PRO/II Application Briefs

R3S - Shortcut Crude Oil Distillation

The feed to a refinery often changes every few days. An existing
refinery has received an Indonesian crude oil and you must simulate
the atmospheric distillation column to establish the correct
operating conditions for a throughput of 120,000 barrels/day.
Process Data
The crude unit configuration and typical operating data are shown
in Figure R3-1. This simulation uses the stripping stream and
pumparound cooling shown in Figure R3-1.
Figure R3-1: Crude Oil Distillation

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The products must meet the specified D86 and TBP points in Table
R3-1, and the yields are to be calculated.
Table R3-1: ASTM D86 (F)

LV% Naptha Kerosene Diesel Gas Oil Topped Crude

0 - 301 446 490 652
5 79 379 516 625 738
95 340 520 665 843 1438
100 376 565 669 889 1464

The crude oil has been analysed as an atmospheric TBP curve and
defined lightend components as shown in Table R3-2.
Table R3-2: Crude Oil Data

TBP at 7600 mmHg Lightends

LV% Temp (F) LV% Temp (F) Components LV%
3 98 50 690 Ethane 0.1
5 149 60 770 Propane 0.2
10 208 70 865 i-Butane 0.3
20 330 80 980 n-Butane 0.7
30 459 100 1600 i-Pentane 0.5
40 590 n-Pentane 1.2
Average API 29.2 Total 3.0
Gravity

The laboratory data for the TBP curve are supplied only up to the
80% point. A typical value is assumed for the 100% point to assist
the extrapolation of the curve.

Methods and Data

The GS thermodynamic system is recommended for calculating
K-values and enthalpies in crude and vacuum systems. The BK10
system may also be used, but it tends to predict slightly less
vaporization. Column temperatures can generally be matched with
either system.
Accurate characterization of the crude oil is vital for good
simulation results. The greatest errors often appear in the residue
stream and can lead to poor results when simulating the

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downstream vacuum column. The characterization may be
improved by supplying gravity and molecular weight curves if they
are available.
The program automatically generates a number of petroleum
fractions and calculates the molecular weight, gravity, and boiling
point for each. These are then used in standard petroleum
correlations to generate all the other required properties.
The TBP curve must be matched to the lightends data to produce a
smooth curve. To assist this, the boiling point (97 F) of the
n-pentane is input as an additional 3.0% point at the front of the
curve.
Viscosity and thermal conductivity data are generated for the
streams for use in other calculations. The API Data Book method is
selected for the liquid viscosities. For crude oil streams, these data
are more accurate than the ©PETROª option used for the other
transport properties.

Simulation Model
The first step in the simulation is to ensure that it is possible to
produce the specified products from the crude oil feed and establish
the material balance. The multidraw shortcut distillation model
(MODEL = REFINE) is a quick and easy tool for these
calculations. This model uses the Fenske calculation method and
considers the column to be a series of two-product columns as
shown in Figure R3-2. The condenser is simulated with an external
flash drum.
The specifications chosen for the shortcut model define the
separation in each section. For this simulation, the 95% distillation
points and 5-95% gaps are used. The data are taken from Table R3-
1.
Five percent and 95% points should always be used instead of
initial and end points, as they are generally more accurate. The
simulated end points are affected by the number of petroleum cuts,
the parameter TBPEP (on the ASSAY statement in Component
Data) which defaults to 98%, and the Fenske model itself, which
tends to overfractionate on the product tails. In addition, the
shortcut simulation ignores the sidestrippers, which also affect the
ends of the curves.

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As crude oil has no defined components, the component flowrate
output is suppressed, and only the stream summary is printed. The
PRINT TBP option gives the TBP and ASTM curves for all
hydrocarbon streams.
It is not known whether or not there will be any vapor product from
the column. As there may be vapor, the condenser is defined as
mixed phase at the defined temperature.
The MODEL=REFINE option specifies no reflux between sections in
the column. The default would assume total reflux between the
sections. The product rate estimates are supplied as volume percent
cutpoints on the crude oil feed.

Figure R3-2: Shortcut Crude Unit Model

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In the shortcut model, the stripping steam is added with the feed.
The main effect of this on the simulation results is that the influence
of the steam on the product temperatures is not modeled, and the
calculated temperatures will be high.

Input Data
The shortcut crude unit model uses default English units of
measure, except for liquid volume where API barrels is specified
instead of cubic feet. Click on the UOM button to make this
change.
Click on the Component to enter the component slate. Note
the pseudocomponents shown in Figure R3-3 initially are not
present. They will be generated after the stream assay data are
supplied.

