130 F = 35 F
325 F + 180 F
= 252.5 F
2

Cp @30 o API = 0.55
=
Cp @40 o API = 0.56
40 32.15
32.15 30
(0.56)
(0.55) +
40 30
40 30
= 0.5522 = 2.312
302 = 302
302 = 6015.07
145
2.312
1.8
302 = 1120273.37
302 = 311.1870
302 =
160 F + 130 F
= 148 F
2

Cp @40 o API = 0.505
=
Cp @50 o API = 0.53
50 44.28
44.28 40
(0.53)
(0.505) +
50 40
50 40
= 0.5157 = 2.159
302 = 302
302 = 26665.625
35
2.159
1.8
302 = 1119437.75
302 = 310.9549
ENERGY BALANCE | 31
5.3 ENERGY BALANCE ACROSS E-304 CRUDE/HGO EXCHANGER

E-304 SHELL SIDE HGO
= 1524.08
= 26652.715
304 = 581 F 280 F = 301 F
304 =
304 = 264 F 246 F = 18 F
581 F + 280 F
= 430.5 F
2

Cp @20 o API = 0.615
=
Cp @30 o API = 0.64
30 32.15
22.27 20
(0.64)
(0.615) +
30 20
30 20
= 0.6207 = 2.599
304 = 304
304 = 1524.08
301
2.599
1.8
304 = 662381.26
304 = 183.9948
304 =
264 F + 246 F
= 255 F
2

Cp @40 o API = 0.58
=
Cp @50 o API = 0.61
50 44.28
44.28 40
(0.61)
(0.58) +
50 40
50 40
= 0.5928 = 2.482
304 = 304
304 = 26652.715
18
2.482
1.8
304 = 661520.39
304 = 183.7557
ENERGY BALANCE | 32
5.4 ENERGY BALANCE ACROSS E-305 CRUDE/FFO (COLD) EXCHANGER

E-305 SHELL SIDE FFO COLD
= 3014.14
= 26652.715
305 = 435 F 300 F = 135 F
305 =
305 = 279 F 264 F = 15 F
435 F + 300 F
= 367.5 F
2

Cp @10 o API = 0.55
=
Cp @20 o API = 0.575
20 19.50
19.50 10
(0.575)
(0.55) +
20 10
20 10
= 0.5719 = 2.394
305 = 305
305 = 3104.14
135
2.394
1.8
305 = 557348.34
304 = 154.8190
305 =
279 F + 264 F
= 271.5 F
2

Cp @40 o API = 0.59
=
Cp @50 o API = 0.61
50 44.28
44.28 40
(0.61)
(0.59) +
50 40
50 40
= 0.5986 = 2.506
305 = 305
305 = 26652.715
15
2.506
1.8
305 = 556597.53
305 = 154.6104
ENERGY BALANCE | 33
5.5 ENERGY BALANCE ACROSS E-306 CRUDE/LGO (HOT) EXCHANGER

E-306 SHELL SIDE LGO HOT
= 6015.07
= 26652.715
306 = 465 F 325 F = 140 F
306 =
306 = 312 F 279 F = 33 F
465 F + 325 F
= 395 F
2

Cp @30 o API = 0.635
=
Cp @40 o API = 0.65
40 32.15
32.15 30
(0.65)
(0.635) +
40 30
40 30
= 0.6382 = 2.672
306 = 306
306 = 6015.07
140
2.672
1.8
306 = 1250065.21
306 = 347.2403
306 =
312 F + 279 F
= 295.5 F
2

Cp @40 o API = 0.60
=
Cp @50 o API = 0.625
50 44.28
44.28 40
(0.625)
(0.60) +
50 40
50 40
= 0.6107 = 2.557
306 = 306
306 = 26652.715
33
2.557
1.8
306 = 1249434.86
306 = 347.0652
ENERGY BALANCE | 34
5.6 ENERGY BALANCE ACROSS E-308 CRUDE/FFO (HOT) EXCHANGER

E-308 SHELL SIDE FFO HOT
= 3014.14
= 26652.715
308 = 592 F 435 F = 157 F
308 =
308 = 405 F 387 F = 18 F
592 F + 435 F
= 513.5 F
2

Cp @10 o API = 0.645
=
Cp @20 o API = 0.665
19.50 10
20 19.50
(0.645) +
(0.665)
20 10
20 10
= 0.6640 = 2.780
308 = 308
308 = 3104.14
157
2.780
1.8
308 = 752684.97
308 = 209.0792
308 =
405 F + 387 F
= 396 F
2

Cp @40 o API = 0.665
=
Cp @50 o API = 0.68
44.28 40
50 44.28
(0.665) +
(0.68)
50 40
50 40
= 0.6714 = 2.811
308 = 308
308 = 26652.715
18
2.811
1.8
308 = 749207.82
308 = 208.1133
ENERGY BALANCE | 35
5.7 ENERGY BALANCE ACROSS E-310 LWK TRIM COOLER

= 5374.86
310 = 135 F 100 F = 35 F
310 =
135 F + 100 F
= 117.5 F
2

Cp @40 o API = 0.485
=
Cp @50 o API = 0.51
50 42.91
42.91 40
(0.51)
(0.485) +
50 40
50 40
= 0.4923 = 2.061
310 = 310
310 = 5374.86
35
2.061
1.8
310 = 215397.51
310 = 59.8326
ENERGY BALANCE | 36
5.8 ENERGY BALANCE ACROSS ALL EXCHANGERS

ENERGY IN
ENERGY OUT
Shell Side
Tube Side
Stream
KJ/sec (KW)
Stream
KJ/sec (KW)
E 301
LWK
389.9585
Crude
389.7996
E 302
LGO (cold)
311.1870
Crude
310.9549
E 303
Naphtha PA
Crude
768.6366
E 304
HGO
183.9948
Desalted Crude
183.7557
E 305
FFO (cold)
154.8190
Desalted Crude
154.6104
E 306
LGO (hot)
347.2403
Desalted Crude
347.0652
E 307
LGO PA
Desalted Crude
878.5525
E 308
FFO (hot)
Desalted Crude
204.1154
204.3410
Table 5 Energy Balance across all Exchangers
5.9 ENERGY BALANCE ACROSS V-301 CRUDE TOWER

5.9.1 ENTHALPY OF STEAM ENTERING IN V-301, V-302, V-303, V-304
For value of H at 758 KPa & 185o C, using Table A6 for Superheated Water (Cengel 920)
H @158.83o C (600 KPa) = 2756.2 KJ/kg
600 =
200 185
185 158.83
(2850.6)
(2756.2) +
200 158.83
200 158.83
600 = 2816.2
H @170.41o C (800 KPa) = 2768.3 KJ/kg

800 =
H @200o C (600 KPa) = 2850.6 KJ/kg
H @200o C (800 KPa) = 2839.8 KJ/kg
200 185
185 170.41
(2839.8)
(2768.3) +
200 170.41
200 170.41
800 = 2803.6
H @600 KPa (185o C) = 2816.2 KJ/kg

758 (185 ) =
H @800 KPa (185o C) = 2803.6 KJ/kg
800 758
758 600
(2803.6)
(2816.2) +
800 600
800 600
ENERGY BALANCE | 37
758 (185 ) = 2806.2
ENERGY IN
ENERGY OUT
V-301 Crude Tower
V-301 Crude Tower
Stream
KJ/sec (KW)
Stream
KJ/sec (KW)
V-301 Feed
7738.42
LWK
632.5829
Total Steam
402.2532
LGO
996.8126
525.739
HGO
321.805
FFO
687.672
Naphtha Ovhd.
3349.63
LPG
11.976
Naphtha Reflux
Desalted Crude
204.1154
Table 6 - Energy Balance across Crude Tower
CHAPTER # 6
EQUIPMENT DESIGN
EQUIPMENT DESIGN: SHELL & TUBE HEAT EXCHANGER | 39
6. EQUIPMENT DESIGN
6.1 SHELL & TUBE HEAT EXCHANGER E-301 LWK/CRUDE

6.1.1 HEAT EXCHANGER?
Heat exchangers are the devices used to recover heat of one fluid and utilize it for other
applications. For example air-to-air equipment are the most practical choice if the points of
recovery and use are close and hence coupled.
6.1.1.1 HEAT EXCHANGER AS HEAT RECOVERY EQUIPMENT

"A heat exchanger is a heat transfer device that is used for transfer of internal thermal
energy between two or more fluids available at different temperatures."
In most of the exchangers the fluids are separated by a heat transfer surface and ideally they
don't mix. The word "EXCHANGER" really applies to all type of equipment in which heat is
exchanged but is often used specifically to denote equipment in which heat is exchanged
between two process fluids. If we are using any service stream then it will be called as heater
or cooler.
6.1.1.2 USES OF HEAT EXCHANGERS
Heat Exchangers are used in

Petroleum industry
Chemical process industry
Refrigeration
Cryogenic applications
Power generation systems
Heat recovery systems.
Common examples of heat exchangers familiar to us in day-to-day use are automobile

radiators, condensers, evaporators, air pre-heaters, and oil coolers.
6.1.1.3 CLASSIFICATION OF HEAT EXCHANGER

In general industrial heat exchangers are classified according to their:
Construction
Degrees of surface compactness
Flow arrangements
Pass arrangements
Phase of the process fluid

Heat transfer mechanism
6.1.1.4 HEAT EXCHANGER SELECTION CRITERIA

When selecting a heat exchanger for a given duty the following points must be considered;
Flow rates
Operating pressure and temperature
Flow arrangements
Performance parametersthermal effectiveness and pressure drops
Fouling tendencies
Types and phases of fluids
Material of construction and ease of construction
Space available
Maintenance, inspection, cleaning, extension, and repair possibilities
Overall economy
Fabrication technique
Intended application
6.1.2 SHELL AND TUBE HEAT EXCHANGER

The most commonly used heat exchanger is shell and tube type. It is the "work horse" of
industrial process heat transfer. These exchangers are being used in 90% of the process
industries now a day. They are the first choice because of well-established design procedures
and manufactured from a wide variety of materials, many years of satisfactory service, and
availability of codes and standards for design and fabrication. They are produced in the
widest variety of sizes and styles. There is virtually no limit on the operating temperature and
pressure.
Figure 8 - Schematic Diagram of Shell & Tube Heat Exchangers
ADVANTAGES OF SHELL AND TUBE EXCHANGER OVER OTHER EXCHANGERS
It is used for high heat transfer duties

Gives more heat transfer area per unit volume
Can handle large flow rates
It occupies less space
Well established design procedure
Its maintenance is easy
It can be fabricated with wide variety of materials depending upon fluid properties
TUBE SIDE & SHELL SIDE FLUID ALLOCATION

The criteria for fluid allocation shall be:
The most corrosive fluid to be tube side

The more dirtier fluid and containing solids to be on tube side
The higher pressure fluid to be tube side
Severe fouling fluids shall be allocated the side which is accessible
Cooling water is normally taken on tube side
On The other hand
Fluids exhibiting low heat transfer rate should be on shell side

Shell side boiling or condensation is usually preferred (phase change occurs)
Specific low pressure fluid on shell side.
Viscous fluids on shell side.
MAIN PARTS OF SHELL AND TUBE HEAT EXCHANGER

1. Shell
2. Fixed tube sheet(tube plate)
3. Channel(end box or header)
4. Branch(nozzle)
5. Tie rod and spacer
6. Fixed tube sheet(tube plate)
7. Channel (end box or header)
8. Cross baffle or tube support plate
9. Support bracket
10. Tube
11. Pass partition
12. Test connection
13. Expansion bellows
INTRODUCTION TO THERMAL DESIGN OF SHELL-AND-TUBE HEAT EXCHANGER

The "rating" problem is a performance analysis for known exchanger geometry with given
specifications. The exchanger dimensions of the known exchanger or tentative estimates of

exchanger dimensions are used as input data to the rating program. The thermal duty and
outlet conditions of the exchanger are calculated if the length is fixed. If the heat duty is
fixed, the length of the exchanger can be calculated.
Besides these parameters, the rating program will also calculate pressure drops for the shell
side and the tube side and the outlet temperature of the tube side; an advanced program will
calculate many other useful parameters. Some advanced programs provide design
modifications. They take the output from the rating subroutines and modify the exchanger
parameters in such a way that the new exchanger configuration will better satisfy the required
process conditions.
DESIGN METHODS
Two approaches are used in designing heat exchangers. In the first approach, the heat
exchanger is taken as a single control volume with an average overall heat transfer
coefficient, and two inlets and two outlets. This is called lumped analysis. In the second
analysis. The heat exchanger is divided into segments or multiple control volumes, with the
outlet of one control volume being the inlet to an adjacent control volume. This is a local
analysis or differential analysis. The heat transfer rate (heat duty) for the heat exchanger is
obtained by integrating the local Values. The first approach is more common and simpler and
it generally provides acceptable results for design.
6.1.3 NOMENCLATURE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
, ho =
= ,
=
=
=
=
=
=
=

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
6.1.4 HEAT DUTY
Q = mS cp,STS,in TS,out = mT cp,T TT,in TT,out
From last chapter
= .
= .
= 5374.86
301 = 389.9585
= 26665.625
301 = 389.7996
6.1.5 DESIGN STEPS, PROCEDURE & CALCULATIONS

6.1.5.1: THERMO-PHYSICAL PROPERTIES
301 = 336 F 135 F = 201 F
301 = 130 F 85 F = 45 F
301 =
336 F + 135 F
= 235.5 F
2
301 =
The arithmetic means of T1 & T2 and t1 & t2 may be used if
130 F + 85 F
= 107.5 F
2
1. neither of the liquids is very viscous at the cold terminal, say not more than 1.0 cP
2. the temperature ranges do not exceed 50 to 100 F, and
3. the temperature difference is less than 50 F

