Optimising preflash for light tight oil
processing
For a crude unit handling light tight oil feedstock, a semi-preflash column can
deliver significant advantages in energy saving, capacity gain and revamp
Soun Ho Lee GTC Technology
T
he basic function of a crude distillation
unit is to provide the initial separation of
crude oil feed into the desired fractions to
feed downstream units. Now, newly introduced
light tight oil feed processing may limit existing
crude distillation unit capacity. The addition of a
feed preflashing option may improve capacity
and/or energy efficiency for light tight oil
processing.
Two preflash options which are commonly
implemented for crude distillation units are a
preflash drum and a preflash column. Each has
strengths and weaknesses.
This article discusses an improved semi-pre-
flash column design that optimises the
traditional preflash drum and preflash column
options. A case study includes revamp econom-
ics for the arrangement.
Light tight oil
Light tight oil describes petroleum fractions
produced from low permeability formations such
as shale or tight sandstone.1 Improved hydraulic
fracturing technology with directional drilling
has increased light tight oil production in North
America, where processing light tight oil can be
a game-changer for refiners. Light tight oil slates
produced in North America have typically light
and sweet natures. However, its characteristics
vary significantly.
Adapting light tight oil as a new feedstock may
require a significant retrofit in a refinery layout
which was originally configured with traditional
crude oil feedstock. Capacity imbalance in down-
stream conversion units and insufficient overhead
train processing capacity are already well recog-
nised issues with refiners. This imbalance issue is
www.digitalrefining.com/article/1001134
more exaggerated in refineries which are designed
with heavy crude slates and a high conversion
ratio. These mismatches between new light tight
oil feedstock and current refinery configurations
are initiated in the crude distillation unit which
provides initial separation of feedstock for entire
downstream refinery processing units.
There has been extensive research to try and
identify ‘magic juice’, blending ratios of light
tight oil and traditional heavy crude oil slates to
fit existing refinery layouts. Meanwhile, it has
been discovered that blending between light
tight oil and traditional heavy crude oil can
cause asphaltene destabilisation due to the
paraffinic nature of light tight oil.2 This destabili-
sation can cause unexpected fouling issues.
This article focuses on debottlenecking and
enhancing crude distillation unit capacity and
energy consumption using various preflash
options. Other retrofit strategies for light tight oil
processing are not discussed.
Crude distillation unit preflashing
Implementing crude feed preflashing has been
one of the common options to debottleneck
crude distillation units. Switching feedstock to a
lighter crude slate can cause undesired feed
vaporisation at the feed furnace pass control
valve and limit capacities in the crude atmos-
pheric column and overhead condensing circuits.
Adding a preflash drum or column can reduce
the charge rate to the feed furnace. In addition,
transfer line vibration due to capacity limitation
can be resolved through adapting feed
preflashing.
Two preflash options that are commonly
implemented in a crude distillation unit are the
PTQ Q3 2015 1
 preflash drum and preflash column. Another
preflash option, GT-IPS is a semi-preflash
column design that may be optimised between
traditional preflash drum and preflash column
options.
Preflash drum option
The preflash drum is the simplest option for
crude preflashing. Complex modification of
equipment and instrumentation is not required
for this option compared to the preflash column,
making it the most economical option with
regards to capital expenditure (Capex).
One weakness of the preflash drum is that this
option does not have the capability to control
preflashed vapour quality in foaming prone
service. Therefore, the preflash drum is prone to
have challenges with entrainment. Entrainment
can be accelerated in a foaming environment.
Improper location of preflashed vapour feeding
and/or undesirably entrained heavy oil boiling
range materials can contaminate rundown prod-
uct qualities.
Introducing preflashed vapour to a flash zone
is the safest configuration to prevent product
contamination. However, lower temperature of
preflash vapour containing entrainment can
quench the main feed vapour and can reduce
feed lifting.3
Although recent technology such as Vortex
Tube Cluster (VTC) helps to discourage the
chances of foaming, a preflash drum should be
sized large enough to prevent foaming. 4
Preflash column option
The preflash column option produces preflashed