Figure R3-3: Component Selection After Pseudocomponent Generation

Click the Thermodynamics button to select the Grayson-

Streed thermodynamic system of method. Proceed to the Modify
Data button to cross check the default settings of K-values and
enthalpy methods shown in Figure R3-4.

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Figure R3-4: Thermodynamic Methods

Lay down a shortcut column onto the PFD. A dialog pops up

requesting whether you want a condenser (yes) or reboiler (yes).
Connect the column to a feed stream.
To enter the stream data (crude oil), lay down a stream on the PFD
and connect it to the column. Double-click on the stream, select
Petroleum Assay from the list box and click on the Flowrate and
Assay button.
Enter the flowrate of 5,000 bbl/day. Then click on Define/Edit
Assay to enter the assay data. TBP distillation data, API gravity
data and lightends data from Table R3-2 are entered as illustrated in
Figure R3-5.

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Figure R3-5: Assay Definition

Click the Lightends button to enter the assay lightends data.

After completing that dialog box, click OK to return to the PFD. A
dialog box pops up to inform you that the assay components have
been generated.

Figure R3-6: Message After Generating Pseudocomponents

By returning to the Components Selection dialog, it is possible to

verify the component slate now includes the pseudo-components,
as shown in Table R3-3. The component slate now is complete.

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Double-click the shortcut column icon to open the main Data Entry
Window for the shortcut column shown in Figure R3-7
Figure R3-7: Shortcut Column Main

 Click the Condenser/Reboiler button to enter data for the

condenser. Because vapor may be present in the product, select
Mixed as the condenser type. As shown in Figure R3-8, set the
operating temperature at 110 F. Click OK to return to the main
shortcut DEW.
Figure R3-8: Shortcut Column Condenser/Reboiler

 Click the Specifications button on the shortcut icon to enter the

product specifications that define the separation in each
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section. In this example, 95% distillation points and 5%-95%
gaps are used. Figure R3-9 illustrates one of the data entry
windows for specification number 2.

Figure R3-9: Shortcut Column Performance Specifications

 Click the Fenske Estimates button and enter the estimated

Fenske Index for each product section. Table R3-3 lists the
estimates used in this example.
Table R3-3: Fenske Index Estimates
Section Index Estimate
1 2.00
2 3.00
3 2.00
4 2.00

 Click the Products button and enter the product rate estimates
and set the phases and pressure of the product streams.
The keyword input listing that follows contains all the data used in
this example.

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Keyword Input File

TITLE PROJECT=APPBRIEF, PROBLEM=R3S
PRINT INPUT=ALL, STREAM=SUMMARY, TBP
DIMENSION ENGLISH, PRES=PSIG, LIQVOL=BBL

COMPONENT DATA
LIBID 1,H2O/ 2,C2/ 3,C3/ 4,IC4/ 5,NC4/ 6,IC5/ 7,NC5 &
BANK = SIMSCI, PROCESS
ASSAY CURVEFIT = IMPR, CONVERSION = API94
CUTPOINTS TBPCUTS=100,800.001,70/1200,20/1600,8,DEFAULT
THERMODYNAMIC DATA
METHOD SYSTEM=GS, VISCOSITY(L)=API, VISCOSITY(V)=PETR, &
CONDUCTIVITY(L)=PETR, CONDUCTIVITY(V)=PETR, SET=GS01
STREAM DATA
PROPERTY STREAM=CRUDE, TEMPERATURE=450, PRESSURE=14, &
PHASE=M, RATE(LV)=4999.99, ASSAY=LV
TBP STREAM=CRUDE, TEMPERATURE=F, PRESSURE(MMHG)=760 &
DATA= 3,97 / 5,149/ 10,208/ 20,330/ 30,459/ &
40,590/ 50,690/ 60,770/ 70,865/ 80,980/ &
100,1600
API STREAM=CRUDE, AVERAGE=29.2
LIGHTEND STREAM=CRUDE, PERCENT(LV)=3, NORMALIZE, &
COMP(LV)=2,0.1/3,0.2/4,0.3/ 5,0.7/ 6,0.5/7,1.2
PROPERTY STREAM=STEAM, TEMPERATURE=600, PRESSURE=60, &
PHASE=M, COMPOSITION(WT,LB/H)=1,20000
NAME CRUDE,CRUDE FEED/ NAPH,NAPHTHA/ KERO,KEROSENE/ &
DIES,DIESEL/ GASOIL,GAS OIL/ TOPPED,TOPPED CRUDE

