CrudeDistillation

Chapter4
 Gases

Polymer- Sulfur
ization Plant
Sulfur

LPG
Sat Gas
Gas Plant

Butanes Fuel Gas

Alkyl
Feed LPG
Alkylation

Gas Polymerization
Separation & Naphtha
Stabilizer Isom-
erization
Light Naphtha
Alkylate
Aviation
Isomerate
Gasoline
Automotive
Gasoline
Reformate
Naphtha Solvents
Heavy Naphtha
Hydro-
Naphtha Reforming
treating Naphtha
Atmospheric
Distillation

Jet Fuels
Kerosene
Crude
Desalter Kerosene
Oil
Distillate Cat Solvents
AGO Hydro- Naphtha Distillate
cracking Treating &
Hydro-
Blending
Heating Oils
treating
Gas Oil Fluidized
Cat Diesel
LVGO Hydro- Catalytic
treating Cracking Distillates
Vacuum
Distillation
Fuel Oil
HVGO
Cycle Oils
Residual
Fuel Oils
DAO
Solvent
Deasphalting SDA
Coker Asphalts
Bottoms
Naphtha Naphtha

Visbreaking Heavy Distillates

Fuel Oil
Coker Bottoms
Vacuum Gas
Lube Oil Lubricant
Residuum Oil
Solvent Greases
Dewaxing
Waxes
Waxes
Coking Light Coker
Gas Oil

Coke

2
CrudeDistillationTechnologies

Provider Features
Foster Wheeler Complex of atmospheric & vacuum distilation for
Shell Global Solutions initial separation of crude oil. May include preflash
TECHNIP column.
Uhde GmbH Vaccum distillation

3
20LargestAtmosphericComplexesinU.S.

4
TypicalCrudeTowerCutPoints

Cut TBPIBP(F) TBPEP(F)

LightNaphtha
80to90 180to220
(LSRGasoline)

HeavyNaphtha 180to220 330to380

MiddleDistillate
330to380 420to520
(Kerosene)
AGO
420to520 650
(AtmGasOil)
LVGO
650 800
(LightVacGasOil)
HVGO
800 950to1100
(HeavyVacGasOil)

VacuumResid 950to1100

5
 TypicalOverallEfficiencies
Typical TypicalNo.of Drickamer&
TypicalNo.of
ColumnService Overall Theoretical Viscosity Maxwell Bradfordin
ActualTrays
Efficiency Trays Ludwig
SimpleAbsorber/Stripper 2030 2030 MolalAve
AveViscosityof
SteamSideStripper 57 2 cP
liquidonplates
Viscosityof RulesofThumbforChemicalEngineers,4thed.
Feed
ReboiledSideStripper 710 34 CarlBranan,GulfProfessionalPublishing,2005
ReboiledAbsorber 2040 4050 0.05 98
0.10 104 79
Deethanizer 2535 6575
0.15 86 70
Depropanizer 3540 7080
0.20 76 60
Debutanizer 3845 8590
0.30 63 50
AlkyDeiC4(reflux) 7590 8590 0.40 56 42
AlkyDeiC4(noreflux) 5570 5565 0.50 50 36
NaphthaSplitter 2535 7075 0.60 46 31
C2Splitter 110130 95100 0.70 43 27
C3Splitter 200250 95100 0.80 40 23
C4Splitter 7080 8590 0.90 38 19
AmineContactor 2024 45 1.00 36 17 EngineeringDataBook,12thed.
AmineStripper 2024 4555 912 1.50 30 7 GasProcessorsAssociation,2004
CrudeDistillation 3550 5060 2030 1.70 28 5
StrippingZone 57 30 2
st
FlashZone1 draw 37 30 12
st nd
1 Draw2 Draw 710 4550 35
2ndDraw3rdDraw 710 5055 35
TopDrawReflux 1012 6070 68
VacuumColumn(G.O.Operation)
Stripping 24 1
FlashZoneHGODraw 23 12
HGOSection 35 2
LGOSection 35 2
FCCMainFractionator 2435 5060 1317
QuenchZone 57 2
QuenchHGODraw 35 23
HGOLCGO 68 35
LCGOTop 710 57

RefineryProcessModeling
GeraldKaes,AthensPrintingCompany.,2000,pg.32

6
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F

ProductYieldCurves CutPoint,Overlap,&Tails

7
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F

ProductYieldCurves CutPoint,Overlap,&Tails

8
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F

ProductYieldCurves CutPoint,Overlap,&Tails

9
TypicalConfiguration
AtmosphericColumnw/oPreflash

RefiningOverview PetroleumProcesses&Products,
byFreemanSelf,EdEkholm,&KeithBowers,AIChE CDROM,2000

