44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

HEAT BALANCE OF THE VACUUM DISTILLATION COLUMN

KEY FOR IDENTIFICATION OF THE REASON FOR LOW
HEAVY VACUUM GAS OIL YIELD
Dicho Stratiev1, Ivelina Shishkova, Petya Dermatova
1

Lukoil Neftochim Bourgas R&D Department, 8104 Bourgas, Bulgaria,

e-mail: stratiev.dicho@neftochim.bg

KEY WORDS: Atmospheric resid vacuum distillation, heavy vacuum gas oil, heat
balance

ABSTRACT
Estimation of heat balance of the vacuum distillation column of
atmospheric resid in the Lukoil Neftochim Bourgas identified the reason for a
decrease in the heavy vacuum gas oil yield. The hypothesis of a leakage of the
heavy vacuum gasoil draw tray was rejected and it was found that the
hydraulic resistance in the heavy vacuum gas oil pump around did not allow an
increase of its flow rate and taking away the heat required for condensation of
heavy vacuum gas oil, contained in atmospheric residue.

Atmospheric residue vacuum distillation process economics is favored by

heavy vacuum gas oil (HVGO) yield increase [1]. Therefore, all over the world
many designs leading to reconstruction of atmospheric residue vacuum
distillation columns in order to increase end boiling point resulting in HVGO
yield growth are realized [2,3]. Two vacuum distillation columns for distillation
of atmospheric residue produced via crude oil fractionation are included in
Lukoil Neftochim Bourgas, Bulgaria crude oil processing scheme. The typical
feed of these vacuum columns is atmospheric residue distilled from Ural crude
oil (Table I). Within 2006 it has been established that at VD-2 (atmospheric
residue vacuum distillation unit - 2) HVGO yield decreases as the unit rate
increases. The principle process diagram of VD-2 unit is shown at Figure 1.
The vacuum column consists of 4 structural Seltzer packing layers and
includes four recycle refluxes, down recycle reflux (DRR); down sharp recycle
reflux (DSRR), upper recycle reflux (URR) and upper sharp recycle reflux
(USRR). The atmospheric residue is fractionated to light vacuum gas oil
(LVGO)(side recovery), heavy vacuum gas oil (HVGO)(side recovery) and
vacuum residue, and minimum quantity light diesel fraction (LDF) is drawn out
from the column top. VD-2 is wet vacuum column since superheated steam is
fed at the bottom to strip entrained lighter hydrocarbons from the vacuum
residue.
The vacuum column K-101 process parameters and material balance
has been recorded as well as produced product physical-chemical parameters
have been determined at different rates in order to identify the cause of HVGO
yield decrease as the VD-2 rate is increased within April 2006 (Tables II-IV).

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

Figure 1 Process diagram of VD-2

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

Table I Density and TBP of atmospheric residue, obtained at Ural crude oil
distillation (feed for VD-1 and VD-2 units)
Density, d420

0.934

TBP distillation range, OC

% recovered

% recovered

10.30
4.75
8.83
14.59
6.36
4.47
6.48
42.73

10.30
15.05
23.88
38.47
44.83
49.30
55.78

IBP - 380
380-400
400-430
430-470
470-490
490-510
510-540
Over 540

Table II VD-2 unit vacuum distillation column process parameters

Parameters

13.04.2006

14.04.2006

17.04.2006

Rate, t/h
Column K-101 inlet temperature, o C
Temperature beneath 1st packing, o C
Temperature beneath 2nd packing, o C
Temperature beneath 3rd packing, o C
Temperature beneath 4th packing, o C
Bottom temperature, o C
Top temperature, o C
URR flow, m3/h
USRR flow, m3/h
DRR, m3/h
DSRR, m3/h
LVGO, t/h
HVGO flow, m3/h (t/h)
LDF, t/h
Darken product, m3/h (t/h)
URR temperature, o C
USRR temperature, o C
DRR temperature, o C
DSRR temperature, o C
Stripping steam quantity, kg/h
Top residual pressure, mmHg
Residual pressure at column feeding
area, mmHg
Residual pressure at the bottom,
mmHg

289
386
203
270
359
366
367
84
111
68
102
13
15
167 (135.5)
1,5

274
386
196
268
355
368
366
90
114
70
104
13

282
382
194
257
338
364
364
90
113
70
102
12

167 (135.5)
1,5

73
173
94
285
960
60.8

73
173
94
285
960
47*

167 (135.5)
1,5
7 (6)
73
173
94
285
960

68.4

52.5*

98.8

148*

* The residual pressure has been measured by absolute pressure gauge with accuracy of 1
mmHg

It is seen from these data that vacuum residue density at 13.04.2006 is

lower (0.95) as compare to typical values of that product (about 1.0). The
vacuum residue lower density supposes higher content of HVGO which