products. Although it requires higher Capex than
a preflash drum, this option is especially effec-
tive when the column top section and overhead
condenser capacities are limited.
A rectifier is a common configuration for a
preflash column. Crude feed is introduced at the
preflash column bottom and preflashed vapour
is rectified by reflux liquid. Overhead vapour can
be condensed through a crude atmospheric
column overhead condenser if the condenser has
ample capacity. An exclusive preflash column
overhead condenser needs to be installed if a
crude atmospheric column overhead condenser
is limited. Some deluxe preflash columns have a
bottom stripping section to control the front end
of the crude atmospheric column top product.
2 PTQ Q3 2015
High Capex is a major drawback of a preflash
column. Moreover, a large plot space is generally
needed to add the equipment.
GT-IPS semi-preflash column option
GT-IPS (Improved Preflash System) has a
‘semi-preflash column’ arrangement compared to
the traditional preflash column. Like the preflash
drum option, the semi-preflash column does not
produce any independent product. This column
functions as a preflash column but the additional
overhead condenser and receiver are not
equipped for the preflash column.
Maintaining a desired preflash vapour quality
is one of the most critical issues. To wash out
the entrained components, some liquid is with-
drawn from the crude atmospheric column and
routed to the semi-preflash column as reflux.
Then controlled preflashed vapour is safely fed
to the middle of the atmospheric column.
One of the benefits of the GT-IPS concept is its
flexibility. The preflash column reflux source and
the preflashed vapour routing can be varied
depending on process conditions, including
crude slate and target performance, and refinery
layout.
To compare the three preflash options in more
detail, the revamping of a crude distillation unit
for light tight oil processing is included as a case
study.
Case study: unit description and study basis
Eagle Ford, a common light tight oil in the US,
was selected as the feedstock. Eagle Ford tight
oil has light and sweet characteristics with
approximately 0.1 wt% sulphur content and is in
a highly variable slate. Published gravity varies
between 40° and 62° API.
The case study’s crude distillation unit receives
100% 60.7° API Eagle Ford; 50 000 b/d of light
tight oils are charged and heated through
pre-heat trains and furnaces, and then intro-
duced into the crude atmospheric column. This
column separates the charged oils to intermedi-
ate products: unstabilised naphtha, kerosene,
diesel and reduced crude (R/C).
The crude atmospheric column equips three
pumparound circuits: top pumparound, kero-
sene and diesel pumparound circuits. A top
reflux stream which is recycled from the unstabi-
lised naphtha (overhead distillate) is combined
with the top pumparound stream before return-
www.digitalrefining.com/article/1001134
ing to the crude atmospheric
Case study crude distillation unit
column. The amount of the top
reflux stream can be adjusted
Case Base
relative to the unstabilised
Parameter Feed
naphtha boiling range of the Crude slate 100% Eagle Ford
processed crudes. The wash Crude charge, BPD 50 000
section is equipped with struc- °API 60.7
-300°F norminal cut fraction, LV% 58.2
tured packing while the rest of
300-450°F norminal cut fraction, LV% 14.7
the sections consist of trays. 450-650°F norminal cut fraction, LV% 13.4
Two side strippers which belong + 650°F norminal cut fraction, LV% 13.7
to the crude atmospheric Operating parameter
Furnace coil outlet temperature, °F 674
column are operated with strip-
Crude atmospheric column top pressure, psi, g 24
ping steam. Figure 1 illustrates Unit bottom stripping steam rate, Lb/BBL 7.9
the base case configuration of Unit kerosene stripping steam rate, Lb/BBL 12.0
the crude distillation unit. Unit diesel stripping steam rate, Lb/BBL 6.2
Fractionation performance
To evaluate the optimum
Naphtha D86 (95 LV%), °F 291
preflashing option, three case Kerosene flash point, °F 100.8
studies are conducted and Kerosene freezing point, °F - 58.0
compared to the base case. Light Diesel D86 (90 LV%), °F 649
Reduced crude D86 (5 LV%), °F 617
tight oil charge rate, quality, and
product yields are maintained
among the four cases.
Since preflash equipment Table 1
pressure is floated by crude
atmospheric column operating
pressure, in each case the
preflash system pressure is set
through a pressure drop predic-
Offgas
tion between the preflash and
hydraulic end point in the crude
Top P/A
atmospheric column.5 In addi-
Unstabilised
tion, no extra capacities are naphtha
available in the crude atmos- to LER
pheric column overhead
condenser and feed furnace. The Kerosene
base case’s crude atmospheric P/A
column overhead condenser and
absorbed feed furnace duties are
defined as maximum. Since Steam