But as our case does not meet all the points both on shell and tube sides, hence we need to
use Caloric Temperature Correction for evaluating the physical properties. The caloric
fraction Fc can be obtained using Page 827 | Fig 17 - Caloric Temperature Correction
(Kern). The computerized method of calculating Caloric Temperature is given on A-9 | Fig.
(7): The Caloric-Temperature Factor Kc, Fc Hydrocarbon Liquids by (Assaad)
R=
FC =
K C = C1 () + C2
1
R
+
KC R1
ln(KC +1)
1+ ln(R)
KC
SHELL SIDE LWK
TUBE SIDE CRUDE
= 0.2586
= 0.0635
= 135 + 0.3613 201 = .
= 85 + 0.3748 45 = .
= 0.3613
= 0.3748
Now at these temperatures, collect thermo-physical properties using the formulas and tables
in (Assaad) of
A-8 | Fig. (6): Specific Gravities of Hydrocarbon Liquids

A-7 | Fig. (5): Thermal Conductivities of Hydrocarbon Liquids
A-6 | Fig. (4): Specific Heats of Hydrocarbon Liquids
A-11 | Viscosity Variation with Temperature of Hydrocarbon Liquids
SHELL SIDE LWK
TUBE SIDE CRUDE
42.91 API @ 207.62 F
44.28 API @ 101.86 F
Density of Fluid
S = 751.43
Viscosity
S = 0.001291 kg/ms
T = 0.002936 kg/ms
Thermal Conductivity
kS = 0.136981 W / m K
kT = 0.1425
Specific Heat
cp,S = 2302.74
Fouling Factor
RdO = 0.00018
kg/m3
T = 788.78
kg/m3
W/mK
J/kg K
cp,T = 2064.511 J/kg K
m2 K / W
Rdi = 0.00035
m2 K / W
Table 7 - Thermophysical Properties for E-301
6.1.5.2: LOG MEAN TEMPERATURE DIFFERENCE

Assuming Counter Current Flow arrangement, due to economics (lesser heat transfer area
required to fulfill same heat duty).
LMTD =
T1 T2
T
ln T1
2
6.1.5.3: HEAT TRANSFER AREA
. .
.
.
= 61.21
Assume Overall Heat Transfer Co-efficient U* = 330 W / m2 K, this would later be

confirmed if over Ucalculated is in 10% range of assumed value.
AHT =
U .
6.1.5.4: CORRECTION FACTOR
LMTD
382301.932 KJ/hr
= 18.92 2
(330)(61.21)
Numerical method of correction factor (fT) calculations is adopted as stted by (Kern) on Page
144 | Eq. (7.41): Fractional ratio of the true temperature difference to the LMTD
R=
Thot in Thot out
Tcold out Tcold in
= 4.66
Corrected HT Area:
AHT =
( )
U . fT . LMTD
6.1.5.5: DESIGN SPECIFICATIONS
S=
(+ + )
(++ + )
Tcold out Tcold in

Thot in Tcold in
= 0.179
= .
382301.932
= 23.65606 2
(330)(0.8)(61.21)
We take a trial design
Length
L
Outside Diameter
do
Thickness
Tube Pitch
PT
Tube Clearance c = PT - Do
Pitch Type
Number of Tube Passes NP
Segmental Baffle
Baffle Spacing
B
=
=
=
=
=
=
=
=
=
6m
0.01905 m (0.75 inch)
0.0027686 (12 BWG)
0.0238 m (15/16 inch)
0.00475 m
Triangular
2
25% Cut
0.06 m
6.1.5.5: OUTER SURFACE AREA OF TUBE [SINGLE TUBE]

aST = dO L = 3.14 0.01905 m 6 m = .
6.1.5.6: THEORETICAL NUMBER OF TUBES

NT =
AHT 23.65606 m2
=
=
aST
0.35908 m2
6.1.5.7: NUMBER OF TUBES PER PASS
6.1.5.8: EQUIVALENT DIAMETER
n=
NT 66
=
=
NP
2
Pitch Type: Triangular
DH = 4
0.0238 m
PT
0.86 PT
do
2
0.86(0.0238 m)
3.140.01905
3.14(0.01905 m)2
8
SHELL SIDE
aS =
DH = .
6.1.5.9: FLOW AREA
aS =
do 2
TUBE SIDE
cT BDS
PT
aT = n di 2
4
0.0047 0.06 0.304

0.0238
aT = 33
aS = .
3.14
(0.0135128)2
4
aT = .
6.1.5.10: LINEAR VELOCITY OF TUBE [INSIDE]

3
qT 0.0093906
uT =
=
= .
aT
0.00473254 2
6.1.5.11: MASS VELOCITY

SHELL SIDE
GS =
TUBE SIDE
mS 1.48670592
=
aS
0.00364992 2
GS = .
GT =
mT 7.40711806
=
aT
0.00473254 2
GT = .
6.1.5.12: REYNOLDS NUMBER

SHELL SIDE
ReS =
TUBE SIDE
DH GS
S
0.0135087 m 407.32607
0.00129
788.78
ReS =
kg
ReT =
T uT di
T
1.7218
m
s
0.00294
0.0135128m
ReT =
6.1.5.13: PRANDTLS NUMBER

SHELL SIDE
PrS =
PrS =
2302.74
TUBE SIDE
cp,S S
kS
0.00129
0.13698
PrS = .
PrT =
PrT =
2064.518
cp,T T
kT
0.00294
0.14250
PrT = .
6.1.5.14: NUSSELTS NUMBER

SHELL SIDE
NuS = 0.36 ReS 0.55 PrS 0.33
NuS = 0.36 42610.55 21.7900.33

= .
TUBE SIDE
NuT = 0.027 ReT 0.8 PrT 0.3
NuT = 0.027 72030.8 42.5420.3

= .
6.1.5.15: FILM CO-EFFICIENT

SHELL SIDE
, =
= 98.54
TUBE SIDE
, =
0.13698
0.013
, = .
= 101.39
0.14250
0.0135
, = 1069.27
6.1.5.16: DIRTY OVERALL HEAT TRANSFER CO-EFFICIENT
=
=
999.24
+ 0.00018 +
+ , +
1
0.01905 0.00035
0.0135
, +
+
0.01905
0.01351069.27
= 334.155
Which is very close to the assumed value of U* = 330 W/m2 K. Hence accept this design.
6.1.5.17: PRESSURE DROP CALCULATIONS

Friction factor (fT) is extracted from graphs of (Kern)
Page 836 | Fig. (26): Tube-side friction factors

Page 839 | Fig. (29): Shell-side friction factors for bundles with 25% cut baffles
SHELL SIDE
TUBE SIDE
Friction factor Fs = 0.003
Friction factor Fs = 0.0005
N = 99
2 ( + 1)
2
= .
= 0.8 KPa
N = 2
2
2
= .
= 13.1 KPa
EQUIPMENT DESIGN: FIRED TUBE HEATER | 49
6.2 FIRED HEATER H 301 CRUDE CHARGE HEATER

6.2.1 FIRED HEATER
A fired heater is a direct-fired heat exchanger that uses the hot gases of combustion to raise
the temperature of a feed flowing through coils of tubes aligned throughout the heater.
Depending on the use, these are also called furnaces or process heaters.
Figure 9 - Labelled Diagram of Fired Tube Heater
6.2.2 FURNACES USED IN PETROLEUM INDUSTRIES

TYPE (A, B, C)
These types of furnaces are used for large capacities i.e. 25-100 million /
They are best suited to oil firing because of large heat duty
Rate of heat varies widely because of large size
Roof construction of these furnaces is very costly. These require very tall stacks.
TYPE (E)
In this type of furnace, heat distribution is very poor i.e. chances of overheating of
shield tubes are more.
It is used for large capacity. It is suited for oil firing.
TYPE (F, G, H)
These are best suited for very low rates of heat absorption.
TYPE (I, K)
These are used when there is need to control rate of heat transfer in high range
i.e. 540-850 C
Figure 10 - Types of Furnaces Used in Petroleum Industries
(a) Large boxtype (b) Separate convection (c) Down convection (d) Straightup (e) A-frame
(f) Circular (g) Large isoflow, (h) Small isoflow (i) Equiflux (j) Double-up fired (k) Radiant
wall.
6.2.3 SELECTION CRITERIA

The selection Criteria of a furnace depends on the following parameters
Kind of Product to be fired

Kind of fuel
Firing Temperature
Quantity to be produced
Required heat duty
Economics
6.2.3.1 SELECTED FURNACE
. (1) Down-convection, but with two rows of tubes on the roof, and with tubes on the floor.
This applies only to large stills., (2) Down-convection, with only roof tubes and for smaller
stills, (3) Down-convection, (4) Straight-up, with half the tubes in the convection section, with
two rows of tubes on each wall, and with a width that is one-fourth of the length., (5)
Straight-up, with one row of radiant wall tubes and a width of 10 center-to-center tube
spacing. Two-thirds of the tubes are in the convection section. (6) Overhead convection, with
two rows of radiant tubes.

Type (d) of Furnace can be used for my required heat Duty as shown by Heat Duty vs. Most
Economical Tube Length Graph. This is (5) Straight up type Furnace with one row of radiant
walls tubes and a width of 10 Center to Center tube Spacing. Others cannot be used as their
advantages and disadvantages are discussed earlier.
6.2.4 NOMENCLATURE
=
=
=
= Cold plane Surface Area
, , =
=
=
=
=
=
=
H = Enthalpy
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
= ,
=
=
=
=
=
, = ,
=
6.2.5 HEAT DUTY

Required Heat Duty Q = 14089393.517 KJ/hr.
Selected Efficiency of Furnace = 75%
Selected Fuel: Natural Gas
6.2.5.1 COMPOSITION OF NATURAL GAS:

Component
Percentage
CH4
90.75
C2H6
5.25
C3H8
1.9
C4H10
0.95
N2
0.65
H2S
0.5
Net heating value of Natural Gas = 51064 KJ/Kg

Heat Liberated by fuel,
=
Molar Flow rate of Fuel,
14089393.517
=
= 18785858.019
0.75
6.2.5.2 NUMBER OF MOLES OF FUEL USED

=
6.2.6 AIR TO FUEL RATIO
367.884
17.83
= 367.884
= 20.62
6.2.6.1 COMBUSTION REACTIONS

4 + 22 2 + 22
2 6 + 3.52 22 + 32
3 8 + 6.52 32 + 42
4 10 + 6.52 42 + 52
2 + 1.52 2 + 2
Fuel Amount
Used
2
(/)
2
(/)
2
(/)
1.083
3.791
2.166
3.249
2 6
3 8
4 10
2
18.72
37.444
0.392
1.960
0.196
1.274
0.134
0.103
Total
18.72
1.176
0.784
0.155
.
Table 8 - Stoichiometric Calculations of H-301 Heater
37.444
2
(/)
1.568
0.980
0.103
0.103
Using 25% excess air

Total O2 Supplied
Total Air supplied
O2 leaving in flue gases
N2 leaving in flue gases
Total combustion products
55.78 2 (/)
265.623 / = 7703.072 /
11.156 /
209.976 /
287.3825473 /
Component
Percentage
15
7.94
3.8
73.06
0.035

= 20.98

6.2.7 DESIGN STEPS IN RADIANT SECTION
1.
Calculation of
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Calculation of gas temperature at bridge wall

Heat balance to find the Radiant Section Heat duty
No. of tubes in Radiant Section
Calculation of Beam Length
Dimensions of Radiant Section
Verification of Overall Heat Exchange Factor
Verification of Gas Temperature
Verification of Radiant Heat Duty
Verification of Assumed Flux
Volume of Radiant Section
6.2.7.1: CALCULATION OF
by assuming flux & overall heat exchange factor.
Assumption of Radiant or Average Flux =68104.28 2
Assumption of Overall Exchange Factor f = 0.55 (Range 0.55 to 0.65)
= 2 = 2 68104.28 = 136208.5521
2
.
= 247651.9022
. .
2
6.2.7.2: CALCULATION OF GAS TEMPERATURE AT BRIDGE WALL

Inlet temperature of Crude Oil
=
221 C
Outlet temperature of Crude oil
=
324 C
Cross Over Temperature
=
265 C
Tube Skin Temperature
=
Ts = Tc + 100 = 321
Tg , Temperature of flue gases leaving the radiant section or Bridge wall Temperature can be
extracted from (Kern) Page 699 | Fig. (19.14): Radiant-section Heat Flux
= .
6.2.7.3: HEAT BALANCE TO FIND THE RADIANT HEAT DUTY

Heat Contained by air at room Temperature (25 C)
Q a = ma
Q a = 193101.586
H at 25 C = 23.76

Heat Absorbed by Furnace wall Q w = 2%
Q w = 375717.153
Heat generated by Flue gases at Bridge wall temperature
Qg = Q2 + Q2 + Q2 + Q2
H2 = 1993.183/
H2 = 3027.869/
H2 = 698.496/
H2 = 12444.45/
Qg = (733260.18 + 1113904.687 + 256965.696 + 4578115.540)
QR = QF + Qa Qw Qg
Q R = 11055864.834
6.2.7.4: NO. OF TUBES IN RADIANT SECTION
= 7547377.611
Economical length of tube can be extracted from the (Nelson) Page 887 | Fig. (23.9): Most
economical tube lengths for some common arrangements of pipe stills
Length of the tube
= 7.924 m
Diameter of the tube
= 0.126 m (5 in)
Center to Center spacing for tube = 0.253 m (10 in)
Surface area per tube
As = = 3.14 0.126 7.924 = 3.160 2
Heat Transfer per tube,
Q t = As
Q t = 225887.458 /
Q R 11055864.834
=
=
=
Qt
225887.458
6.2.7.5: CALCULATION OF BEAM LENGTH
Ratio for beam length according to Lobo and Evans method
Radiant Section:
1: 2: 3