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

complies with HVGO lower recovery. When the unit rate has been decreased
from 289 t/h to 274 t/h, it is established that HVGO recovery increases that
corresponds to the higher density of vacuum residue sampled at lower rate.
Obviously, the column rate has effect on the extent of deriving HVGO from
vacuum residue. One of the primary suppositions for the HVGO low yield has
been that HVGO product collective tray is leaky.
Table III VD-2 products density data
D420
Vacuum residue
HBGO
LVGO
LDF

13.04.2006
0.9502
0.9136
0.882

14.04.2006
0.9984
0.9096
0.882
0.856

Table IV Distillation data of LVGO, HVGO and LDF sampled at 3.04.2006

Distillation, % v/v
IBP
5
10
20
30
40
50
60
70
80
90
95
98
Recover up
3600, % v/v

to

HVGO,
ASTM D-1160
254
362
380
394
407
417
432
444
459
474
497
518

LVGO,
ASTM D-86
279
291
298
306
315
323
332
340
349
361

LDF,
ASTM D-86
147
184
196
219
234
248
261
275
291
308
345
354
363

79

In order to check this supposition material and heat balances of

sections from which LVGO and HVGO are drawn out has been calculated
(Tables V and VI).

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

Table V Material and heat balance calculations of the LVGO sampling loop
1st packing material balance
Vapor quantity at 1st packing inlet Vin
Vin = LVGO + USRR + steam + LDF = 15 + 54 + 0.96 + 1.5 = 71.5 t/h
(1)
Vapor quantity at 1st packing outlet Vout
Vout = steam + LDF = 0.96 + 1.5
(2)
Liquid quantity leaving 1 packing Lout
Lout = USRR
1st packing heat balance
LVGO vapor enthalpy 106 kcal/kg*
Superheated steam enthalpy 675 kcal/kg
LDF enthalpy - 91 kcal/kg*
LVGO liquid enthalpy 16.74 kcal/kg*
LVGO specific heat capacity 0.5 kcal/kg0C*
Inlet heat quantity - Qin
Qin = 15 000 106 + 54 000 106 + 960 675 + 1500 91 = 8 098 300 kcal/h
(3)
Heat quantity released from 1st packing with vapors Qvapour out
Qvapour out = 1500 91 + 960 675 = 784 300 kcal/h
(4)
Heat quantity released with USRR, LVGO and URR - Qliquidout
Qliquidout = 54 000 X 16.74+15000 X16.74 + 95000 X 0.5 X (203-73) = 7 329 825 kcal/h

(5)
According the heat balance Qin = Qvapour out + Qliquidout
Qvapour out + Qliquidout = 7 329 825 + 784 300 = 8 114 125 kcal/h
(6)
Difference between total Qvapour out + Qliquidout and Qin is 15 825 kcal/h and
0,19% of Qin. Hence, there is no rupture of the collective tray from which
LVGO is drawn out.
*Enthalpy and the specific heat capacity values are calculated by the help of
software simulator ChemCad and use of the Lee-Kesler model, that is suitable
for hydrocarbon systems [4]

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

Table VI HVGO and LVGO drawing out loop material and heat balance
calculations
3rd packing material balance
3rd packing inlet vapor quantity Vin is:
Vin = HVGO + DSRR + LVGO + steam + LDF =
= 135.5 + 9.8 + 15 + + 0.96 + 1.5 = 216.7 = 162.7 t/h.

(7)
Vapor quantity, computed by software simulator Chemcad at column feeding
rate of 289 t/h atmospheric residue has been 165t/h. The phase equilibrium
constants have been computed according to Chao-Seader model [5]
The vapor quantity computed by equation 7 and by Chemcad is in good
compliance.
3rd packing heat balance
LVGO specific heat capacity 0.433 kcal/kg0C*
3rd packing inlet heat - Qin is:
Qin = 32.64 X 106 kcal/h

(Computed by use of ChemCad simulator)

Heat quantity, released by DRR QHVGO is:

QHVGO = 86 400 X 0,433 x (359-94) = 9 913 968 kcal/h
(8)
Heat quantity, released by URR QLVGO is:
QLVGO = 95 000 X 0.500 X (203-73) = 6 175 000 kcal/h
(9)
Heat quantity, released by LVGO QLVGO is:
QLVGOprod = 251 049 kcal/h
Heat quantity, released by HVGO QHVGOprod is:
QHVGOprod = 17 X 106 kcal/h
Total released heat quantity Qout is:
Qout = QHVGOprod + QLVGOprod + QLVGO + QHVGO =
=17 X 106 + 251 049 + 6 175 000 + 9 913 968 = 33.3 X 106 kcal/h
(10)
Difference between Qin and Qout, is 0,66.106 kcal/h and is 2%, therefore it is
considered as negligible. Hence, the tray from which HVGO is drawn out is
not leaky and can not be considered as cause for HVGO low yield.
*The specific heat capacity values are calculated by the help of software
simulator ChemCad and use of the Lee-Kesler model [3].