preflashing options let down Kerosene

Diesel P/A
preheat train pressure, an addi-
tional booster pump is required
to transport the remaining feed
to the feed furnace and crude Desalted Steam
crude
atmospheric column. Additional Diesel
feed booster pump discharge
pressure is set to prevent vapor- Steam
isation through the entire Crude
atmospheric Reduced
preheat train and the feed column crude
furnace pass control valve. Table
1 depicts the process conditions
of the crude distillation unit. Figure 1 Crude distillation unit: base configuration

www.digitalrefining.com/article/1001134 PTQ Q3 2015 3

 Case study A: preflash drum
Case study A illustrates how
Offgas
preflash drum implementation
is conducted. A modified config-
Top P/A
uration is illustrated in Figure 2.
Unstabilised
naphtha Considering that potential
to LER rundown product contamination
can occur by entrainment,
Kerosene preflashed vapour is introduced
P/A to the crude atmospheric
column flash zone. The preflash
drum operating pressure is
Steam determined per the crude
Kerosene atmospheric column flash sone
Diesel P/A
Desalted
pressure and the pressure drop
crude through the preflash vapour line
circuit.
Preflash
Steam Preflashing requires a higher
drum
Diesel furnace coil outlet temperature
to maintain the current total
Steam distillate yields. Higher internal
Crude reflux ratios for fractionation
atmospheric Reduced
column crude sections are also required to
achieve target distillate product
Figure 2 Crude distillation unit: case study A preflash drum configuration yields and qualities. The preflash
drum operating temperature is
selected based on reusing atmos-
Offgas pheric column overhead
condenser duty. A higher
Offgas
preflash temperature can
increase the amount of preflash-
Top P/A
ing but it requires a higher
Unstabilised
naphtha
furnace coil outlet temperature
to LER and a simulated overhead
condenser duty that exceeds the
current value. Therefore, the
Kerosene
P/A position of the preflash drum in
this case study is determined by
Preflash overhead condenser duty
column Steam limitation.
Kerosene
Diesel P/A Case study B: preflash column
Desalted
crude Case study B gives an overview
of implementing a preflash
Steam column. The preflash column is
Diesel configured as a rectifier in this
case study, and is equipped with
Steam an independent overhead
Crude receiver and overhead
atmospheric Reduced condenser. The preflash column
column crude
is positioned between the
Figure 3 Crude distillation unit: case study B preflash column configuration preheat train and furnace to

4 PTQ Q3 2015 www.digitalrefining.com/article/1001134

maximise the amount of
preflashing.
The preflash column overhead
vapour streams are split into two
streams. The amount of
preflashed vapour stream
charged to the crude atmospheric
column overhead condenser is
quantified by the crude atmos-
pheric column overhead
condenser limitation. The Semi-
remaining preflashed vapour preflash
column
stream is condensed through an
additional preflash column over-
Desalted
head condenser. The reflux rate crude
for the preflash column is driven
from the new preflash condenser
and overhead receiver. Produced
preflash overhead liquid distillate
is combined with crude atmos-
pheric overhead distillate and
transported to a naphtha stabi-
liser for further separation. A
modified configuration for this
case is illustrated in Figure 3. Figure 4 Crude distillation unit: case study C GT-IPS configuration
Case study C: GT-IPS semi-preflash column
option
Case study C describes implementation of the
GT-IPS semi-preflash column. A modified config-
uration for this case is illustrated in Figure 4.
Prior to being sent to the crude atmospheric
column, produced preflashed vapour is rectified
by the reflux stream recycled from the crude
atmospheric column. The reflux source for the
semi-preflash column is the crude atmospheric
column overhead distillate in this particular case
study. This reflux routing configuration is deter-
mined based on the amount of preflashed vapour
and quality. Case study results show that the
rectified preflashed vapour is suitable for mixing
with the unstabilised naphtha stream.
Nevertheless, preflashed vapour is introduced
underneath the naphtha/kerosene fractionation
section, taking floating semi-preflash column
pressure into consideration.
The semi-preflash column operating pressure
is determined by the crude atmospheric column
operating pressure and the preflash vapour line
pressure drop. The column operating tempera-
ture is selected based on reusing atmospheric
column overhead condenser duty. A higher
www.digitalrefining.com/article/1001134
Offgas
Top P/A
Unstabilised
naphtha
to LER
Kerosene
P/A
Steam
Kerosene
Diesel P/A
Steam
Diesel
Steam
Crude
atmospheric Reduced
column crude
preflash temperature can increase the amount of
preflashing but it requires a higher furnace coil
outlet temperature and simulated overhead
condenser duty that exceeds the current value.
Like the case study A preflash drum, the
semi-preflash column is also located in the
middle of the preheat train. However, a higher
preflash percentage through the semi-preflash
column allows the semi-preflash column to be
located in a higher temperature zone of the
preheat train, compared to case study A.
Case study results
The three case study results are summarised and
compared with base case conditions in Table 2.
Since feed preflashing results in a lower
preflash drum or column bottom temperature,
the temperature drop through each preflash
option is quantified. The crude atmospheric
column pumparound balance for each case is
adjusted to maintain base case product yields
and product qualities. These temperature drop
values through preflashing and shifted pumpa-
round balances are reflected in preheat train
temperature profiles and furnace inlet tempera-
ture prediction. Identification of the cracking
PTQ Q3 2015 5
 The case study A preflash
100