Length
Width
Height
= 7.924 m
= 2.639 m
= 5.282 m
Mean beam Length =
23
2
= 37.294 2.639 5.282
3
3
Mean beam Length = 3.075
6.2.7.6: DIMENSIONS OF RADIANT SECTION
= 2 = 2 2.639 5.282 = 27.911 2
End Walls
= 2 = 2 7.294 5.282 = 83.736 2
Side Walls
Floor and arch = 2 = 2 2.639 7.294 = 41.86 2
Total Area of Radiant Section, ART = 27.911 + 83.736 + 41.86

= 153.516 2
Acp = = 102.657 2
Acp =
Acp
= 2.012 2
Nt
6.2.7.7: VERIFICATION OF OVERALL HEAT EXCHANGE FACTOR

c
0.253
=
= 2
. h 0.126
(Nelson) Page 594 | Fig. (18.3): Distribution of radiation to tubes suspended in front of a
wall
Effectiveness factor
= 0.88
= 90.338 2
Selecting 8 Shield tubes
= 1.771 2
( ) = .
= 7.085 2
= ( ) +
= 97.423 2

Effective refractory Surface
AR = ART = 153.516 97.423 = 56.0922
56.092
=
= 0.55
97.423
(Nelson) Page 605 | Fig. (18-10): Combustion data on cracked-gas and oil fuels.
Partial Pressure of 2 + 2 = 0.801
P.P Mean Beam Length = 0.556 ATM m
(Nelson) Page 604 | Fig. (18-9): Flame emissivity

Gas Emissivity () = 0.41
New overall exchange factor from the (Kern) Page 700 | Fig. (19.15): Overall heatexchange factor in radiant section
The value of f = 0.47
6.2.7.8: VERIFICATION OF GAS TEMPERATURE

QR
11055864.834
=
= 22431.451 /
Acp .
97.423 0.47
For the verification of flue gas temperatureTg from the (Kern) Page 699 | Fig. (19.14):
Radiant-Section heat flux
Tg = 718
Which is almost equal to our assumed value
6.2.7.9: VERIFICATION OF RADIANT HEAT DUTY

Heat Balance on Radiant Section= +
Q R = 10862763.248
6.2.7.10: VERIFICATION OF ASSUMED FLUX

=
10862763.248
=
= 70722.99972 /. 2
153.516
Which is very close to our assumed Radiant Flux
6.2.7.11: VOLUME OF RADIANT SECTION

= 7.924 2.639 5.282 = 110.599 3
6.2.8 DESIGN STEPS IN CONVECTION SECTION

1.
2.
3.
4.
5.
Calculation of Convection Section Duty

Calculation of Overall Convective Heat Transfer Surface
Calculation of Number of tubes in Convective Section
Calculation of Volume of Convective Section
Calculation of Volume of Furnace
6.2.8.1: CALCULATION OF CONVECTION SECTION DUTY

Required heat duty in Convection Section, =
Q = 14089393.517 10862763.248 = 3226630.266 /.
Stack gas Temperature,

Inlet Temperature of Crude Oil
Ts
Cross over Temperature

Bridge wall Temperature
=
=
=
260
221
265
718
1 2
1
2
(718 265) (260 221)

(718265)
(260221)
= 169.22
Mean Gas film Temperature, T = 0.5 (1 + + ) = = 327

= 0.5 (221 + 265 + 169.22)
= 327
6.2.8.2: CALCULATION OF OVERALL CONVECTIVE HEAT TRANSFER SURFACE

Overall Heat transfer Coefficient in Convection section
4.5
= ( + + )
Where,
=
=
=
=
2.461 0.759 + 1.659 2

0.7655 + 21.3732 9.6625 2
9.7938 30.809 + 14.333 2
/1000

=
= 2.61
= 10.32
For the calculation of G mass velocity of flue gases
= 3.82
= (. ) = 1.014

= (. . )
= 0.505
= = 4.025 2
(Evans) Page 8 | Fig. (1.6): Flue Gas Rates
Mass Flow rate of Flue Gas = 0.000438 / = 18785858.019 0.000438

=
Now by putting all the values
= 8255.304 /.
= 2049.54
=
0.567

2
sec 2
= 77.406688
6.2.8.3: CALCULATION OF NUMBER OF TUBES IN CONVECTIVE SECTION

Area of Convection Section=
UC LMTD
3226630.266
77.406 169.22
= 246.333 2
246.333
=
= 78
3.14 3.14 0.1267.926
6.2.8.4: CALCULATION OF VOLUME OF CONVECTIVE SECTION
Tube Length
C-C Spacing of tubes
Diameter of the tube
Tubes per pass
=
=
=
=
7.924 m
0.253 m
0.126 m
4 (assumed)
Height of Convection Section

( 1 + 1)( ) = (19 + 1)(0.253) = 5.06
Width of the Convective Section

(. + 1) = (8 + 1)(0.253) = 2.104
Volume of the Convective Section
= 7.924 2.104 5.06 = 84.360 3
6.2.8.5: CALCULATION OF VOLUME OF FURNACE
= + = 110.599 + 84.360 = 194.95 3
6.2.9 SPECIFICATION SHEET

Equipment name
Fired Heater
Name in Flow sheet
H-301 Crude Charge Heater
Numbers Required
Operation
Continuous
Material of Construction
Stainless Steel
Refractory
Fire Clay
Burner type
Muffle Burner
14089393.517 /.
Heat Duty
367.884 /.
Fuel Required
Radiant heat Duty, QR
Number of tubes in Radiant Section
10862763.248 /.
52
7.924
Tube Length
0.126
O.D of the tubes
0.253
Center to Center Tube spacing
110.599 3
Volume of the Radiant Section

Convection Section Heat Duty, QC
Number of tubes in Convection Section
3226630.266 /.
78
77.4066 /. 2
UC
84.360 3
Volume of the Convection Section

Total Volume of Furnace
Table 9 - Spec Sheet of Heater
194.95 3
EQUIPMENT DESIGN: FRACTIONATING TOWER | 62
6.3 FRACTIONATING TOWER V-301 CRUDE TOWER
Figure 11 - Energy Balance Boundary
Draw the flash-vaporization curve of the crude oil

Estimate the amount of steam required for stripping
Estimate the temperatures and pressures at all important point a in the tower.
Adopt the number of plates to be used between cuts
Compute a heat balance, and determine the amount of reflux.
Compute the diameter of the tower
6.3.1.1: VAPORIZATION CURVE

Slope of the TBP curve is calculated and is then used to find the slope of the Flash
Vaporization Curve. The following TBP curve is generated for an API 44.28 Crude using
Aspen HYSYS V8.4.
Figure 12 - Flash Vaporization Curve of Crude Distillation
70% = 645
10% = 210
645 210
= 7.25
70 10
Figure 13 - Relationship between the slopes of distillation curves

= .
Slope of Flash Curve is extracted using (Nelson) Page 112 | Fig. (4-18): Relationship
between the slopes of distillation curves.
50% = 475
50% = 475 42.9 = 432.1
Correction 42.9 F is extracted using (Nelson) Page 113 | Fig. (4-19):
Figure 14 - Relationship between distillation temperatures
6.3.1.2: VAPORIZER TEMPERATURE

All the losses and products above feed plate must be vaporized. Which sums up to be 93
vol%. The Temperature is obtained from the Flash Curve,
= 50% + 43

= 432.1 + 43 4.7 = .
The Vaporizer Temp, as obtained from Flash Curve at 760 mmHg, must be corrected for
tower pressure (20 psi) and for the effect of steam (516.04 kg/hr.).
= 760 +
Specific
Gravity
Naphtha
0.7374
12.17
Kerosene
0.8113
Light Gas Oil

Heavy Gas Oil
20
760 = 1795
14.7
MABP
= ( )3
MWa
262.7384
177
10381.21 22838.66
12.18
504.9089
248
5374.86
11824.69
47.68
0.8647
12.60
833.326
454
6015.07
13233.15
29.15
0.9202
12.61
1102.399
527
1524.08
3352.976
6.36
kg/hr.
lb./hr.
lbmoles
129.032
212.2225
Steam
18
1135.288 63.07156
Total Moles Gas
275.2941
Table 10 - Extracted Data for Crude Tower Design
a. Molecular Weight is extracted using Molal Avg. Boiling Point (Nelson) Page 178 | (Fig.59): Molecular weights, pseudo critical temperatures, Characterization Factors, and
gravities of petroleum fractions
=

1795

212.22
1795 =
275.30
Vaporizer temperature at tower conditions, by correcting 634.2F to 1383 mmHg by means

of (Nelson) Page 208 | (Fig. 5-27): Vapor pressure and boiling-point corrections for
normal paraffin hydrocarbons and petroleum fractions is
=
6.3.1.3: TOWER TEMPERATURES
This tower, the stock that is being processed, and the quantities of steam are all normal.
Under these conditions, the side-draw temperatures and top temperature may be estimated
from (Nelson) Page 470 | (Fig. 16-4): Range of top and side-draw temperatures in a
topping (or atmospheric pressure) tower
Tower Top
Kerosene
Light Gas Oil
Heavy Gas Oil
Side Draw Temp
Latent Heat a
284.00
378.00
489.00
593.00
128.00
102.00
76.00
68.00
a. estimated from (Nelson) Page 173 | (Fig. 5.5) Atmospheric latent heat of vaporization
as a function of molecular weight (preferred) or API gravity
6.3.1.4: BOTTOM TEMPERATURE

The bottom temperature may be estimated from (Nelson) Page 475 | Eq. (16-2):
=
=
=
=
=
=
=
=
= 1.2 + 35
( ) + 0.65 ( )
feed less bottom temperature, F

per cent removed by stripping
lb oil per hr
lb steam per hr
temperature of oil, F
temperature of air, F
temperature of incoming steam
tower diameter, ft
= 1.2() + 35
58664.375
=
=
=
=
=
=
=
3
58664.375 /
415.822 /
604
77
365
6
(604 77 ) + 0.65
=
415.822
58664.375
(604 365 )
= 604 7 =
6.3.1.5: HEAT BALANCE OF TOWER TO TOP PLATE
Avg. T
Cp a
F
BTU/lb. F
Mass Flow Rate

Lb./hr.
delta T
F
Q
BTU/hr.
Naphtha
Kerosene
Light Gas Oil
Heavy Gas Oil
Fuel Furnace Oil
22838.662
11824.692
13233.154
3352.976
6829.108
(604 - 284) = 320

(604 - 378) = 226
(604 - 489) = 115
(604 - 593) = 11
(604 - 597) = 7
444.00
491.00
546.50
598.50
600.50
0.558
0.566
0.582
0.597
0.708
4,078,071.49
1,512,567.30
885,695.00
22,018.99
33,845.06
Cooling Steam
1135.288
( 365 - 284 ) = 81
324.5
0.5
45,979.16
Total Sensible Heat

Mass Flow Rate
Lb./hr.
Condense LWK
11824.692
Condense LGO
13233.154
Condense HGO
3352.976
6,578,177.00
Latent Heat
BTU/lb.
128.00
102.00
76.00
Q
BTU/hr.
1,513,560.58
1,349,781.71
254,826.18
Total Latent Heat
3,118,168.46
Total Heat to be Removed
9,696,345.46
Table 11 - Heat Balance of Tower Top Plate
a. estimated from (Nelson) Page 170 | (Fig. 5.2) Specific beats of Mid Continent oil vapors
with a correction factor for other bases of oils
6.3.1.6: LIQUID DENSITY AT TOP PLATE

The density of the Naphtha at 284F can be obtained from (Nelson) Page 190 | (Fig. 5.14)
Approximate change of specific gravity of intermediate-base oils with temperature
= @ 284 = 0.625 62.5 / 3
= 39.0625 / 3
6.3.1.7: VAPOR DENSITY AT TOP PLATE

For this, we first calculate the number of gas moles at the top of the tower and then calculate
the respective Volume of moles of vapor. Using which we can get density of vapor at this
plate. Same process can be followed for the other plates as well. But as we are dealing with a
crude tower of uniform diameter, hence we dont need any complications.
Mass Flow Rate
Lb./hr.
Internal (Hot) Reflux
Top (Naphtha) Product
Steam
9696345.46 /
128 /
= 75752.70
22838.66
1135.29
lb
hr
lb
hr
Moles
BTU/lb.
lb
hr
427.98
129.03
63.07
99726.65
Total
lb
hr
620.08
Table 12 - No of Moles Calculations
By perfect gas laws
460 +
14.7
= . 379
= .
520
+ 14.7
99726.65

=
=
= . /
3
178442.18
6.3.1.8: ALLOWABLE VAPOR FLOW RATE OF TOWER
For minimum entrainment we use a tray spacing of 22 inch, for discussion on tray spacing vs.
entrainment see (Nelson) Page 490. The allowable mass velocity of the vapors at the top of
the tower can be computed from (Nelson) Page 493 | Eq. (16-8).
= ( )
The constant K can be obtained from (Nelson) Page 494 | (Fig. 16.13) Effect of tray spacing
and type of service on allowable vapor load of fractionators. At a tray spacing of 22 in
and when using conventional bubble plates (curve 3), the value of K is 730 or higher.
= 7300.5588 (39.0625 0.5588) = .
6.3.1.9: CROSS-SECTIONAL AREA OF TOWER

=
= 29.45 2
99726.65
3386.34
6.3.1.10: DIAMETER OF TOWER
= .
29.45 2
That is very close to our assumption of 6 ft. Hence Diameter is checked.
6.3.1.11: LINEAR VELOCITY

3
178442.18
3600
=
=

29.45 2
= 1.68 /
Which is within the allowable range mentioned in (Nelson) on Page 491 | (Table. 16.4).
6.3.1.12: NUMBER OF STAGES

