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Inaccurate feed characterisation and process modelling errors are major contributors
to poor performance in a vacuum unit as refiners switch to heavier crude types
R
efinery grassroots or revamp
vacuum units frequently fail 1800
Assay TBP
to meet expected product 1600
yield, product quality or run length
targets. Real performance versus 1400 HVGO TBP
Temperature, ºF
1400
Temperature, ºF
1200
1000
Tower packings, 800
catalyst support 600
ASTM D2892 ASTM D5236 Extrapolated
0
0 10 20 30 40 50 60 70 80 90 100
wt%
Temperature, ºF
TBP temperature to be higher than 1000
a well-fractionated sample with
800
little overlap. In fact, when plotting
raw test measurements, there is a 600
step change between the D2892 and
400
D5236 portions of the TBP curve
HTSD
caused by the lack of fractionation 200
Assay TBP
typical of the difference in D2892 0
and D5236 test methods. The ASTM 0 10 20 30 40 50 60 70 80 90 100
D5236 temperature is higher. Weight%
The authors have been using TBP
curves generated with high-temper- Figure 3 TBP vs HTSD comparison for 20 °API heavy crude
ature simulated distillations (HTSD)
since 1994 to characterise crude oils equipment simulations must be
and diesel and heavier products. Vapour modified to take into account non-
The HTSD results are input to the idealities such as phase separation
process simulation directly as TBP and critical velocity constraints.
Liquid
by weight. More than 50 vacuum Transfer lines usually have long
units have been field tested to horizontal runs with line diameters
confirm the validity of using HTSD of 36-84in or larger prior to entering
(ASTM D7169) as a TBP curve to Figure 4 Transfer line stratified flow the column flash zone. These large-
model crude and vacuum unit diameter horizontal runs cause the
operation. The field work included with ASTM D7169 has proven liquid and vapour phases to sepa-
extensive use of the HTSD to char- much better at predicting VGO rate. Calculated phase regimes are
acterise the whole crude and to yields and matching actual vacuum either stratified or stratified wavy
characterise all the product streams unit operating conditions than (see Figure 4). In the stratified flow
heavier than diesel. These field test conventional TBP crude assays or regime, liquid and vapour have poor
runs also included data consistency other tests such as D1160 or D2887 mass and energy exchange across
checks, such as synthesising the simulated distillation that has a the interface. Hence, liquid and
whole crude from the corrected limit of 1000°F (538°C). Since vapour contacting is poor. Thus,
material balance and individual ASTM D7169 is a chromatograph phase separation causes vapour to
streams HTSD distillations and test it does not have the same flow through the top of the horizon-
specific gravities. The synthesised inherent problem of limiting pot tal portion of the transfer line. This
TBP distillation and whole crude temperatures because of oil crack- vapour becomes superheated due to
HTSD TBP distillation were ing as physical distillation tests pressure reduction as the vapour
compared to ensure data consisten- and can characterise the oil up to a approaches the column flash zone.
cies prior to input to the process temperature of 1364°F (740°C). Vapour and liquid entering the flash
model. Prior to the HTSD method D7169 was specifically designed to zone of a vacuum column are not in
being recently accepted by the characterise heavy oils such as phase equilibrium.
ASTM, HTSDs were used by only a crude oil and resids. This test Calculating the transfer line pres-
few refiners to characterise crude expands the capability of the D2887 sure profile requires the use of a
oil. test, which has an EP limit of single model linking together the
ASTM D7169 high-temperature 1000°F (538°C). Field measure- vacuum column flash zone, transfer
simulation distillations, from a prop- ments and process modelling show line and vacuum heater. The model
erly calibrated and well- that ASTM D7169 produces a more must identify the location and pres-
maintained machine, produce a TBP accurate TBP for the 800°F (427°C) sure in the transfer line where
curve with lower temperatures in plus portion of the curve than liquid and vapour separate and are
the 700°F (371°C) plus portion of the ASTM D5236. no longer in equilibrium. The
curve compared to a TBP curve hydraulic tool used to calculate the
generated with ASTM D2892 and Transfer line non-idealities transfer line pressure profile must
D5236. This difference in TBP curves After feed is characterised accu- properly calculate critical two-phase
generated by HTSD versus conven- rately, the process simulation must mass velocities and adjust the pres-
tional methods is generally more be structured to ensure it correctly sure so that critical velocity is not
pronounced with heavy, low-API represents the actual transfer line exceeded. Few hydraulic models
gravity crude oil (see Figure 3). operation. The transfer line does can accurately make the critical
Characterising vacuum unit feed not operate ideally. Process and mass velocity calculation, hence
EPSILON 3 RANGE
Elemental analysis by XRF
Compliant crude oil control
ASTM D4294-10
ASTM D6052-08
ISO 8754:2003
ISO 20847:2004
EPA Method 9075