Distillation equipment capacity,

Base drum does not provide signifi-
90 Preflash drum cant furnace duty savings.
Preflash column
80 Moreover, the calculated capaci-
GT-IPS
70
ties of this preflash drum case
are similar to those in the base
%

60
case. Higher internal reflux
50 ratios for fractionation sections
40 erode gain in distillation capac-
30
ity. A lower preflash drum
temperature requires the higher
20
discharge pressure of a new

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compared to the other two
fra er
fra aph

D
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K
Ke
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cases: the preflash column and

Figure 5 Crude atmospheric column distillation equipment capacity the semi-preflash column
options.
Case study result summary Table 2 shows that the case B
preflash column option achieves
the highest preflashing percent-
Case Base Preflash drum Preflash column GT-IPS age among three cases.
Parameter
Preflash condition
Meanwhile, the highest tempera-
Preflash inlet temperature1, °F - 282 395 353 ture drop is observed in the case
Preflash vapour/product %, vol% of feed 16% 41% 32% B preflash option, resulting in
Yield structure
Crude charge, BPD Base ∆0% ∆0% ∆0% the lowest furnace inlet tempera-
Unstabilised naphtha, BPD Base ∆0% ∆0% ∆0% ture. Nevertheless, the lowest net
Kerosene, BPD Base ∆0% ∆0% ∆0%
Atmospheric gas oil, BPD Base ∆0% ∆0% ∆0%
amount of furnace charge
Reduced crude (R/C), BPD Base ∆0% ∆0% ∆0% provides the minimum absorbed
Operating parameter furnace duty. The preflash
Furnace inlet temperature, °F Base - ∆14°F - ∆68°F - ∆38°F
Furnace coil outlet temperature, °F Base + ∆31°F + ∆45°F + ∆42°F column also provides the highest
Absorbed furnace duty, MMBTU/hr 100% 97% 82% 87% distillation equipment capacity
Preflash condenser duty, MMBTU/hr 100% - Additional -
Overhead condenser duty, MMBTU/hr 100% 100% 100% 100%
gain.
Top pumparound duty, MMBTU/hr 100% 100% 45% 71% In case C, the GT-IPS
Kerosene pumparound duty, MMBTU/hr 100% 86% 100% 77% semi-preflash column option
Diesel pumparound duty, MMBTU/hr 100% 76% 100% 91%
Fractionation performance shows lower furnace duty saving
Kerosene 5% -naphtha 95% , °F 2
Base ∆0°F + ∆2°F ∆0°F and distillation equipment
Diesel 5% - kerosene 95%2, °F Base ∆0°F ∆0°F ∆0°F
Reduced crude 5% -Diesel 95%2, °F Base ∆0°F ∆0°F ∆0°F capacity gain compared to the
Kerosene flash point, °F Base ∆0°F + ∆1°F ∆0°F preflash column option.
1. Prior to preflashing 2. ASTM D86 (LV%)
However, furnace duty saving
and crude atmospheric column
capacity gain are still substan-
Table 2 tial compared to the base case
and the case A preflash drum.
tendency of the chosen light tight oil slate can
help optimise furnace coil outlet temperature Case study: retrofit economic evaluations
further. The case A preflash drum option provides the
The capacities of crude atmospheric column simplest unit modification among the three
distillation equipment are calculated with simu- cases. The required plot for the preflash drum
lated traffic. Calculated capacities are based on implementation is also smaller than for the other
the packed wash section and fixed valve trays for cases. However, the aforementioned higher
the rest of the section. The calculated capacity discharge pressure of the new booster pump
for each section is plotted in Figure 5. increases Capex substantially.