There is no accurate way to calculate the number of stages, but can be estimated using
(Nelson) Page 527 | (Table. 16.13). Trays used in Commercial oil equipment, as follows
PLATES BETWEEN FRACTIONS
LITERATURE
RECOMMENDATION
OUR ESTIMATE
Naphtha & kerosene
3-6
3-5
Kerosene & Gas oil
4-7
4-5
Gas Oil & lube distillate
4-5
4-5
Inlet to Lowest side draw
3-4
2-4
Stripping bottom
4-6
4-5
TOTAL NO OF TRAYS
23
Table 13 - Number of Stages Estimation in Crude Tower
6.3.1.13: HEIGHT OF TOWER

With 22 inch tray spacing, and 23 Number of stages the approximate height comes out to be:
= (23 + 1)
22
= 44
12
6.3.1.14: L/D RATIO
44
=
=
= .
6.12
EQUIPMENT DESIGN: SHELL & TUBE CONDENSER | 70
6.4 SHELL & TUBE CONDENSER E-309 OVERHEAD VAPORS/WATER

6.4.1 CONDENSER?
A condenser is a two-phase flow heat exchanger in which heat is generated from the
conversion of vapor into liquid (condensation) and the generated heat is removed from the
system by a coolant. Condenser is a chamber which converts a substance from its gaseous
state to its liquid state. Condensers may be classified into two main types. Those in which the
coolant and condensing vapor are:
I.
II.
Separated by a solid surface, usually a tube wall

Brought into direct contact
The direct contact type of condenser may consist of a vapor which is bubbled into a pool of
liquid, a liquid which is sprayed into a vapor, or a packed-column in which the liquid flows
downwards as a film over a packing material against the upward flow of vapor.
Condensers in which the streams are separated may be subdivided into three main types:
I.
II.
III.
Air cooled
Shell & tube
Plate
In the air-cooled type, condensation occurs inside tubes with cooling provided by air blown
or sucked across the tubes. Fins with large surface areas are usually provided on the air side
to compensate for the low air-side heat transfer coefficients. In shell and-tube condensers,
the condensation may occur inside or outside the tubes. The orientation of the unit may be
vertical or horizontal.
The overhead vapors from the distillation column passes through the condenser, where all
vapors converts to liquid phase by means of a coolant.
6.4.2 SELECTION CRITERIA

For the products having final temperature above ambient, the choice is usually between air
and cooling water. Direct contact condensers are only suitable where there is no objection to
mixing. Plate condensers are not common as they need well sealed gaskets. Compact
condensers are efficient but maintenance is difficult. Shell & Tube condensers are commonly
used in industries, it has
easy availability,
high heat transfer rates,
low pressure drop,
easy maintenance,
And gives design flexibility.
6.4.3 NOMENCLATURE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
= ,
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
= .
= .
=
=
=
= g
=
=
=
= , (/ )0.14
6.4.4 HEAT DUTY
SHELL SIDE
Q = mS (+cp,S TS,in TS,out ) = mT cp,T TT,in TT,out
The specific heat values are extracted from (Nelson) Page 170 | Fig. (5-2): Specific heats of
Mid Continent oil vapors and latent heat values from Page 176 | Fig. (5-8): Latent heats
(paraffinic or naphthenic stocks) as a function of temperature
= 18286.83
301 = 516.04
= 140 64 = 76
= 64 60 = 4
= 18286.83
(647.56
+ 1.86.
76)
TUBE SIDE
= 516.04 (4.28 + 2.1.

76)
= + = 4485638.1
= 43 30 = 13
= =
= =
43 + 30
= 36.5
2
= .
4485638.1
36.5 1

6.4.5.1: WEIGHTED LOG MEAN TEMPERATURE DIFFERENCE
To calculate weighted temperature difference,
first calculate LMTD for De-Superheat zone
followed by LMTD for Condensation zone
DE-SUPERHEAT
CONDENSATION
= 140 43 = 97
= 64 39.66 = 24.44
= 32.83
= 8.78
= 64 39.66 = 24.44
= 60 30 = 30
737592
=
= 22467.02
32.83
2152131
=
= 245117.4
8.78
6.4.5.2: CORRECTION FACTOR
= .
2889722.934
(22467.02 + 245117.4)
Numerical method of correction factor ( ) calculations is adopted as stated by (Kern) on

Page 144 | Eq. (7.41): Fractional ratio of the true temperature difference to the LMTD
Thot
R=T
in
Thot out
cold out Tcold
in
= 6.15
CORRECTED LMTD
( )
S=
(+ + )
(++ + )
Tcold out Tcold

Thot
in
Tcold
in
in
= 0.12
= .
= 12.44 0.935 = .

AHT =
Q
2889722.934
= .
=
Ud LMTDweighted
800 2 10.44
Length
L = 4.57 m
Outside Diameter
do = 0.0254 m (1 inch)
Thickness
= 0.0027686 (12 BWG)
ii
Tube Pitch
PT = 0.03176 m (1 inch)
Tube Clearance c = PT - Do = 0.00636 m
Pitch Type
= Triangular
Number of Tube Passes NP = 2
Baffle Spacing
B = 10 in
Outside Surface Area per linear m = 0.024332
6.4.5.5: NUMBER OF TUBES

Nt =
A
9.558 2
=
= 350
(a )(L) (0.02433 2 )(4.57 )

Nearest standard value of tubes for 0.0254 m OD tube with 0.03176 pitch triangular pitch,
at shell ID of0.686 . Using (Kern) on Page 841 | Table. (9): Tube Sheet Layout Tube
Count)
= 334
Area of tubes = = (Nt a L) = 121.94 m2
6.4.5.6: CORRECTED OVERALL HEAT TRANSFER COEFFICIENT

Ud =
Q
2889722.934
=
A LMTDweighted 121.94 2 10.44
= . /
The equivalent diameter for triangular pitch is calculated from (Kern 1950) Page 139 | Eq.
(7.5)
De = 4
2T 0.86 PT
do
do 2
6.4.5.8: FLOW AREA
0.0318 m
2
0.86(0.0318 m)
3.140.0254
= .
3.14(0.0254 m)2
SHELL SIDE
TUBE SIDE
cT BDS
PT
0.0064 0.25 0.686
aS =
0.0318
aT = n di 2
4
3.14
aT = 334
(0.019944 )2
4
aS =
= .
= .
6.4.5.9: MASS VELOCITY

SHELL SIDE
TUBE SIDE
mS 11.49064
GS =
=
aS
0.0353212 2
mT 54.248315
GT =
=
aT
0.0516434 2

= .
= .
= /
= .
6.4.5.10: REYNOLDS NUMBER

SHELL SIDE
ReS =
ReS =
TUBE SIDE
De GS
S
0.01829 m 325.31858
0.0000304
ReS =
ReT =
ReT =
1031.07686
G di
T
0.019944m
0.0076155
ReT =
6.4.5.11: HEAT TRANSFER CO-EFFICIENT DE-SUPERHEATING

SHELL SIDE
TUBE SIDE
f from (Kern 1950) Page 839 | Fig. (29)
f from (Kern 1950) Page 836 | Fig. (26)

friction factor = 0.0002
friction factor = f = 0.0014
jH from (Kern 1950) Page 838 | Fig. (28)

j = 300
hi = 4601.815
k c 3
W
ho = j = 425.411 2
m .
De k
hio = hi
m2 .
ID
W
= 3612.592 2
m .
OD
6.4.5.12: CONDENSATION ZONE

Assume condensing over 65% tube length
Condensation Loading
= 0.65 = 3.105
G From (Kern 1950) Page 266 | Eq. (12.43)
Assume ho = 1400
G =
= 84.2928
..
L(Nt )23
m2 .
Temperature of Tube Wall

Tv = 61.9
From (Kern) Page 98 | Eq. (5.31)
Average film Temperature
ho
(T Ta ) = 43.44
ho + hio v
Tw = Ta +
Tf =
At Tf = 52.444,
(Tv + Tw )
= 52.444
2
Conductivity k = 0.086.
.
Sp. Gravity = 0.7
Viscosity = 0.5 cP
From (Kern) Page 267 | Fig. (12.9) Condensing coefficients
ho = 1474.76
m2 .
6.4.5.13: WEIGHTED CLEAN OVERALL COEFFICIENT

DE-SUPERHEATING ZONE
CONDENSING ZONE
Ud =
hio ho
W
= 380.601 2
m .
hio + ho
Uc =
ho hio
ho + hio
= 1047.0788
m2 .
U =
UAc
W
= 826.43 2
m .
Ac
6.4.5.14: DIRT FACTOR

Dirt factor is calculated from (Kern) Page 108 | Eq. (6.13)
Rd =
Uc Ud
m2 .
= 0.0002
Uc Ud
6.4.5.15: CLEAN SURFACE AREA REQUIRED

Ad =
CONDENSING ZONE
qd
= 38.29572
Ud t d
Ac =
qc
= 77.4652
Uc t c
A = Ad + Ac = 115.62
6.4.5.16: PRESSURE DROP TUBE SIDE
Pressure drop along tube side is calculated by (Kern) Page 148 | Eq. (7.45)
Pt =
fG2 Ln
5.22E10 Ds
0.0002 (1031.076)2 4.394 2

Pt =
5.22E10 0.01982 1 1
6.4.5.17: RETURN LOSS
Pt = 1.013 psi
Return loss is calculated from (Kern) Page 148 | Eq. (7.46)

Pr =
6.4.5.18: TOTAL PRESSURE
4n v 2
s 2g
Pr = 1.419
PT = Pt + Pr = 2.413 psi
6.4.5.19: TOTAL PRESSURE DROP SHELL SIDE

CONDENSING ZONE
Ps =
fGs 2 (N + 1)
5.22E10 De s
P =
= 1.61
1 fGs 2 Ds (N + 1)
2 5.22E10 De s
= 0.51
P = Ps + Pc = 2.12
6.4.6 SPECIFICATION SHEET

ID
Unit
Type
Pitch
Material of Construction
E-309
Overhead Condenser
Shell & Tube Condenser [Total]
114 Triangular
Cast Iron
SHELL SIDE [OVERHEAD VAPORS]

No. of Passes
1
Shell ID, m
0.686
No. of Segmental Baffles 21
GS, kg/m2.s
325.318
ho, W/m2.oC
425.411
2o
Ud, W/m . C
380.601
2
Ad, m
38.296
CONDENSING ZONE
, lb/lin.ft.hr
84.3
2o
ho, W/m . C
1474.76
2o
1047.088
, W/m . C
Ac, m2
77.465
P, psi
2.12
TUBE SIDE [COOLING WATER]

No. of Passes
2
Tube OD, m
0.0254
No. of Tubes Nt
334
Tube length L, m
4.57
BWG
12
2
GT, kg/m .s
131.076
Velocity v, m/s
1.03
2o
hi, W/m . C
4601.815
hio, W/m2.oC
3612.6
, psi
2.413
Clean Overall Coefficient ,

W/m2.oC
Clean Surface Area Required AT, m2
Dirt Factor Rd, m2.oC/W
826.43
115.6
0.0002
Figure 15 - Spec Sheet of Condenser
EQUIPMENT DESIGN: REBOILER | 79
6.5 REBOILER:
Reboiler is a vaporizing exchanger used to supply the heat requirement of a distillation
process as vapors at the bottom of distillation column.
6.5.1 TYPES OF REBOILER:

1.
2.
3.
4.
Kettle Reboiler
Vertical Thermosyphon Reboiler
Horizontal Thermosyphon Reboiler
Internal Reboiler
6.5.1.1 KETTLE REBOILER:

Kettle type, in which boiling takes place on tubes immersed in a pool of liquid; there is no
circulation of liquid through the exchanger. This type is also, more correctly, called a
submerged bundle Reboiler.
ADVANTAGES:
1. Relatively easy to design.
2. Simple pipinag.
DISADVANTAGES:
1. Not suitable for foaming liquids
2. Not suitable for fouling liquids
3. They have relatively lower heat transfer coefficients.
6.5.1.2 VERTICAL THERMOSYPHON REBOILER:

The vertical thermosyphon is usually a conventional 1-1 exchanger. Upper tube sheet is
placed close to the liquid level of the bottoms in the distilling column.
ADVANTAGES:
1. Higher heat transfer coefficient.
2. Used for fouling liquids.
DISADVANTAGES:
1. Require higher head room.
2. Design procedure is slightly difficult as compared to Kettle Reboiler.
6.5.1.3 HORIZONTAL THERMOSYPHON REBOILER:

All the liquid from the bottom tray flows to the reboiler. None of the liquid from the bottom
of the tower flows to the reboiler. All the bottoms product comes from the liquid portion of

the Reboiler effluent. None of the liquid from the bottom tray flows to the bottom of the
tower.
ADVANTAGES:
1. No head room is required.
2. Easily maintained than vertical.
DISADVANTAGES:
1. More complex pipe-work
2. Requires large plot area
3. High structural costs
6.5.1.4 INTERNAL REBOILER:

Tube bundles are inserted in the distillation column and steam is used as heating media.
ADVANTAGES:
1. No ground area separately required.
2. Low capital cost.
DISADVANTAGES:
1. Does not give sufficient heat transfer area to fulfill the requirement.
6.5.2 CHOICE OF TYPE:

The choice of the best type of Reboiler for a given duty will depend on the following factors:
1. The nature of the process fluid, particularly its viscosity and propensity to fouling,
2. The operating pressure: vacuum or pressure.
3. The equipment layout, particularly the headroom available.
6.5.3 HEAT DUTY
Q = mNaphtha @400 ,60.4 = 1358.25

6.5.4.1: THERMO-PHYSICAL PROPERTIES
E-403 SHELL SIDE NAPHTHA
E-403 TUBE SIDE LGO
301 = 400 F 371 F = 29 F
301 = 489 F 410 F = 142.2 F
301 = 385.5 F
301 . = 449.5 F

