CrudeOilDistillation

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

Updated:July5,2017
2
Copyright2017JohnJechura(jjechura@mines.edu)
Atmospheric&VacuumDistillationinU.S.

EIA,Jan.1,2017database,publishedJune2017
http://www.eia.gov/petroleum/refinerycapacity/

Updated:July5,2017
3
Copyright2017JohnJechura(jjechura@mines.edu)
Topics

CrudeStills Configuration Maybeas

Historicallytheoldestrefining manyasthreecolumnsin
process series
Onlythefirststepincrudeoil CrudeStabilizer/Preflash Column
processing ReducetrafficintheAtmospheric
Column
Purpose
AtmosphericColumn
Torecoverlightmaterials
VacuumColumn
Fractionateintosharplight
Reducedpressuretokeepblow
fractions
crackingtemperatures

ProductYieldCurves Cut
Point,Overlap,&Tails

Updated:July5,2017
4
Copyright2017JohnJechura(jjechura@mines.edu)
Configuration:
Atmospheric
Vacuum
Preflash

Updated:July5,2017
Copyright2017JohnJechura(jjechura@mines.edu)
Atmospheric&VacuumTowerComplex

Updated:July5,2017
6
Copyright2017JohnJechura(jjechura@mines.edu)
Atmospheric&VacuumTowerComplex

Modifieddrawingfrom:
Revampingcrudeandvacuumunitstoprocessbitumen,Sutikno,PTQ ,Q22015

Updated:July5,2017
7
Copyright2017JohnJechura(jjechura@mines.edu)
AtmosphericColumnwithPreflash

ModificationoffigureinIncreasingdistillateproductionatleastcapitalcost,Musumeci,Stupin,Olson,&Wendler,PTQ,Q22015

Updated:July5,2017
8
Copyright2017JohnJechura(jjechura@mines.edu)
Preflash Options TightOilExamplewithnoAGO

Optimising preash forlighttightoilprocessing,Lee,PTQ,Q32015

Updated:July5,2017
9
Copyright2017JohnJechura(jjechura@mines.edu)
FeedPreheatTrain&Desalter
FeedPreheatTrain
Initialheatexchangewithstreamsfromwithin
thetower
Heatrecoveryimportanttodistillationeconomics!
o Firstabsorbpartoftheoverhead
condensationload
o Exchangewithoneormoreoftheliquidsides
streams,beginningwiththetop(coldest)side
stream
Requireflexibility
o Changesincrudeslate
o Temperatureatdesalter
o Limitsontwophaseflowthroughnetwork
Finalheatinginadirectfiredheater
Heatenoughtovaporizelightportionsofthe
crudebuttemperaturekeptlowtominimize
thermalcracking
o Inlettypically550oF,outlet600to750oF.
o Heaviercrudescannotbeheatedtothe
highertemperatures
Updated:July5,2017
Copyright2017JohnJechura(jjechura@mines.edu)
Desalter
Temperaturecarefullyselected donotlet
watervaporize
Lightercrudes(>40oAPI)@250oF
Heaviercrudes(<30oAPI)@300oF
Allcrudescontainsalts(NaCl,MgCl,)
Saltpresentintheemulsifiedwater
Treatedinthefieldwithheat&chemicalstobreak
oilwateremulsions.
Saltcancausedamagetoequipment
o Scaleinheatexchangers
o HCl formationcanleadtocorrosion
o Metalscanpoisonrefinerycatalysts
Removesalts&dissolvedmetals&dirt
Oilmixedwithfreshwashwater&demulsifiers.
Separationinelectrostaticsettlingdrum
Washwaterupto10%ofcrudecharge
~90%ofthewatercanberecovered
Effluentwatertreatedforbenzene
10
CrudeElectrostaticDesalting

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

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

Updated:July5,2017
11
Copyright2017JohnJechura(jjechura@mines.edu)
CrudeDesalting

Breakingthecrudeoil/wateremulsionimportanttominimizedownstream
problems
Performanceofadditives
maybecrudespecific

Picturefrom:
Removingcontaminantsfromcrudeoil
McDaniels &Olowu,PTQ Q1,2016

Updated:July5,2017
12
Copyright2017JohnJechura(jjechura@mines.edu)
DirectFiredHeater

Ref:Usefultipsforfiredheateroptimisation
Bishop&Hamilton,PetroleumTechnologyQuarterly,Q22012

Updated:July5,2017
13
Copyright2017JohnJechura(jjechura@mines.edu)
AtmosphericDistillationSummary