UNIT OPERATIONS
SHORTCUT UID=SC01, NAME=CRUDE TOWER
FEED CRUDE,STEAM
PROD STREAM=OVER, CUTPOINT(LV)=25, PHASE=M, PRESS=8.4999
PROD STREAM=KERO, CUTPOINT(LV)=40, PHASE=L, PRESS=11.8
PROD STREAM=DIES, CUTPOINT(LV)=55, PHASE=L, PRESS=12.5
PROD STREAM=GASOIL, CUTPOINT(LV)=75, PHASE=L, PRESS=13.3
PROD STREAM=TOPPED, PHASE=L, PRESSURE=14.4
CONDENSER TYPE=MIX, TEMPERATURE=110
EVALUATE MODEL=REFINE, TRIAL=50
FINDEX 2,3,2,2
SPEC STREAM=OVER, D86(95,F), VALUE=340
SPEC STREAM=KERO, D86(5,F), MINUS, STREAM=OVER, &
D86(95,F), VALUE=40
SPEC STREAM=KERO, D86(95,F), VALUE=520
SPEC STREAM=DIES, D86(5,F), MINUS, STREAM=KERO, &
D86(95,F), VALUE=10
SPEC STREAM=DIES, D86(95,F), VALUE=665

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SPEC STREAM=GASOIL, D86(5,F), MINUS, STREAM=DIES, &
D86(95,F), VALUE=-30
SPEC STREAM=GASOIL, TBP(95,F,VOL), VALUE=885
SPEC STREAM=TOPPED, TBP(5,F,VOL), VALUE=695
FLASH UID=FL01, NAME=CONDENSER
FEED OVER
PRODUCT V=OFF_GAS, L=NAPH, W=DECANT
ISO TEMPERATURE=110, PRESSURE=5.3
END

Output
The shortcut column results are shown on the next page. The
shortcut model predicts the minimum number of trays, calculated at
total reflux, needed to meet the specified separations. Typical
values for crude oil separations for each column section are shown
in Table R3-4.
Table R3-4: Typical Shortcut Trays
Column Section Index Estimate
Naphtha - Kerosene 3.5 - 5.0
Kerosene - Diesel 2.5 - 3.5
Diesel - Gas Oil 2.0 - 3.0
Gas Oil - Topped Crude 1.3 - 1.8

As long as the shortcut model reports figures within these ranges,

the separations will be feasible. Significant departures from these
values mean a difficult, if not impossible, separation.
The simulation predicted no overhead vapor at the desired
condenser conditions. This is not unusual for crude unit simulations
because some lightends may have been lost in sampling the crude
oil, or because lightends produced by cracking in the furnace are
not included in the simulation model.
Once the shortcut model is solved, the material balance is defined.
If difficulties occur solving the rigorous model, then the heat
balance is likely to be at fault.
The shortcut column profiles can be obtained by clicking on the
Generate Report button, which generates the entire flowsheet
report, or by selecting the column and clicking View Results, which
will generate a table of results for just the column.

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Shortcut Column Output

UNIT 1, 'SC01', 'CRUDE TOWER'
FEEDS
STREAM PHASE
------------ ------
CRUDE MIXED
STEAM VAPOR
PRODUCTS
------------- TOTAL STREAM RATES -------------
MOLES WEIGHT LIQUID VOL NORM VAPOR(1) NUM
STREAM + PHASE LB-MOL/HR LB/HR BBL/HR FT3/HR SECTION TRAYS
------------ - ---------- ---------- ---------- ---------- ------- -----
OVER M 2950.52 291750.51 1131.76 1119672.59 1 3.25
(FREE WATER) W 1106.44 19932.76 56.92 419874.17
KERO L 1006.35 181138.51 627.01 381894.69 2 3.10
DIES L 591.52 152295.47 499.80 224472.19 3 2.37
GASOIL L 687.83 230044.41 725.82 261019.00 4 1.33
TOPPED L 1317.16 686460.01 2015.80 499840.66

TOTALS 7659.82 1561621.67 5057.11 2906773.30 10.05

SPECIFICATIONS

PARAMETER COMP. SPECIFICATION SPECIFIED CALCULATED

TYPE NUM TYPE VALUE VALUE
----------------- ------- ------------- ---------- ----------
STRM OVER D86 95 PCT 3.400E+02 3.400E+02
STRM KERO D86 5 PCT 4.000E+01 4.000E+01
STRM KERO D86 95 PCT 5.200E+02 5.200E+02
STRM DIES D86 5 PCT 1.000E+01 9.997E+00
STRM DIES D86 95 PCT 6.650E+02 6.650E+02
STRM GASOIL D86 5 PCT -3.000E+01 -3.001E+01
STRM GASOIL TBP 95 PCT 8.850E+02 8.850E+02
STRM TOPPED TBP 5 PCT 6.950E+02 6.950E+02
(1) STANDARD VAPOR VOLUME IS 379.49 FT3/LB-MOLE (60 F AND 14.696 PSIA)

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