The arithmetic means of T1 & T2 and t1 & t2 may be used
Now at these temperatures, collect thermo-physical properties using the formulas and tables
in (Assaad, Computerized Heat Exchanger Design Procedure) of
A-8 | Fig. (6): Specific Gravities of Hydrocarbon Liquids

A-7 | Fig. (5): Thermal Conductivities of Hydrocarbon Liquids
A-6 | Fig. (4): Specific Heats of Hydrocarbon Liquids
A-11 | Viscosity Variation with Temperature of Hydrocarbon Liquids
SHELL SIDE NAPHTHA
TUBE SIDE LGO PA
60.4 API @ 400 F
32.15 API @ 436 F
Density of Fluid
S = 582.84
kg/m3
T = 722.04
kg/m3
Viscosity
S = 0.00035
kg/ms
T = 0.00052
kg/ms
Thermal Conductivity
kS = 0.14127
W/mK
kT = 0.11850
W/mK
Specific Heat
cp,S = 2900.61
Fouling Factor
RdO = 0.00018
J/kg K
cp,T = 2739.90
J/kg K
m2 K / W
Rdi = 0.00035
m2 K / W
Table 14 - Thermophysical Properties for Reboiler
6.5.4.2: LOG MEAN TEMPERATURE DIFFERENCE

Assuming Counter Current Flow arrangement, due to economics (lesser heat transfer area
required to fulfill same heat duty).
LMTD =
T1 T2
T
ln T1
2
= 20

AHT =
U . LMTD
= 39.7 2
Length
Outside Dia
Thickness
L
do
=
=
=
7m
0.0254 m (1 inch)
0.0027686 (12 BWG)
Tube Pitch
PT
Tube Clearance c = PT - Do
Pitch Type
Number of Tube Passes NP
Segmental Baffle
Baffle Spacing
B
=
=
=
=
=
=
0.0318 m (1.25 inch)

0.0064 m
Triangular
2
25% Cut
0.06 m
6.5.4.5: OUTER SURFACE AREA OF TUBE [SINGLE TUBE]

aST = dO L = .
6.5.4.6: THEORETICAL NUMBER OF TUBES

NT =
6.5.4.7: NUMBER OF TUBES PER PASS
n=
AHT
=
aST
NT 71
=
=
NP
2
Pitch Type: Triangular
DH = 4
PT
0.86 PT
do
do 2
6.5.4.9: FLOW AREA
= .
SHELL SIDE
aS =
TUBE SIDE
cT BDS
PT
aT = n di 2
4
aS = .
aT = .
6.5.4.10: LINEAR VELOCITY OF TUBE [INSIDE]

uT =
qT
= .
aT
6.5.4.11: OVERALL HEAT TRANSFER CO-EFFICIENT
+ , +
= 1595.39
, +
Which is very close to the assumed value of U* Hence accept this design.
CHAPTER # 7
INSTRUMENTATION &
CONTROL
INSTRUMENTATION & CONTROL | 85
7. INSTRUMENTATION & CONTROL

7.1 INTRODUCTION
Due to the advancement of technology instrumentation has grown up from a series of devices
developed to fill specific needs of measurements and control, to a science itself where
economics of entire plant and processes are based on suitable control strategies and
instrumentation systems. Control system technologies are developed for rapid expansions in
chemical and petroleum industries.
As a process is designed for a particular output and is then found, sometimes by trial and
error and sometimes by inference from previous experience that control of a particular
variable associated with some stages of the process is necessary to achieve the desired
efficiency. Instrumentation generally and process control specially are directly responsible for
processes which are complex, integrated and large, both physically and in terms of through
put. More critical and hazardous operation can be carried out because of suitable control
equipment.
In manual control an operator may periodically read the process variable and adjust the
input up or down in such a direction as to derive the temperature to its desired value. Manual
control is used in non-critical applications, where any process conditions occur slowly and in
small increments and where a minimum of operator attention is required.
While in automatic control, measurements and adjustments are made
automatically on a continuous basis. Today automatic control is used in industry due to
following benefits:
Improvement in product quality

Increase in process yield or production rate
Increase safety for personnel and equipment
Economics saving in materials, energy or time
Improvement of working conditions.
Achievement of operation not possible by manual control
7.1.1 INSTRUMENT
An instrument is a device that measures and/or regulates process variables such as flow,
temperature, level, or pressure. Instruments include many varied contrivances which can be
as simple as valves and transmitters, and as complex as analyzers. Instruments often comprise
control systems of varied processes such as refineries, factories, and vehicles.
7.1.2 CONTROL
The control of processes is one of the main branches of applied instrumentation.
Instrumentation can also refer to handheld devices that measure some desired variable and

with the help of control loop we able to control the desired variable value into acceptable
limits.
7.1.3 INCENTIVES OF CONTROL

Basically process control has three main incentives:
Suppressing the influence of external disturbances
Ensuring the stability of a chemical process
Optimizing the performance of a chemical process
7.2 OBJECTIVES
The primary objectives of the designer when specifying instrumentation and control schemes
are:
7.2.1 SAFE PLANT OPERATION

To help the process variables within known safe operating limits
To detect dangerous situations as they develop and to provide alarms and automatic
shutdown systems
To provide inter locks and alarms to prevent dangerous operating procedures
7.2.2 PRODUCTION RATE

To achieve product output at the desired rate within design limits.
7.2.3 PRODUCTION QUALITY

To maintain the product composition within specified quality standard.
7.2.4 COST
To operate at the lowest production cost, commensurate with the other objective. These are
not separate objectives and must be considered together.
7.3 COMPONENTS OF THE CONTROL SYSTEM

7.3.1 PROCESS
Any operation or series of operations that produces a desired final result is a process. In this
discussion the process is the production of naphtha.
7.3.2 MEASURING MEANS

Of all the parts of the control system the measuring element is perhaps the most important.
Measurement is a fundamental requisite of process control either the control will be affected

automatically, semi-automatically or manually. The quality of the control obtainable is a
function of the accuracy, repeatable and reliability of the measuring devices employed.
7.3.3 MAIN PROCESS VARIABLES & THEIR CONTROL
Temperature measurement
Pressure measurement
Flow rate measurement
Level measurement
Their measurement and control is given below:
7.3.3.1 TEMPERATURE MEASUREMENT & CONTROL

This is used to control the temperature of outlet and inlet streams in heat exchanger,
condenser, heater and column, most temperature measurement in the industrial processes is
made by means of thermocouples to facilitate bringing measurements to a centralized
location. Usually where high measurement accuracy is required resistance thermometer are
used. For the control of temperature, pneumatic feedback control is used.
Outlet temperature of the system is measured, with the help of thermocouple. This
temperature is fed to a comparator. The difference between the set point and the input signal
is called error, is fed to the controller, which controls diaphragm valve to adjust the flow of
hot or cooling medium.
7.3.3.2 PRESSURE MEASUREMENT & CONTROL

The temperature and pressure are valuable indications of material state and composition. In
fact, these two measurements considered together are the evaluating devices of industrial
materials. In compressed gas systems etc., pressure is of primary importance; pumping
equipment are furnished with pressure measuring devices. Pressure measurement becomes an
indication of the increase or decrease. Most pressure measurement in the industry is made
through elastic devices, either directly connected for local use or transmission type to a
centralized location.
7.3.3.3 LEVEL MEASUREMENT & CONTROL

Most flow measurements in the industry are done by variable head devices. To lesser extent
variable area and displacement types are used.
7.3.4 CONTROLLER
The controller is the mechanism that responds to any error indicated by the error detecting
mechanism. The output of the controller is some predetermined function of the error. In the
controller there is also an error-detecting mechanism which compares the measured variables
with the desired value of the measured variable, the difference being the error.

Controller is the interface between the process and its control system. The job of the
controller is to convert the sensor signal (mille-volts, mechanical movement, pressure
difference etc.) into a control signal 3 to 15 psig air pressure signal. Electrical signals of 4 to
20 mA may also be used. The decision is made by comparing the incoming signal with a set
point. The error signal issued is proportional to the difference between the input signal and
the set point.
7.3.5 FINAL CONTROL ELEMENT

The final control element receives the signal from the controller and by some predetermined
relationships changes the energy input to the process.
7.4 CLASSIFICATION OF CONTROLLER

In general the process controllers can be classified as:
Pneumatic controllers
Electronic controllers
Hydraulic controllers
7.4.1 MODES OF CONTROL

The various type of control are called "modes" and they determine the type of response
obtained. In other words these describe the action of the controller that is the relationship of
output signal to the input or error signal. It must be noted that it is error that actuates the
controller. The four basic modes of control are:
On-off Control
Proportional Control
Integral Control
Rate or Derivative Control
7.5 TYPES OF CONTROL

For instrumentation and control of different sections and equipment of plants, following
control loops are most often used:
Feedback control loop
Feed forward control loop
Cascade control loop
Ratio control loop
Auctioneering control loop
Split range control loop
Two major categories are:
7.5.1 FEEDBACK CONTROL LOOP

A method of control in which a measured value of a process variable is compared with the
desired value of the process variable and any necessary action is taken. Feedback control is
considered as the basic control loops system. Its disadvantage lies in its operational
procedure. For example, if a certain quantity is entering in a process, then a monitor will be
there at the process to note its value. Any change in the value will be sent to the final control
element through the controller to adjust the incoming quantity, according to desired value (set
point). But in fact changes have already occurred and only corrective action can be taken
while using feedback control system.
7.5.2 FEED FORWARD CONTROL LOOP

A method of control in which the value of disturbance is measured than action is taken to
prevent the disturbance by changing the value of a process variable. This is a control method
designed to prevent errors from occurring in a process variable. This control system is better
than feedback control because it anticipates the change in the process variable before it enters
the process and takes the preventive action. While in feedback control system action is taken
after the change has occurred.
7.6 CONTROL SCHEME OF V- 401 STABILIZER

7.6.1 OBJECTIVE
Basic objective to use the control loop on the stabilizer is to run the column at steady state &
to keep the composition of the product up to desired value.
7.6.2 MANIPULATED VARIABLES

One or any combination of following may be the manipulated variables:
Reflux ratio
Utility flow rates
Top & bottom product flow rates
7.6.3 LOADS / DISTURBANCES

Following are typical disturbances:
Change in the level of the bottom product in the boiler
Variation in the level of the top product in the condenser.
The effect of the disturbance in the temperature and pressure within the column is
controlled by controlling utility stream flow rates through the heat exchangers.
7.6.4 CONTROLLER
Proportional integral controller
7.6.5 FINAL CONTROL ELEMENT

Pneumatic control valve
Figure 16 - Control Scheme of V-401 Stabilizer
HAZOP STUDY | 91
CHAPTER # 8
HAZARD OPERABILITY
HAZOP STUDY | 92
8. HAZARD OPERABILITY
8.1 HISTORY & APPLICATION
HAZOP was initially instigated by Dr H G Lawley and associates of ICI at Wilton in the
United Kingdom in the 1960s. Subsequently, C J Bullock and A J D Jenning from ChE
Dept. Teesside Polytechnic under supervision of T.A. Kletz applied the method at higher
institution (post-graduate level). In 1977, Chemical Industries Association published the
edited version. Later on it was used by ICI, and the use of checklists was also promoted.
The technique gained popular acclaim within the chemical industries after the Fix Borough
disaster, which resulted in the deaths of 28 people owing to a chemical plant explosion many of the deceased were ordinary house holders living nearby. Through the general
exchange of ideas and personnel, the system was adopted by the petroleum industries, which
has a similar potential of major disasters. This was then followed by the food and water
industry, where the hazard potential is as great, but of a different nature, the concern being
more to do with contamination rather than explosions or chemical release.
8.2 INTRODUCTION
HAZOP has been used and develop for decades in order to identify the potential hazard and
operability problems caused by deviation from the design intent of both the new and existing
process plants. Before going further, it is best to clarify some aspects of these statements.
The concept of HAZOP involves investigating how the plant might deviate from the design
intent. If, in the process of identifying problems during a HAZOP study, a solution becomes
apparent, it is recorded as part of the HAZOP result; however, care must be taken to avoid
trying to find solutions which are not so apparent, because the prime objective for the
HAZOP is problem identification. Although the HAZOP study was developed to enhance a
new designs experience-based practices, its use has several dimensions, with experts
belonging to different backgrounds interacting and identifying more problems when working
together than when working separately and combining their results.
8.2.1 HAZARD
A hazard is defined as any operation that could possibly cause a release of toxic, flammable
or explosive chemicals or any action that could result in injury to personal or harm to the
environment.
8.2.2 OPERABILITY
Operability can be defined as any operation inside the design envelope that would cause a
shutdown that could possibly lead to a violation of environmental, health or safety regulations
or negatively impact profitability.
8.2.3 TYPES OF HAZOP

HAZOP STUDY | 93
PROCESS HAZOP
The HAZOP technique was originally developed to assess plants

and process systems.
HUMAN HAZOP
A family of specialized HAZOPs, more focused on human

errors than technical failures.
PROCEDURE HAZOP
Review of procedures or operational sequences, sometimes

denoted SAFOP Safe Operation study.
SOFTWARE HAZOP
Identification of possible errors in the development of Software
8.2.4 THE REASONS FOR SUCH WIDESPREAD USE OF HAZOPS

Safety and reliability in plant design relies upon the application of various codes of practice,
or design codes and standards. These standards represent the accumulation of knowledge and
experience of both individual experts and the industry as a whole. Such application is usually
backed up by the experience of the engineers involved, who might well have been previously
concerned with the design, commissioning or operation of similar plant.
Although codes of practice are extremely valuable, it is however considered important to
supplement them with an imaginative anticipation of deviations which might occur because
of equipment malfunction or operator error. Furthermore, most companies will admit that for
a new plant, design personnel are under pressure to keep the project on schedule. This
pressure always results in errors and oversights. The HAZOP Study is an opportunity to
correct these before such changes become too expensive, or impossible to accomplish.
Even though no statistics are available to verify the claim, it is generally believed that the
HAZOP methodology is perhaps the most widely used aid to loss prevention. The reason for
this can most probably be summarized as follows:
It is easy to learn.
It can be easily adapted to almost all the operations that are carried out within process
industries.
No special level of academic qualification is required.
8.2.5 WHEN TO PERFORM A HAZOP?