Condenser
PartialcondenserifnoStabilizerColumn.
TotalcondenserifStabilizerColumnto
removelightends.
butnoreboiler.
Feedpreheatexchangertrain
Alloftheheattodrivethecolumncomes
fromthehotfeed.
Asmuchas50%oftheincomingcrudemay
beflashed.
Overflash
o Extraamountofmaterialvaporizedto
ensurerefluxbetweenflashzone&
lowestsidedraw
o Typically2vol%offeed
Pumparounds
Movecoolingdowncolumn.
Liquidreturnedabovedrawtray
Sidedraws
Sidestrippers
Cleanupsideproducts
Strippingsteam
Reducehydrocarbonpartialpressure
Condensed&removedasasecondliquid
phase.
Conditionssetsoitdoesntcondense
withinthecolumn canleadtofoaming
Mustbetreatedassourwater

Updated:July5,2017
14
Copyright2017JohnJechura(jjechura@mines.edu)
AtmosphericDistillationSummary

WashZone SideDraws&Strippers
Coupletraysbetweenflashzone&gasoil Sidestrippersremovelightcomponenttail&
draw. returntomaincolumn
Refluxtowashresins&otherheavymaterials Steamstripperstraditional
thatmaycontaminatetheproducts. Reboiled strippersreduceassociatedsourwater&
mayreducesteamusage
Condenser
Typically0.5to20psig. Trays&PressureProfile
Balancingact Typically32traysintower
Lowpressuresreducecompressiononoverhead 0.1psipertrayfordesign&targetfor
system operation
Highpressuresdecreasevaporizationbutincrease Mayfindashighas0.2psipertray,butprobably
flashzonetemperatures&furnaceduty;affects flooding!
yields Condenser&accumulator
Pumparounds 3to10psiacrosscondenser
Liquidstaticheadinaccumulator
Reducesoverheadcondenserload&achieves
moreuniformtowerloadings Typically6to16psiacrossentirecolumn.
Providesliquidrefluxbelowliquiddraws

Updated:July5,2017
15
Copyright2017JohnJechura(jjechura@mines.edu)
VacuumDistillation

RefiningOverview PetroleumProcesses&Products, Considerpracticalconditionsforvacuumunitmodeling

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

Updated:July5,2017
16
Copyright2017JohnJechura(jjechura@mines.edu)
VacuumDistillation Traysvs.Packing

Packingusedinvacuumtowers
insteadoftrays
Lowerpressuredropsacross
thetower vaporslidesby
liquidinsteadofpushing
throughthelayeronthetray
Packingalsohelpstoreduce
foamingproblems

Foaminginfractionationcolumns
M.Pilling,PTQ,Q42015

Updated:July5,2017
17
Copyright2017JohnJechura(jjechura@mines.edu)
VacuumDistillationSummary

ColumnConfiguration Feed
Vacuumconditionstokeepoperating Atmosphericresiduum
temperatureslow Allvaporcomesfromtheheatedfeed
Largediametercolumn Undervacuum(0.4psi)
Verylowdensitygases Separatehigherboilingmaterialsat
Condenseronlyforwatervapor lowertemperatures
Liquidrefluxfrompumparounds Minimizethermalcracking
Noreboiler Products
Strippingsteammaybeused
Mayhavemultiplegasoils
Neededfordeepcuts(1100oF)
UsuallyrecombineddownstreamtoFCCU
Commonproblem cokinginfired afterhydrotreating
heater&washzone Vacuumresid
Firedheater highlinearvelocitiesto Blended asphalt,heavyfueloil
minimizecokeformation
Furtherprocessing thermal,solvent
Washzone sufficientwashoilflowto
o Dependsonproducts&typesofcrude
keepthemiddleofthepackedbedwet

Updated:July5,2017
18
Copyright2017JohnJechura(jjechura@mines.edu)
VacuumDistillationSummary

DrySystem SteamEjectors&VacuumPumps
1050oF+cuttemperature&nostrippingsteam Vacuummaintainedontoweroverhead
Smallertowerdiameters Steamsystemsconsideredmorereliable
Reducedsourwaterproduction Wastesteamissour&mustbetreated
Pressureprofile Combinationssystems Laststeamstage
Flashzone:2025mmHgabs&750to770oF. replacedwithavacuumpump
Topoftower:10mmHgabs

DeepCutSystem
1100oF+cuttemperature&strippingsteam
Steamreduceshydrocarbonpartialpressures
Pressureprofile
Flashzone:30mmHgabs
HCpartialpressure1015mmHgabs
Topoftower:15mmHgabs