10
CrudeElectrostaticDesalting

DrawingbyMiltonBeychok
http://en.citizendium.org/wiki/File:Desalter_Diagram.png

BFDsfrom:
RefiningOverview PetroleumProcesses&Products,
byFreemanSelf,EdEkholm,&KeithBowers,AIChE CDROM,2000

11
DirectFiredHeater

Ref:
Usefultipsforfiredheateroptimisation
Bishop&Hamilton,PetroleumTechnologyQuarterly,Q22012

12
FractionationColumns&Trays

DrawingsbyHenryPadleckas
http://en.wikipedia.org/wiki/Fractionating_column

13
FractionationColumnsTrayTypes

http://www.termoconsult.com/empresas/acs/fractionation_trays.htm

14
Trays&Packing

http://www.ec21.com/product-details/Tower-Internals--3942077.html

15
FeedPreheatTrain&Desalter
FeedPreheatTrain
Initialheatexchangewithstreamsfrom
withinthetower
Heatrecoveryimportanttodistillation
economics!
o Firstabsorbpartoftheoverhead
condensationload
o Exchangewithoneormoreofthe
liquidsidesstreams,beginningwith
thetop(coldest)sidestream.
Finalheatinginadirectfiredheater
Heatenoughtovaporizelightportions
ofthecrudebuttemperaturekeptlow
tominimizethermalcracking
o Inlettypically550F
Outlet600to750F.
o
Heaviercrudescannotbeheated
tothehighertemperatures
Desalter
Temperaturecarefullyselected donotlet
watervaporize
Lightercrudes(>40API)@250F
Heaviercrudes(<30API)@300F
Allcrudescontainsalts(NaCl,MgCl,)
Saltpresentintheemulsifiedwater
Treatedinthefieldwithheat&chemicalsto
breakoilwateremulsions.
Saltcancausedamagetoequipment
o Scaleinheatexchangers
o HCl formationcanleadtocorrosion
o Metalscanpoisonrefinerycatalysts
Removesalts&dissolvedmetals&dirt
Oilmixedwithfreshwashwater&demulsifiers.
Separationinelectrostaticsettlingdrum
Washwaterupto10%ofcrudecharge
~90%ofthewatercanberecovered
Effluentwatertreatedforbenzene
16
AtmosphericDistillationSummary
ColumnConfiguration
Condenser
PartialcondenserifnoStabilizer
Column.
TotalcondenserifStabilizerColumn
toremovelightends.
butnoreboiler.
Feedpreheatexchangertrain
Alloftheheattodrivethecolumn Strippingsteam
comesfromthehotfeed.
o Asmuchas50%oftheincoming
crudemaybeflashed.
o Overflash
Extraamountofmaterial
vaporizedtoensurereflux
betweenflashzone&lowest
sidedraw
Typically2vol%offeed
Pumparounds
Movecoolingdowncolumn.
Liquidreturnedabovedrawtray
Sidedraws
Sidestrippers
Cleanupsideproducts
Reducehydrocarbonpartial
pressure
Condensed&removedasasecond
liquidphase.
o Conditionssetsoitdoesnt
condensewithinthecolumn can
leadtofoaming
o Mustbetreatedassourwater
17
AtmosphericDistillationSummary
WashZone
Coupletraysbetweenflashzone&
gasoildraw.
Refluxtowashresins&otherheavy
materialsthatmaycontaminatethe
products.
Condenser
Typically0.5to20psig.
Balancingact
Lowpressuresreducecompression
onoverheadsystem
Highpressuresdecreasevaporization
butincrease
flashzonetemperatures&furnace
duty;affectsyields
Pumparounds
Reducesoverheadcondenserload&
achievesmoreuniformtower
loadings
Providesliquidrefluxbelowliquid
draws
SideDraws&Strippers
Cutpointrelatedtofinalboiling
pointofdrawstream
Sidestrippersremovelight
componenttail&returntomain
column
Steamstripperstraditional
Reboiled strippersreducesteam
usage&
associatedsourwater
Trays&PressureProfile
Typically32traysintower
0.1to0.2psipertray
Condenser&accumulator
3to10psiacrosscondenser
Liquidstaticheadinaccumulator
Typically6to16psiacrossentire
column.
18
VacuumDistillation

RefiningOverview PetroleumProcesses&Products, Considerpracticalconditionsforvacuumunitmodeling

byFreemanSelf,EdEkholm,&KeithBowers,AIChE CDROM,2000 R.Yahyaabadi,HydrocarbonProcessing,March2009