The HAZOP study should preferably be carried out as early in the design phase as possible,
so as to have influence on the design. On the other hand; to carry out a HAZOP we need a
rather complete design. As a compromise, the HAZOP is usually carried out as a final check
when the detailed design has been completed. A HAZOP study may also be conducted on an
existing facility to identify modifications that should be implemented to reduce risk and
Operability problems.
HAZOP STUDY | 94
HAZOP studies may also be used more extensively, including:
At the initial concept stage when design drawings are available.

When the final piping and instrumentation diagrams (P&ID) are available.
During construction and installation to ensure that recommendations are implemented.
During commissioning.
During operation to ensure that plant emergency and operating procedures are
regularly reviewed and updated as required.
8.2.6 SUCCESS OR FAILURE OF THE HAZOP

The success or failure of the HAZOP depends on several factors:
The completeness and accuracy of drawings and other data used as a basis for the
study.
The technical skills insights of the team.
The ability of the team to use the approach as an aid to their imagination in
visualizing deviations, causes, and consequences.
The ability of the team to concentrate on the more serious hazards which are
identified.
8.3 OBJECTIVES OF HAZOP STUDY

The objectives of a HAZOP study can be summarized as follows:
To identify (areas of the design that may possess a significant hazard potential.
To identify and study features of the design that influence the probability of a
hazardous incident occurring.
To familiarize the study team with the design information available.
To ensure that a systematic study is made of the areas of significant hazard potential.
To identify pertinent design information not currently available to the team.
To provide a mechanism for feedback to the client of the study teams detailed
comments.
8.4 FEATURES OF HAZOP STUDY

Subsystems of interest
Line and valve, etc.

Equipment, Vessels
Modes of operation
Normal operation
Start -up mode
Shutdown mode
Maintenance /construction / inspection mode
Human failure
Equipment /instrument/component failure
Supply failure
Emergency environment event
Trigger events
HAZOP STUDY | 95
Other causes of abnormal operation, including
instrument disturbance
Effects within plant
Hazardous conditions
Corrective action Change of

process design
How would hazardous

Conditions detected?
Contingency actions
Changes in chemical conditions

Changes in inventory
Change in chemical physical conditions
Release of material
Changes in material hazard characteristics
Operating limit reached
Energy source exposed etc.
Change of operating limits
Change of system reliability
Improvement of material containment
Change control system
Add/remove materials
During normal operation
Upon human failure
Upon component failure
In other circumstances
Improve isolation
Improve protection
Table 15 - Features of HAZOP
8.5 HAZOP STUDY METHODOLOGY

A HAZOP study is conducted in the following steps:
8.5.1 SPECIFY THE PURPOSE, OBJECTIVE, AND SCOPE OF THE STUDY.

The purpose may be the analysis of a yet to be built plant or a review of the risk of an
existing unit. Keeping in view the purpose and circumstances of the study, the objectives
listed above can be made more specific. The range of the study lies within the physical unit
boundaries, and also the choice of events and variables considered. For example, at one time
HAZOP's were mainly focused on fire and explosion endpoints, while now the scope may
include toxic release, offensive odor, and environmental end-points. The initial establishment
of purpose, objectives, and scope is very important and should be precisely set down so that it
will be clear, now and in the future, what was and was not included in the study. Responsible
management is required to make these decisions.
8.5.2 SELECT THE HAZOP STUDY TEAM

As many other experts are to be included in the team, covering all aspects of design,
operation, process chemistry, and safety; a team leader should be skilled in interpersonal
techniques in order to facilitate successful group interactions, as well as having a grasp of
HAZOP. He should instruct the team in the HAZOP procedure, in addition to emphasizing
HAZOP STUDY | 96
the fact that the end objective of a HAZOP survey is to identify hazards; solutions to
problems are a separate effort.
8.5.3 COLLECT DATA.

Theodore16 has listed the following materials that are usually needed:
1. Process description
2. Process flow sheets
3. Data on the chemical, physical and toxicological properties of all raw materials,
intermediates, and products.
4. Piping and instrument diagrams (P&IDs)
5. Equipment, piping, and instrument specifications
6. Process control logic diagrams
7. Layout drawings
8. Operating procedures
9. Maintenance procedures
10. Emergency response procedures
11. Safety and training manuals
8.5.4 CONDUCT THE STUDY

Using the information collected, the unit is divided into study "nodes" and the sequence
diagrammed in Figure above is followed for each node. The points in the process where
process parameters (pressure, temperature, composition, etc.) have known and intended
values are termed as Nodes. These values change between nodes as a result of the operation
of various pieces of equipment such as distillation columns, heat exchanges, or pumps.
HAZOP STUDY | 97
Various forms and work sheets have been developed to help organize the node process
parameters and control logic information.
When the nodes and parameters are identified, each node is studied by applying the
specialized guide words to each parameter. These guide words and their meanings are
thought to be the key elements of the HAZOP procedure.
The key words are divided into two subsets.
PRIMARY KEY WORDS:

Primary key words focus on a particular aspect of the design intent or an associated
process condition or parameter.
These reflect both the process design intent, and the operational aspects of the plant
being studied. Typical process oriented words might be as follows.
Note: The list below is purely illustrative, as the words employed in a review will
depend upon the plant being studied.
Flow
Pressure
Composition
Separate
Temperature
Level
Corrode
React
Remembering that the technique is called Hazard and Operability studies, added to the above
might be relevant operational words such as:
Isolate
Drain
Inspect
Maintain
Vent
Purge
Start up
Shut down
SECONDARY KEY WORDS:

Secondary key words when combined with a primary key word, suggest possible
deviations. They tend to be a standard set as listed below:
Word
Meaning
Explanation
No
Negation of design intent
The design intent does not occur (e.g. flow),

or the optional aspect is not achieved
(Isolate/No)
Less
Quantitative decrease
in the design intent occur (e.g. Pressure/Less)
More
quantitative increase
in the design intent occur (e.g.

Temperature/More)
HAZOP STUDY | 98
Part of
quantitative decrease
As well as
quantitative increase
Reverse
Logical opposite of the intent
Other
Complete substitution
The opposite of the design intent occurs (e.g.

Flow/Reverse)
The activity occurs, but not in the way
intended (e.g. Flow/Other) could indicate a
leak or product flowing where it should not,
or composition/other might suggest
unexpected proportions in a feedstock
GUIDE WORDS ACCORDING TO PARAMETER:

Parameter
Guide word / Deviation
Time
Too early, too late
Sequence
Wrong sequence, omissions, wrong action
Procedure
Not available, not applicable, not followed
Measurement
Instrument failure, observation error
Organization
Unclear responsibilities, not fitted for purpose
Communication
Failed equipment, insufficient / incorrect information
Personal
Lack of competence, too few, too many
Position
Wrong position, movement exceeding tolerances
Power
Complete loss, partly lost
Weather
Above limitation causing delayed operation.
Repeated cycling through this process, which considers how and why each parameter might
differ from the intended and the consequence, is an integral part of the HAZOP study.
8.5.5 WRITE THE REPORT.

It is customary to record as much detail about the events and their consequences as is
uncovered by the study. However, if the HAZOP identifies a not improbable sequence of
events that would result in a disaster, appropriate follow-up action is required. Hence,
although risk reduction action is not a part of the HAZOP, the HAZOP may trigger the need
for such action.
HAZOP STUDY | 99
The HAZOP studies are time consuming and expensive. Just getting the P & ID's up to date
on an older plant may be a major engineering effort. For processes with significant risk, they
are cost effective when balanced against the potential loss of life, property, business, and
even the future of the enterprise that may result from a major release.
Even though considerable man-hours are spent on the study, it must be kept in mind that
HAZOP Report is a key document pertaining to the safety of the plant. It is crucial that the
benefit of this study is easily accessible and comprehensible for future reference in case the
need arises to alter the plant or its operating conditions.
The major part of such a report is of course the printed Minutes, which contains the team
members, meeting dates, keywords applied, and of course every detail of the study teams
findings. However, it is usual to include with this a general summary. The contents of such a
summary might typically be:
An outline of the terms of reference and scope of the study.
A very brief description of the process which was studied.
The procedures and protocol employed. The Keyword combinations applied
should be listed, together with the explanatory meanings given to the team at the start
of the study. Also the fact that Action Sheets have been produced and responses will
be recorded should be explained. A brief description of the Action File (described in
the following section) should be included.
General comments. If, for example, the team were assured that high point vents and
low point drains would be universally provided, mention that statement and its
source. If certain details of vendor packages were not available, explain and list the
items which were not reviewed.
Results. This usually states the number of recommended actions.
Also included in the HAZOP Report would be an Appendix containing:
o Master copies of the drawings studied
o Copies of technical data used.
o Cause and Effect charts (i.e. matrices showing the executive action of safety
related instruments and trips).
o Any calculations produced.
o Relevant correspondence between departments, from contractor to vendor, or
client to contractor.
8.5.6 HAZOP METHOD FLOW DIAGRAM

A HAZOP study is conducted in the following steps:
HAZOP STUDY | 100
Deviation
Cause
Consequences
Safeguard
Action
In considering the information to be recorded in each of these columns is given below.
DEVIATION
These are departures from the intention which are discovered by systematically applying the
guide words (e.g. more pressure).
HAZOP STUDY | 101
CAUSE
Causes are the reasons why deviations might occur. Once a deviation has been found to have
a credible cause, it can be treated as a meaningful deviation. These causes can be hardware
failures, human errors, an unanticipated process state (e.g., change of composition), external
disruptions (e.g. loss of power), etc.
CONSEQUENCES
Consequences are the results of the deviations should they occur (e.g. release of toxic
materials). Trivial consequences, which are relative to the study objective, are dropped.
There are two outlets from which a consequence can arise: 1) from the effect of the deviation,
e.g. loss of dosing results in complete separation; 2) from the cause itself, e.g. cavitation in
pumps, with possible damage if prolonged.
SAFEGUARDS
Safeguards are usually any existing protective devices, which either prevent the cause, or
safeguards against the adverse consequences. For example, you may consider recording,
Local pressure gauge in discharge from pump might indicate problem was arising. Note
that safeguard needs not to be restricted hardware where appropriate credit can be taken for
procedural aspects, such as regular plants inspections.
ACTION
If a credible cause results in a negative consequence, it must be decided whether some action
should be taken. Consequences and associated safeguards are also considered at this stage. If
it is deemed that the protective measures are adequate, then no action should be taken, and
words to that effect are recorded in the action column. Actions fall in two groups:
Action that removes the cause
Action that mitigates or eliminates the consequences
Always examine removing the cause first, and only where necessary alleviate the
consequences. In the end, always take into account the label of training experience, especially
of personnel who will operate the plant. If operators do not understand how actions, which
require elaborate and sophisticated protective systems, are to be performed; actions are
wasted. It is not unknown for devices to be disabled, either deliberately or in error, because
no one knows for sure how to maintain and calibrate them. Having gone through the
operations involved in recording a single deviation, these can now be put into the context of
the actual study meeting procedure. From the flow diagram below it can be seen that it is very
much an iterative process, applying in a structured and systematic way the relevant keyword
combinations in order to recognize potential problems.
HAZOP STUDY | 102
8.6 CONCLUSIONS
HAZOP Results:
Improvement of system or operations.