Drawingfromhttp://www.enotes.com/topic/Injector

Updated:July5,2017
19
Copyright2017JohnJechura(jjechura@mines.edu)
ExampleCrudePreheatTrains

Ref:ImproveenergyefficiencyviaHeatIntegration
Rossiter,ChemicalEngineeringProgress,December2010

Updated:July5,2017
20
Copyright2017JohnJechura(jjechura@mines.edu)
CompositeCurveforPreheatTrain

Compareamountofheat
available&atwhat
temperatures
Goalistoshiftthehot&
coldcompositecurvesas
closeaspossible
Pinchtechnology
Thiswillreducethe
amountofexcessheat
tobethrownawayto
theenvironment
Thiswillalsoreducethe Ref:Energysavingsinpreheattrainswithpreash
Bealing,GomezPrado,&Sheldon,PTQ,Q22016
amountoffreshheat
addedtothesystem

Updated:July5,2017
21
Copyright2017JohnJechura(jjechura@mines.edu)
Example ExistingPreheatTrain

Ref:Energysavingsinpreheattrainswithpreash
Bealing,GomezPrado,&Sheldon,PTQ,Q22016

Updated:July5,2017
22
Copyright2017JohnJechura(jjechura@mines.edu)
Example ImprovedPreheatTrain

Ref:Energysavingsinpreheattrainswithpreash
Bealing,GomezPrado,&Sheldon,PTQ,Q22016

Updated:July5,2017
23
Copyright2017JohnJechura(jjechura@mines.edu)
ProductYieldCurves

Updated:July5,2017
Copyright2017JohnJechura(jjechura@mines.edu)
TypicalCutPointDefinitions

Cut TBPIBP(oF) TBPEP(oF)

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

Updated:July5,2017
25
Copyright2017JohnJechura(jjechura@mines.edu)
ProductYieldCurves CutPoint,Overlap,&Tails

Industrialdistillationcolumnsdonotprovide
perfectlysharpseparations
Initialcalculationsusingcrudeoilassays
assumethatallmaterialsatacertainboiling
pointgoestooneproductoranother
Imperfectseparationsresultinlightends&
heavyendstailsinadjacentproducts
Presenceoftailscomplicatethedefinitionof
cutpoint

Analysis
Scaledistillationcurvestorepresentthe
volumeremoved
Cutpointtemperaturerepresentsthefeeds
TBPcorrespondingthecumulativevolume
removed
Tailrepresentsthelightfractionsamount Ref:R.N.Watkins,PetroleumRefineryDistillation,2nd ed.,1979

abovethecutpoint&theheavyfractions
amountbelowthecutpoint

Updated:July5,2017
26
Copyright2017JohnJechura(jjechura@mines.edu)
Example AtmosphericTowerProducts

Updated:July5,2017
27
Copyright2017JohnJechura(jjechura@mines.edu)
Example AtmosphericTowerProducts

Updated:July5,2017
28
Copyright2017JohnJechura(jjechura@mines.edu)
Example ScaletoFractionofCrudeCharge

Updated:July5,2017
29
Copyright2017JohnJechura(jjechura@mines.edu)
ScaletoFractionofCrudeCharge

Updated:July5,2017
30
Copyright2017JohnJechura(jjechura@mines.edu)
CutPoints&OverlapsforExample

Updated:July5,2017
31
Copyright2017JohnJechura(jjechura@mines.edu)
BoilingPointRangesforExample

Updated:July5,2017
32
Copyright2017JohnJechura(jjechura@mines.edu)
Summary

Updated:July5,2017
Copyright2017JohnJechura(jjechura@mines.edu) 33
Summary

Reportedrefinerycapacitytiedtocharge
tocrudedistillationcomplex
IncreasecapacitywithPreflashcolumn
Complexcolumnconfigurations
Noreboilers,heatfromfeedfurnaces
Reuseheatviaheatexchangebetween
feed&internalcolumnstreams
Sidedraws,pumparounds,sidestrippers
Pumparounds ensureproperliquidreflux
withinthecolumn
Strippingsteam
3phasecondensers
Condensedwaterwillhavehydrocarbons&
dissolvedacidgases
Preheattrainrecyclesheat
Products&internalstreamsheatthefeed
Feedcoolstheinternalstreams&products
Vacuumcolumntoincreasetheeffective
cutpoints
Vacuumcolumnslargediametertokeep
vaporvelocitieslow
Vacuumgasoilsrecombined only
separatedforoperatingconsiderations
Pressuredropsareimportant,especially
inthevacuumcolumn
Steamstrippingaidsinseparation
withoutcracking
Metalsareundesirable.Canremove
somemetalsviadesalters.