19
VacuumDistillationSummary
ColumnConfiguration
Vacuumconditionstokeepoperating
temperatureslow
Largediametercolumn
Verylowdensitygases
Condenseronlyforwatervapor
Liquidrefluxfrompumparounds
Noreboiler
Strippingsteammaybeused
Neededfordeepcuts(1100F)
Commonproblem cokinginfired
heater&washzone
Firedheater highlinearvelocities
tominimizecokeformation
Washzone sufficientwashoilflow
tokeepthemiddleofthepacked
bedwet
Feed
Atmosphericresiduum
Allvaporcomesfromtheheatedfeed
Undervacuum(0.4psi)
Separatehigherboilingmaterialsatlower
temperatures
Minimizethermalcracking
Products
Mayhavemultiplegasoils
UsuallyrecombineddownstreamtoFCCU
afterhydrotreating
Vacuumresid
Blended asphalt,heavyfueloil
Furtherprocessing thermal,solvent
o Choicedependsonproducts&typesof
crude

20
VacuumDistillationSummary
DrySystem SteamEjectors&VacuumPumps
1050F+cuttemperature&nostripping Vacuummaintainedontoweroverhead
steam
Steamsystemsconsideredmorereliable
Smallertowerdiameters
Wastesteamissour&mustbetreated
Reducedsourwaterproduction
Combinationssystems Laststeam
Pressureprofile stagereplacedwithavacuumpump
Flashzone:2025mmHgabs&750to
770F.
Topoftower:10mmHgabs
DeepCutSystem
1100F+cuttemperature&stripping
steam
Steamreduceshydrocarbonpartial
pressures
Pressureprofile
Flashzone:30mmHgabs
HCpartialpressure1015mmHgabs
Topoftower:15mmHgabs
Drawingfromhttp://www.enotes.com/topic/Injector

21
 CrudeDistillationUnitCosts

Atmosphericcolumnincludes Vacuumcolumnincludes
Sidecutswithstrippers Facilitiesforsinglevacuumgasoil
Allbatterylimitsprocessfacilities 3stagevacuumjetsystemat30 40mmHg
Heatexchangetocoolproductstoambienttemperature HeatexchangetocoolVGOtoambienttemperature
Centralcontrolsystem

22
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F

ProductYieldCurves CutPoint,Overlap,&Tails

23
ProductYieldCurves CutPoint,Overlap,&Tails
Industrialdistillationcolumnsdonotprovideperfectlysharpseparations
Initialcalculationsusingcrudeoilassaysassumethatallmaterialsatacertainboilingpoint
goestooneproductoranother
Imperfectseparationsresultinlightends&heavyendstailsinadjacentproducts
Presenceoftailscomplicatethedefinitionofcutpoint
Analysis
Scaledistillationcurvestorepresentthevolumeremoved
CutpointtemperaturerepresentsthefeedsTBPcorrespondingthecumulativevolume
removed
Tailrepresentsthelightfractionsamountabovethecutpoint&theheavyfractions
amountbelowthecutpoint
Overlaprepresentstherangebetweenlightfractionsendpoint&theheavyfractionsinitial
point
Endpointmayberepresentedby99%
Initialpointmayberepresentedby1%

24
Example AtmosphericTowerProducts

25
ScaletoFractionofCrudeCharge

26
CutPoint,Overlap,&Tails

Ref:R.N.Watkins,PetroleumRefineryDistillation,2nd ed.,1979

27
CutPoints&OverlapsforExample

28
BoilingPointRangesforExample

29
Summary
Reportedrefinerycapacitytiedtochargetocrudedistillationcomplex
IncreasecapacitywithPreflashcolumn
Complexcolumnconfigurations
Noreboilers,heatfromfeedfurnaces
Reuseheatviaheatexchangebetweenfeed&internalcolumnstreams
Sidedraws,pumparounds,sidestrippers
Pumparounds required toensureliquidrefluxwithinthecolumn
Strippingsteam
3phasecondensers
Condensedwaterwillhavehydrocarbons&dissolvedacidgases
Preheattrainrecyclesheat
Products&internalstreamsheatthefeed
Feedcoolstheinternalstreams&products
Vacuumcolumntoincreasetheeffectivecutpoints
Vacuumcolumnslargediametertokeepvaporvelocitieslow
Vacuumgasoilsrecombined onlyseparatedforoperatingconsiderations
Pressuredropsareimportant,especially inthevacuumcolumn
Steamstrippingaidsinseparationwithoutcracking
Metalsareundesirable.Canremovesome metalsviadesalters.

30
Topics
CrudeStills
Historicallytheoldestrefiningprocess
Onlythefirststepincrudeoilprocessing
Purpose
Torecoverlightmaterials
Fractionateintosharplightfractions
Configuration Maybeasmanyasthreecolumnsinseries
CrudeStabilizer/Preflash Column
ReducetrafficintheAtmosphericColumn
AtmosphericColumn
VacuumColumn
Reducedpressuretokeeptemperaturesbelow650F

ProductYieldCurves CutPoint,Overlap,&Tails

31