Reduced risk and better contingency.
More efficient operations.
Improvement of procedures.
Logical order.
Completeness.
General awareness among involved parties.
Team building.
8.7 ADVANTAGES
Systematic examination.
Multidisciplinary study.
Utilizes operational experience.
Covers safety as well as operational aspects.
Solutions to the problems identified may be indicated.
Considers operational procedures.
Covers human errors.
Study led by independent person.
Results are recorded
8.8 LIMITATION OF THE HAZOP TECHNIQUE

8.8.1 REQUIRES A WELL-DEFINED SYSTEM OR ACTIVITY
The HAZOP process is a thorough analysis tool that systematically analyzes each part of a
system. The analysis team must have access to detailed design and operational information, if
they are to apply the HAZOP guide words and address potential accidents that can result
from the guide word deviations. The process methodically identifies specific engineered
safeguards (e.g., instrumentation, alarms, and interlocks) that can be seen in the form of
detailed engineering drawings.
8.8.2 TIME CONSUMING

The HAZOP process systematically reviews credible deviations, identifies potential accidents
that can result from the deviations, investigates engineering and administrative controls to
protect against the deviations, and generates recommendations for system improvements.
This detailed analysis process requires a substantial commitment of time from both the
analysis facilitator and other subject matter experts, such as crew members, engineering
personnel, equipment vendors, etc.
HAZOP STUDY | 103
8.8.3 FOCUSES ON ONE-EVENT CAUSES OF DEVIATIONS

The HAZOP process focuses on identifying single failures that can result in accidents of
interest. If the objective of the analysis is to identify all combinations of events that can lead
to accidents of interest, more detailed techniques should be used.
8.9 HAZOP STUDY OF SHELL & TUBE HEAT EXCHANGER

In this study, temperature and level will be used as variables (secondary words) different
guide words (primary words) will be applied to these words
Pressure
Deviation
Cause:
Consequence:
Shell side very high

pressure
Exchanger outlet
discharge SDV
closes.
Exchanger shell side

will be over
pressurized.
Low pressure on
shell side
Feed pump trips
Tube side high

pressure
Tube ruptures
No significance
effect as system
remains within the
design limits
Tube may over
pressurize, but since
shell and tube are
designed at same
pressure hence no
significant effect is
there.
Action
Recommended:
High pressure
security must be
installed on shell
outlet which if
actuated will close all
SDVs.
Not available
High pressure
security must be
installed on tube
outlet which if
actuated will close all
SDVs.
Temperature
Tube side high
temperature
Flow
No flow on shell side
SDV on tube side

outlet is suddenly
closed
Shell side outlet SDV Flow through

closes suddenly
compressor will
reduce tube side
temperature will
shoot up.
High temperature
security must be
there that will close
tube side SDVs.
Low flow security to
be installed on pump
discharge which if
actuated will trip
feed pump and can
trip the whole plant.
HAZOP STUDY | 104
8.10 HAZOP STUDY OF RAW CRUDE OIL STORAGE TANK

A HAZOP study is to be conducted on RAW CRUDE OIL storage tank, as presented by the
piping and instrumentation diagram shown in figure 9.2. In this scheme, crude oil is unloaded
from tank trucks into a storage tank maintained under pressure until it is transferred to the
process. Application of the guide words to the storage tank is shown in Table 9.2 along with a
listing of consequences that results from process deviation. Some of the consequences
identified with these process deviations have raised additional questions that need resolution
to determine whether or not a hazard exists.
Raw Crude
Oil Storage
Tank
HAZOP STUDY | 105
Deviations
from
operating
conditions
What event could cause this

deviation
Consequences of
this deviation on
Process indications
item of equipment
under consideration
Tank runs dry
Pump cavitates
Level:
Less
LIA-1,
FICA-1
Rupture of discharge line
Oil released
LIA-1,
FICA-1
More
V-3 open or broken
Oil released
LIA-1
V-1 open or broken
Oil released
LIA-1
Tank rupture (busting of

vessel)
Oil released
LIA-1
Tank overfills
LIA-1
Tank overfills
LIA-1
Unload too much from column

Temperature
:
Less
More
Pressure:
Less
Reverse flow from process

Possible vacuum
Temperature of inlet is colder
than normal
Temperature of inlet is hotter
than normal
Oil released
External fire
Tank fails
Break in line to flare or to

nitrogen line
Potential fire
PICA-1
Tank implodes
PICA-1
Tank implodes
PICA-1
Oil released via RV1
PICA-1
PV-2 fails closed

PICA-1 fails, closing PV-2
More
PICA-1 Fails, closing PV-1

V-7 closed
HAZOP STUDY | 106

Overfill tank
High pressure in flare header
Volatile impurity in feed

See event 6
Same as less
No
PICA-1
PICA-1
PICA-1
PICA-1
CHAPTER # 9
ENVIRONMENT IMPACT
ASSESSMENT
ENVIRONMENT IMPACT ASSESSMENT | 108
9. ENVIRONMENTAL IMPACT ASSESSMENT

General information is given on some toxic and hazardous compounds handled or produced
in typical crude distillation operations. The equipment in the plant has to be designed for safe
operation under normal conditions. Adequate relief valves have to be installed to prevent
failure of equipment from overpressure. Additional metal thickness has to be provided in
piping and vessels for a corrosion allowance. Periodic inspection of equipment should be
made to assure safe operation. Safety equipment should be provided for use when working
under hazardous conditions.
9.1 HYDROGEN SULFIDE

Gas and some liquid streams in a crude unit can contain hydrogen sulfide (2 ) depending
upon the 2 content of the crude. Hydrogen sulfide is a very dangerous and deadly gas. The
gas is probably one of the most dangerous hazards that can exist in the plant, this does not
mean that you are in extreme danger at all times when working in the plant. The gasoline in
the gas tank of your car contains sufficient energy to cause an explosion comparable to
several sticks of dynamite, if detonated under the right conditions. Gasoline, when properly
handled, is not normally thought of as dangerous. Under normal conditions, hydrogen sulfide
is confined in the piping and vessels and is not dangerous.
9.1.1 NPI RANK:

About 400 substances were considered for inclusion on the NPI reporting list. A ranking and
total hazard score was given based on health and environmental hazards, and human and
environmental exposure to the substance. H2S was ranked as 37 out of 400. On a healthhazard rating of 0-3, hydrogen sulfide registers 1.8. A score of 3 represents a very high
hazard to health, 2 represents a medium hazard and 1 is harmful to health.
Since hydrogen sulfide is heavier than air, which can result in the gas settling in low places
near the vicinity where it is released, plant personnel should never knowingly vent any
appreciable quantity of 2 containing gas to the atmosphere without burning it. No work
should be undertaken on the unit when there is danger of breathing excessive2 , and no one
should ever or remain in such an area unless wearing a suitable gas mask.
Hydrogen Sulphide is highly toxic, colorless gas heavier than air with the odor of rotten eggs.
It burns with a blue flame and produces sulfur dioxide, a very irritating gas with a pungent
odor. It forms explosive mixtures with air, the lower limit of complete flammability being 4.3
percent hydrogen sulfide and the upper limit 46.0 percent. It is soluble in water but becomes
less soluble as the temperature of the water increases. The sense of smell cannot be depended
upon to detect hydrogen sulfide for two reason s. First, the sense of smell is lost in two to

fifteen minutes of exposure to concentrations as low as 0.010 to 0.015 percent by volume of
the gas. Second, exposure to higher concentrations for less than a minute dulls the sense of
smell and may result in fatality. There are a number of qualitative tests which will indicate
the presence of the gas. One such test is the darkening of paper soaked in lead acetate.
However, for an accurate determination of the presence of the gas as well as of its percentage
in the air, a suitable detector should be used.
9.2 SYMPTOMS OF HYDROGEN SULFIDE POISONING

The susceptibility varies according to the individual, but appears to be increased by previous
exposure. Acquired immunity has never been observed, and the gas has no cumulative
effects. The poisoning may be either sub-acute or acute. Sub-acute poisoning consist s of the
irritant action of the gas on exposed tissues and mucous membranes producing conjunctivitis
and respiratory distress. Acute poisoning (strangling) may occur after a few seconds of
inhalation of a high concentration and results in panting respiration, pallor, cramps, paralysis
of the pupil , and almost immediate loss of consciousness with loss of speech and no other
warning a cry. Death may occur with extreme rapidity from respiratory and cardiac paralysis.
Even sniffing of a sufficiently high concentration may cause the latter effects.
The following data indicates the physical effect upon the human body of arlous
concentrations of hydrogen sulfide:
1. 0.005% and lower has the characteristic odor of rotten eggs. In higher concentrations,
the sense of smell is quickly paralyzed. Therefore, do not rely on the sense of smell to
detect hydrogen sulfide.
2. 0.002% or 20 ppm is the maxi mum allowable limit of concentration for continuous
exposure during an-hour period.
3. 0.005% to 0.010% or 50 to 100 ppm for 30 to 60 minutes results in conjunctivitis
(inflammation of the eyes) and respiratory tract irritation.
4. 0.010% to 0.020% or 100 to 200 ppm for 2 to 15 minutes results in the loss of the
sense of smell; a to 48 hours results in death.
5. 0.020% to 0.050% or 200 to 500 ppm for 1 to 4 hours results in death.
6. 0.050% to 0.060% or 500 to 600 ppm for 30 to 60 minutes results in death.
7. 0.060% to 0.15% or 600 to 1500 ppm for 2 to 15 minutes results in death.
9.3 TREATMENT OF ACUTE HYDROGEN SULFIDE POISONING

Hydrogen sulfide in high concentrations acts quickly tithe nerves controlling respiration.
Persons who may be overcome by hydrogen sulfide lose consciousness quickly and are
unable to escape from the contaminated area. For this reason, any person attempting to rescue
a hydrogen sulfide victim must wear a mask.
Remove the victim at once to fresh air. If breathing has not stopped, keep the victim in fresh
air and keep him quiet. If Possible, put him to bed. Secure a physician and keep the patient
quiet and under close observation for about 48 hours for possible edema of the air pas sages
or lungs.

In cases where the victim has become unconscious and breathing has stopped, resuscitation
must be started at once. Fai lure of respiration for even a very short time can result in
permanent injury. It is strongly advised that a resuscitation apparatus be available in the plant
first aid room, and also that portable resuscitators be located in areas likely to contain H2S. If
a resuscitator is not immediately available, mouth-to-mouth resuscitation should be started.
Speed in beginning resuscitation is essential:
Anyone who is revived from unconsciousness due to hydrogen sulfide will generally recover
quickly without after effects inasmuch as hydrogen sulfide does not have harmful effects on
the blood stream as in the case of carbon monoxide. The following tabulation shows the
importance of immediately applying resuscitation:
Minutes Delay
Chances of
Recovery
98 out of 100
92 out of 100
72 out of 100
50 out of 100
25 out of 100
11 out of 100
8 out of 100
5 out of 100
2 out of 100
10
1 out of 100
The use of oxygen is of assistance in speeding return to consciousness but resuscitation

should be applied immediately and continued while someone else is bringing the oxygen
apparatus to the location and preparing it for use. Resuscitation should be continued until
normal breathing has been regained or until rigor mortis develops.
Any person overcome by hydrogen sulfide should be treated for shock; that is, kept warm
while resuscitation is being applied and kept quiet for a period following return to
consciousness. The method for mouth-to-mouth resuscitation is given below:
1. Examine victims mouth for foreign matter (mucus, food, sand, tobacco) in his mouth,
turn his head to one side and remove it with your fingers or a cloth wrapped around
your fingers.

2. Lift the victims neck, place a folded coat, blanket etc. under his shoulders. Tilt his
head back as far as possible
3. Grasp the jaw with thumb in one side of the mouth and pull it forward. Maintain this
position to keep air passage open
4. Pinch victim's nostrils shut, take a deep breath and place your mouth over his mouth
and your thumb, thus creating a tight seal; or close the victim's mouth, take a deep
breath and place your mouth over his nose. Blow into the victims mouth or nose until
you see his chest rise. For an infant breathe through both nose and mouth, with thumb
in the mouth. A handkerchief placed over victim's mouth or nose prevents need of
direct contact. This does not greatly affect the passage of air
5. Remove your mouth and listen for out-flaw of air. For an adult, inflate lungs at rate of
about 12 times per minute. For a child, inflate lungs up to 20 times per minute using
relatively shallow breaths.
6. If first few attempts to inflate the lungs are unsuccessful, turn victim on his side and
administer several sharp blows between the shoulders in an attempt to dislodge any
obstruction.
7. Now repeat the entire procedure.
8. Do not give up. Men have been revived after more than four hours of artification
respiration.
If other persons are present, send one of them for a physician. Others should rub the patient's
arms and legs and apply hot water bottles, blankets, or other sources of warmth to keep him
warm.
After the patient is revived, he should be kept quiet and warm, and remain under observation
for 48 hours for the appearance of edema of the air passages or lungs.
In all cases of acute H2S poisoning, the use of oxygen containing 5% carbon dioxide is
recommended as an inhalant, whether or not breathing has stopped. This mixture is a
respiratory stimulant.
9.4 TREATMENT OF SUB-ACUTE HYDROGEN SULFIDE POISONING

Headache, inflammation of the eyes and throat, dizziness, indigestion, excessive saliva, and
weariness are all symptoms which follow continued exposure to 2 in low concentrations.
Edema of the air passages and lungs may also occur.
Keep the patient in the dark to reduce eyestrain and have a physician treat the inflamed eyes
and throat. Watch for possible edema.
Where sub-acute poisoning has been suspected, the atmosphere should be checked repeatedly
for the presence of 2 by such methods as testing by odor, use of moist lead acetate paper,
or by suitable gas detection equipment so as to make sure that the condition does not
continue.
9.5 PREVENTION OF HYDROGEN SULFIDE POISONING


The best method for prevention of 2 poisoning is to stay out of areas known or suspected
to contain it. The sense of smell is not an infallible guide as to its presence, for although the
compound has a distinct and unpleasant odor (rotten eggs) it will frequently paralyze the
olfactory nerves to the extent that the victim does not realize that he is breathing 2 . This is
particularly true of higher concentrations of the gas.
Gas masks suitable for use with hydrogen sulfide must be used in all work where exposure to
H2S is likely to occur. Such masks must be checked frequently to make sure that they are not
exhausted, and are in good working order. Whenever work is done on or in equipment
containing appreciable concentrations of 2 , men must wear gas masks and should work in
pairs so that one may effect rescue or a call for help should the other be overcome?
As mentioned before, the atmosphere in which men work should be checked from time to
time for small concentrations such as would cause sub-acute poisoning.
Remember - Just because your nose says it's not there doesnt mean its not.
CHAPTER # 10
COST ESTIMATION
COST ESTIMATION | 114
10. COST ESTIMATION

10.1 PLANT COST ESTIMATION
When the large portion of the chemical plant design project is completed then we estimate the
cost of the plant. As the final process-design stage is Complete, it becomes possible to make
accurate cost estimation because detailed equipment specification and definite plant facility
information are available. Direct price quotation based on detailed specification can then be
obtained from various manufacturers. However the design project should proceed to the final
stages before costs are considered and cost estimate should be made through out all the early
stages of the design when complete specifications are not available. Evaluation of costs in the
preliminary design is said predesign cost estimation. Such estimation should be capable of
providing a basis for company management to decide if further capital should be invested in
the project.
Evaluation of costs in the preliminary design phase is some time called guess estimations. A
plant design obviously must present a process that is capable of operating under condition
which will yield a profit. A capital investments is required to any industrial process, and
determination of the necessary investment is an important part of a plant design project. The
total investment for any process consists of the physical equipment and facilities in the plant
plus the working capital for money which must be available to pay salaries keep raw
materials and products on hand and handle other special items requiring a direct cast out lay.
10.2 CAPITAL INVESTMENT