6 PTQ Q3 2015 www.digitalrefining.com/article/1001134

 The case B preflash column
option provides the best perfor- 10
mance improvement but it 9 EFO: $55/BBL
requires an additional overhead EFO: $35/BBL
8
condenser and receiver for the EFO: $25/BBL

Pay-out per year

7
preflash column and complex
piping modification which influ- 6
ence retrofit cost. The highest 5
Capex is identified for the case B 4
preflash column option. The 3
larger plot requirement for the
2
modification is another draw-
1
back in case B. If space is
limited in the existing unit, this 0
Preflash drum Preflash column GT-IPS
case is not viable for
implementation.
In case C, GT-IPS does not Figure 6 Profitability index – payback period
necessitate substantial addition
of equipment as is required in the case B Conclusion
preflash column. Also, new booster pump differ- The technical results and economic evaluations
ential pressure and capacity requirements in from three case studies show that the GT-IPS
case C are lower than those in case A. semi-preflash column can deliver significant
Calculations of pay-back period are conducted energy savings and capacity gains compared to
to gauge retrofit economics. Gains in crude the preflash drum option. Meanwhile, the lower
atmospheric column capacity and/or furnace/ investment cost for GT-IPS provides better
transfer line capacity significantly improve retro- retrofit economics compared to the preflash
fit profitability. However, profits through these column case. These benefits show that GT-IPS is
factors vary noticeably per refinery layout and a viable option for efficient light tight oil
equipment limitations. Therefore, these factors processing. Actual preflashing options and
are not considered in the pay-back period calcu- designs can be customised after reviewing the
lations and only furnace heating medium saving specific circumstances of a crude distillation unit
is used for economic evaluations. configuration and refinery layout. Retrofit
Profitability indexes are expressed with regard economics can be precisely gauged after reflect-
to pay-back period. These indexes are shown in ing actual profit gains.
Figure 6. The modification costs are estimated
based on the US Gulf region. Most US refiners
utilise both refinery fuel gas and natural gas as This article is an updated version of a presentation given at AIChE
furnace heating mediums. However, the mixing 2015 Spring Meeting Kister Distillation Symposium, 27-30 April
2015, Austin, Texas.
ratio between two different utilities depends
upon the particular refinery. Therefore, a single
GT-IPS is a mark of GTC Technology US, LLC.
equivalent fuel oil (EFO) basis is selected. Three
different fuel oil prices are selected through the
last four-year fuel gas and natural gas trend.6 References
Typical furnace efficiency and EFO lower heating 1 Mills R, The myth of the oil crisis: overcoming the challenges
values are used for heating medium consump- of depletion, geopolitics, and global warming, Greenwood
tion predictions. Publishing Group, 2008.
Figure 6 shows that case C’s GT-IPS is identi- 2 Sandu C, et al, Innovative solutions for processing shale oils,
fied to provide better retrofit economics Hydrocarbon Processing, July 2013.
compared to the other two cases. Adding extra 3 Golden S W, Prevent preflash drum foaming, Hydrocarbon
Processing, May 1997.
profit through capacity gain can further improve
4 Golden S W, Crude unit preflash drums and columns, PTQ
retrofit profitability.
Revamps, 2005.

www.digitalrefining.com/article/1001134 PTQ Q3 2015 7

 5 Libermann N P, Troubleshooting Process Operations, PennWell
Books, 4th Edition.
6 US Energy Information Administration Web Site.
Soun Ho Lee is Manager of Refining Application with GTC
Technology in Euless, Texas, specialising in process design,
simulation modelling, energy saving design and troubleshooting
for refining and aromatic applications.
Email: sounho@gtctech.com
8 PTQ Q3 2015
LINKS
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Crude Vacuum Units
Energy Efficiency / Energy Management
Mass Transfer & Separation
Revamps, Shutdowns and Turnarounds
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