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

Material and heat balances calculations show complete compliance

between calculated and real USRR and DSRR flows. That means that
supposition for LVGO and HVGO collective trays rupture is not true. Hence,
crux for HVGO low yield and 360oC minus fraction low content in LVGO (up to
360oC distilled 79 -80%) is another.
An experiment has been carried out on 14.04.2006 that consists of
following: The DSRR quantity has been decreased from 13 to 0 m3/h and
hence, DRR quantity increases from 102 to 104 m3/hv i.e. DRO + DSRR total
flow decreases from 115 to 104 m3/h. At that H-105 pump pressure along the
compressed line increases from 0.9 MPa to 0.95 MPa. That means that along
the DRR line resistance exists and impedes DRR flow increase. Another
experiment has been carried out on 17.04.2006 that consists of following: The
DSRR flow has been increased from 12 to 21 m3/h and at that DRR flow
decreases from 102 to 100 m3/h i.e. total flow increases from 112 to 121 m3/h.
That once again shows that the reason for impossibility to increase DRR flow
is not due to the H-105 pump capacity but to the resistance along DRR line.
Because of that reason DRR possesses restricted resource for heat
withdrawing out and for condensation of higher HVGO quantities. That is why
as the K-101 rate is increased the HVGO drawing out decreases since it is not
possible to keep high feed evaporation degree. On 17.04.2006 as the inlet
temperature has been increased from 382 to 386oC the packing temperatures
increase by about 10oC, HVGO drawing out does not increase but LVGO
drawing out increases and vacuum residue drawing out decreases. The
LVGO drawing out growth is due to the increase content of high boiling
components in this fraction. If the yield of component distilled to 360oC is of
80% order in this fraction the last can not be used as feed for motor diesel fuel
with sulfur content of 50 ppm production. It is established from carried out
investigations by the research laboratory that among all middle distillate
fractions produced from Ural crude oil processing at Lukoil Neftochim
Bourgas-AD LVGD from VD is the most difficult to be hydrotreated [6]. That is
why the smallest quality fraction worsening makes impossible production of
diesel fuel with 50 ppm sulfur content when this fraction is included in the feed
for hydrotreatment.
The conclusion may be derived from carried out investigation that crux
for the unsatisfactory operation of VD-2 K-101 column at high rate is due to
the insufficient resource for heat withdrawing out by DRR. This explains why
at low rates HVGO drawing out and LVGO quality are satisfactory.
It has been established that DRR distribution device is damaged and
part of it is broken and partially obstruct the line connecting DRR with
distribution device within the VD-2 unit plan overhaul. Obviously because of
this cause it has been impossible to increase DRR flow. As the DRR
distribution device has been rehabilitated it becomes possible to increase its
flow and at parameters of vacuum column shown in Table 1, at column rate of
288 t/h and all other equal conditions the DRR flow has been increase from
102 to 140 m3/h and as a result HVGO quantity increases from 135.5 t/h to
141 t/h.

44th International Petroleum Conference, Bratislava, Slovak Republic, September 21-22, 2009

CONCLUSIONS
It is established that the narrow point of VD-2 vacuum column K-101 operation
at high rate is restricted heat withdrawing by DRR. Because of that reason at
high rates of order over 260 t/h the heat that may be withdrawn by DRR is
insufficient for condensation of the all 360 -540 oC fraction quantity contained
in atmospheric residue. At high rates the operation personnel is forced to keep
lower atmospheric residue evaporation degree since otherwise that HVGO
part that could not condensate because of restriction for heat withdrawing by
DRR and could not be drawn as HVGO product, will be drawn as LVGO and
may even be drawn as LDF because of considerable temperatures increase
along the column height. This explains low HVGO drawing out and why part of
it remains in the vacuum residue. The removal of hydraulic resistance along
the DRR line within the plan overhaul allows HVGO drawing out increase of
2%.

REFERENCE
1. S. W. Golden, G. R. Martin, Improve HVGO quality and cutpoint,
Hydrocarbon Processing, November, 69 74,1991.
2. N. P. Lieberman, E. T. Lieberman, Design, Installation Pitfalls Appear
In Vac Tower Retrofit, Oil&Gas Journal, Aug 26, 57-59, 1991.
3. S. W. Golden, A. W. Sloley, Simple methods solve vacuum column
problems using plant data, Oil&Gas Journal, Sept. 14, 74-79, 1992.
4. B. I. Lee, M. G. Kesler, AIChE J.,21,510, 1975.
5. K. C. Chao, J. D. Seader, A General Correlation of Vapor-Liquid
Equilibria in Hydrocarbon Mixtures, AIChE Journal, No4,7, 1961.
6. D. Dobrev, D. Stratiev, G. Argirov, T. Tzingov, A. Ivanov, Investigation
on middle distillates ultra low hydrodesulphurization at Lukoil Neftochim
Bourgas, Oxidation Communication, No3, 668-677, 2007.