Before the industrial plant can be put into operation, a large sum of money must be available
to purchase and install the required machinery and equipment. Land must be obtained,
service facilities must be made available, and the plant must be erected complete with all
piping, controls and services. In addition, funds are required with which to pay the expenses
involved in the plant operation before sales revenue becomes available. The capital needed to
supply the required manufacturing and plant facilities is called the fixed capital investment
(FCI) ,while that necessary for the operation of the plant is termed the working capital
(WC).The sum of the fixed capital investment and the working capital is known as the total
capital investment(TIC).The fixed capital portion may be further subdivided into
manufacturing fixed-capital investment , also known as direct cost and nonmanufacturing
fixed capital investment, also known as indirect cost.
10.2.1 FIXED-CAPITAL INVESTMENT

Manufacturing fixed-capital investment represents the capital necessary for the installed
process equipment with all components that are needed for complete process operation.
Expenses for site preparation, piping, instruments, insulation, foundation and auxiliary
facilities are typical examples of cost included in the manufacturing fixed-capital investment.
The capital required for construction overhead and for all plant components that are not
directly related to the process operation is designated the nonmanufacturing fixed-capital
investment. These plant component include the land, processing buildings, administrative and
other offices, warehouses, laboratories , transportation, shipping and receiving facilities,
utility and waste disposal facilities ,shops ,and other permanent parts of the plant .The
construction overhead cost include field offices and supervision expenses, home office
expenses , miscellaneous construction costs, tractors fee and contingencies. In some cases,
construction overhead is proportional between manufacturing and nonmanufacturing fixedcapital investment.
10.3 WORKING CAPITAL

The working capital for an industrial plant consist of the total amount of money invested
1. Raw material and supplies carried in stock
2. Finished products in sock and semi finished product in the process of being
manufactured
3. Accounts receivable
4. Cash kept on hand for monthly payment or operating expenses ,such as salaries
,wages and raw material purchase
5. Accounts payable
6. Taxes payable
7. Estimation of Capital Investment
The estimate of capital investment are based on the cost of the equipment required
10.4 METHODS FOR ESTIMATING CAPITAL INVESTMENT

Various methods can be employed for estimating capital investment.
A. Detailed Item Estimate
B. Unit Cost Estimation
C. Percentage of Delivered-Equipment Cost
D. Lang factors for Approximation of capital investment
E. Power factor Applied to Plant/Capacity ratio
F. Investment Cost per Unit of capacity
G. Turnover Ratio
The accuracy of an estimate depends on the amount of design detail available; and the
accuracy of the cost data available; and the time spent on preparing the estimate. In the early
stages of a project only an approximate estimate will be required a justified by the amount of
information then developed.
10.4.1 PERCENTAGE OF DELIVERED - EQUIPMENT COST

This method for estimating total investment requires the determination of the delivered
equipment cost. The cost of purchased equipment is the basis of several pre design methods
for estimating capital investment. The most accurate methods for determining process
equipment costs is to obtain firm bids from fabricators or suppliers. Percentage of delivered
equipment cost is the method used for estimating the fixed or total capital investment requires
determination of the delivered equipment cost. The other items included in the total direct
plant cost are then estimated as percentage of the delivered equipment the addition
components of the capital investment are based on average percentage of total direct plant
cost total direct and indirect plant costs or total capital investment. Estimating by percentage
of delivered equipment cost is commonly used for preliminary and study estimates. It yields
most accurate results when applied to a project similar in configuration to recently
constructed plants.
(E/fixed Capital investment )
+ + +
Working Capital investment
. .
W.C.I
15%
Purchased equipment Cost in 2014 Using Nelson-Farrar Refinery Cost Index
Percent Cost = original cost (index value at present/index value at time original cost was
obtained)
10.5 COST
COST
Heat Exchanger
Air blown Cooler
Heater
Pump
= $ 52500 (1,287.3/1,344.7)
= 8 $50258.97
= $ 402071.76
= $76500 (2,785.5/2,601.4)
= 5 $81913.87
= $409569.36
= $27900 (1,019.3/974.6)
= 1 $29179.63
= $29179.63
= $32400 (2,010.9/1,758.4 1)
= 11 37052.31
= $407575.41

= $4151586
Separating Vessel
Fractional Column
= $115230 (2,785.5/2,601.4)
= 3 123384.77
= $370154.31
= $148209.25
= $80000 (2,785.5/2,601.4)
= $85661.56
= $40000 (2,785.5/2,601.4)
= $ 4283.78
Reboiler
Total Purchased Equipment Cost = $1708495.81
10.5.1 INDIRECT COST

Engineering and supervision
Construction Expenses
Total indirect Cost
Total direct and indirect cost
Contractor's fee
Contingency
Engg & Supervision
Construction expenses
Total Indirect Cost
Total Direct & Indirect Cost
Contractors fee
Contingency
10.5.2 DIRECT COST
= 10%
= 12%
=
= +
5 %( + ) =
10 %( + ) =
= 0.10 1708495.81
= $170849.58
= 0.12 1708495.81
= $205019.49
= $375869.07
= $1718498.81
= 0.05 1718498.81
= $85924.94
= 0.10 1718498.81
= $171849.881
Purchased Equipment Cost = E
COMPONENTS
% of E
Purchased-equipment installation
25%
Instrumentation and controls (Installed)
11%
Piping(Installed)
12%
Electrical (installed
9%
Building (Including Service)
6%
Yard improvement
4%
Service Facilities(installed)
8%
Land
3%
Total Direct cost
Total direct cost
=D
COMPONENTSS
% xE
Cost ($)
Purchased-equipment
installation
Instrumentation & Controls
(Installed)
0.25 $1708495.81
$427123.95
Piping(Installed)
Electrical (installed
0.12 $51708495.81
$205019.49
Building (Including
Service)
Yard improvement
0.06 $1708495.81
Service Facilities(installed)
Land
Total Direct Cost
0.11 $1708495.81
0.09 $1708495.81
0.04 $1708495.81
0.08 $1708495.81
0.03 $1708495.81
$.
$187934.53
$153764.62
$102509.74
$68339.83
$136679.66
$51254.87
10.6 FIXED CAPITAL INVESTMENT

Fixed Capital Investment = Total direct + indirect cost + contingency + Contractors fee
= 1332626.69 + 375869.07 + 171849.881 +
85924.94
= $1966270.58
Total capital investment
Working Capital
Total capital investment
(1- 0.15 Total capital investment)
Total Capital Investment
= +
= 0.15 ( )
= 0.15( +
= 1966270.58
= (1966270.58/. 85)
= $2313259.506
10.7 ESTIMATION OF TOTAL PRODUCT COST

(i)
(ii)
(iii)
Variable production Cost

Fixed Charges
Plant Overhead costs
10.7.1 FIXED CHARGES:

a) DEPRECIATION:(10% OF FCI)
= 0.10 6001383.5
= $600138.35
b) LOCAL TAXES: (3-4% OF FCI)
Assume 3%
= 0.03 1966270.58
= $58988.11
c) INSURANCES: (0.4-1% OF FCI)
Assume 0.7%
= 0.007 1966270.58
= $13763.89
d) RENT:(8-12% OF FCI)
Assume 10%
= 0.10 1966270.58
= $196627.058
Therefore total fixed charges (TFC) = $269379.05
But Fixed Charges
= (10 20% )
Assume 15%
Therefore Total Product cost (TPC) = 269379.05/0.15 =
10.7.2 VARIABLE PRODUCTION COST

Raw Material
Operating labor
Direct supervision & electric labor
Utilities
Maintenance & repair
Operating supplies
Laboratories charges
Patent and realities
$1795860.33
0.3 1795860.33
$538758.099
0.14 1795860.33
$251420.44
0.10 1795860.33
. 13 1795860.33
0.06 1795860.33
0.14 1795860.33
0.101795860.33
0.04 1795860.33
= $1813817.89
$179586.03
$233461.84
$107751.61
$251420.44
$179586.03
$71834.41
10.7.3 PLANT OVERHEAD COST

50-70% of (Operating Labor OL+ Operating supplies OS+ Maintenance M)
Assume 65%
Plant Overhead cost
= 0.65(179586.03 + 251420.44 + 107751.61)
= $350192.75
10.8 GENERAL EXPENSES

Admit cost
0.50 1795860.33
$897930.16
Distribution & selling
0.20 1795860.33
$359172.06
R&D
0.03 1795860.33
$53875.80
= $1310978.03
Manufacturing cost (MC)
=Operating labor + fixed charges + Plant overhead expenses

= 179586.03 + 269379.05 + 350192.75
= $799157.83
10.9 TOTAL PRODUCTION COST
= +
= 107751.61 + 1310978.03
= $ 1418729.64 = 120592019.4
10.10 GROSS EARNINGS
320
= . 109 /
= /
= 575000 320 109
= . 1.288 1010

=
= (1.288 1010 120592019.4)
= . 1.275 1010
REFERENCES | 121
REFERENCES
Assaad, Magdi. Computerized Heat Exchanger Design Procedure. Concordia University
Libraries, 1979.
Cengel, Yunus. Thermodynamics - An Engineering Approach. 5th. Boston: McGraw-Hill,
2006.
Evans, Frank L. Equipment Design Handbook. 2nd. Vol. 2. Gulf Publishing Company, 1980.
Fouling Factors. n.d.
<http://www.engineeringpage.com/technology/thermal/fouling_factors.html#fouling_
factors>.
Kern, Donald Quentin. Process Heat Transfer. Tata McGraw-Hill Education, 1950.
Maxwell, J. B. Databook on Hydrocarbons. Malabar, Florida: Robert E. Krieger Publishing
Company, 1950.
Nelson, W.L. Petroleum Refinery Engineering. 4th. McGraw Hill Book Company, 1958.
Perry, Robert. Chemical Engineers Handbook. 7th. 2007.
Phillips, S. L. A Technical Databook for Geothermal Energy Utilization. Lawrence Berkeley
Laboratory, University of California, 1981.
Riazi, M. R. Characterization and Properties of Petroleum Fractions. 1st. ASTM
International, 2005.
Richardson, Coulson &. Particle Technology & Separation Processes. 5th. Vol. 2nd. Elsevier
Science, 2002.
Technical Data Book - Petroleum Refining. 6th Ed. American Petroleum Institute, 1997.
Timerhaus, Max. S Peters & Klaus D. Plant Design & Economics for Chemical Engineers.
4th. McGraw Hill, 1984.
"Using VSEP to Treat Desalter Effluent." 2003. New Logic Research Inc.
Watkins, Robert N. Petroleum Refinery Distillation. Houston, Texas: Gulf Publishing
Company, 1979.

FYP Thesis - Recovery of Naphtha From Crude Oil

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FYP Thesis - Recovery of Naphtha From Crude Oil

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RECOVERY OF NAPHTHA FROM CRUDE OIL

SESSION: 2010 2014

Rai Mahmood Hussain

DEPARTMENT OF CHEMICAL ENGINEERING

RECOVERY OF NAPHTHA FROM CRUDE OIL

This project is submitted to Department of Chemical Engineering,

for the partial fulfillment of the requirements for the

Dr. Shah Muhammad

DEPARTMENT OF CHEMICAL ENGINEERING

In the name of Allah,

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

1.2 CRUDE OIL FORMATION ............................................................................................................................... 3

2.1.7 Bottom Stripping Section of Crude Tower ...................................................................................... 10

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

6.1.2 Shell and Tube Heat Exchanger ..................................................................................................... 40

6.1.3 Nomenclature ............................................................................................................................... 42

6.2 FIRED HEATER H 301 CRUDE CHARGE HEATER .............................................................................................. 49

6.2.4 Nomenclature ............................................................................................................................... 52

6.2.6 Air to Fuel Ratio ............................................................................................................................ 53

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

6.2.7 Design Steps in Radiant Section ..................................................................................................... 55

6.2.8 Design Steps in Convection Section ................................................................................................ 59

6.2.9 Specification Sheet........................................................................................................................ 61

6.4 SHELL & TUBE CONDENSER E-309 OVERHEAD VAPORS/WATER ........................................................................ 70

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

6.4.6 Specification Sheet........................................................................................................................ 78

6.5.2 Choice of Type: ............................................................................................................................. 80

7. INSTRUMENTATION & CONTROL ............................................................................................................... 85

7.3.4 Controller ..................................................................................................................................... 87

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

8.5.5 Write the report. ........................................................................................................................... 98

8.6 CONCLUSIONS ........................................................................................................................................ 102

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

Short Description / Example

straight- or branched-chain molecules

ringed structures with one or more rings rings contain six

ringed structures with one or more rings rings contain only

linear or branched chain molecules containing two carboncarbon double-bonds

is a whole number, usually from 1 to 20

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

half of the hydrocarbons are Naphthenes,

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

1.2 CRUDE OIL FORMATION

1.3 CRUDE OIL EXTRACTION

1.4 OIL SANDS

1.5 WORLDWIDE OIL PRODUCTION

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

Kerosene Crude Exchanger, E-301,

Heavy Gas Oil Crude Exchanger, E-304,

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

2.1.1 HEAVY GAS OIL CIRCUIT

2.1.2 LIGHT GAS OIL CIRCUIT

2.1.3 LIGHT GAS OIL PUMPAROUND CIRCUIT

RECOVERY OF NAPHTHA FROM CRUDE OIL | SLAM

2.1.4 LIGHT WEIGHT KEROSENE CIRCUIT

2.1.5 NAPHTHA PUMPAROUND CIRCUIT

2.1.6 CRUDE TOWER OVERHEAD CIRCUIT