Updated:July5,2017
34
Copyright2017JohnJechura(jjechura@mines.edu)
SupplementalSlides

Updated:July5,2017
Copyright2017JohnJechura(jjechura@mines.edu)
CrudeDistillationUnitCosts

Atmosphericcolumnincludes
Sidecutswithstrippers
Allbatterylimitsprocess
facilities
Heatexchangetocool
productstoambient
temperature
Centralcontrolsystem

PetroleumRefiningTechnology&Economics,5th ed.
Gary,Handwerk,&Kaiser
CRCPress,2007

Updated:July5,2017
36
Copyright2017JohnJechura(jjechura@mines.edu)
CrudeDistillationUnitCosts

Vacuumcolumnincludes
Facilitiesforsinglevacuumgas
oil
3stagevacuumjetsystemat
30 40mmHg
HeatexchangetocoolVGOto
ambienttemperature

PetroleumRefiningTechnology&Economics,5th ed.
Gary,Handwerk,&Kaiser
CRCPress,2007

Updated:July5,2017
37
Copyright2017JohnJechura(jjechura@mines.edu)
CrudeDistillationTechnologies
Provider Features

FosterWheeler

ShellGlobalSolutions Complexofatmospheric&vacuumdistillationforinitialseparationof
crudeoil.Mayincludepreflashcolumn.
TECHNIP

Uhde GmbH Vacuumdistillation

Updated:July5,2017
38
Copyright2017JohnJechura(jjechura@mines.edu)
TypicalDistillationColumn
Topofcolumn condensertoremoveheat
Providesliquidrefluxthroughtopofcolumn
Partialcondensermayhavevaporbutnoliquiddistillateproduct
Coldesttemperature coolingmediamustbeevencolder
Lowestpressure
Topsectionstripsheavycomponentsfromtherisingvapors

Feed
Vapor,liquid,orintermediatequality
Introducedinvaporspacebetweentrays

Internals
Traystocontactrisingvaporswithfallingliquids
Pressuredropacrosstrays overcomestaticheadofliquidontray,

Bottomofcolumn reboilertoaddheat
Providesvaportrafficinbottomofcolumn
Highesttemperature heatingmediamustbeevenhotter
Highestpressure
Bottomsectionstripslightcomponentsfromthefallingliquid

DrawingbyHenryPadleckas &modifed byMiltonBeychok:

http://en.wikipedia.org/wiki/File:Continuous_Binary_Fractional_Distillation.PNG

Updated:July5,2017
39
Copyright2017JohnJechura(jjechura@mines.edu)
FractionationColumns&Trays

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

Updated:July5,2017
40
Copyright2017JohnJechura(jjechura@mines.edu)
FractionationTrayTypes

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

Updated:July5,2017
41
Copyright2017JohnJechura(jjechura@mines.edu)
Trays&Packing

http://www.ec21.com/productdetails/TowerInternals3942077.html

Updated:July5,2017
42
Copyright2017JohnJechura(jjechura@mines.edu)
 TypicalOverallEfficiencies
Typical TypicalNo.of Drickamer&
TypicalNo.of
ColumnService Overall Theoretical Viscosity Maxwell Bradfordin RulesofThumbforChemicalEngineers,4thed.
ActualTrays
Efficiency Trays Ludwig CarlBranan,GulfProfessionalPublishing,2005
SimpleAbsorber/Stripper 2030 2030 MolalAve
AveViscosityof
SteamSideStripper 57 2 cP Viscosityof
liquidonplates
ReboiledSideStripper 710 34 Feed
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 EngineeringDataBook,12thed.
AmineContactor 2024 45 1.00 36 17 GasProcessorsAssociation,2004
AmineStripper 2024 4555 912 1.50 30 7
CrudeDistillation 3550 5060 2030 1.70 28 5
StrippingZone 57 30 2
FlashZone1stdraw 37 30 12
1stDraw2ndDraw 710 4550 35
nd rd
2 Draw3 Draw 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
RefineryProcessModeling
HGOLCGO 68 35
GeraldKaes,AthensPrintingCompany,2000,pg.32
LCGOTop 710 57

Updated:July5,2017
43
Copyright2017JohnJechura(jjechura@mines.edu)
VacuumTowerTransferLines

Masstransfereffectsinthetransferlinecomplicatetheeffectsatthebottom
oftheVacuumTower

Mythofhighcutpoint indryvacuumunits,S.Golden,T.Barletta,&S.White,PTQ,Q22014

Updated:July5,2017
44
Copyright2017JohnJechura(jjechura@mines.edu)