Mm. Mie vil- Refining-Petrochemicals-Chemicals-Engineering MULTIPLE DRAW OFF COLUMNS: OPERATING VARIABLES PRODUCT CUT POINTS IN MULTIPLE DRAW OFF COLUMNS. 1 + Cut point definition... 2 ~ Cut point and product characteristics. CUT POINTS AND CONTROL SYSTEMS ....2.:0:sn 1 + Overhead cut flow rate - Overhead gasolinelkerosene cut point. 2 - Side streams: cut points 3 - Atmospheric residue - Overall material balance. MODIFICATION OF PRODUCT CUT POINTS 1. = Modification of the setting of @ controler determining the overhead product rate. 2 = Modification in the setting of a side stream flow rate controller : CHANGE IN A SINGLE CUT POINT. 1 = Change in the cut point between gasoline and Kerosene 2 - Change in the cut point between two side streams. PARAMETERS DETERMINING SEPARATING POWER IN DIFFERENT ZONES OF THE COLUMN. Impact of separating power on fracnaton quay = Fractionation quality control. . = Change in the liquid-vapor trafic = Variables acting on the separating power. Modification ofthe crude ol inlet temperature inthe column, Modification ofthe heat rates extracted by pumparounds Examples of optimizing the separating power in a multiple draw off distillation column OPERATING PRESSURE..... CHARACTERISTICS OF CRUDE OILS PROCESSED A-Rev. 4 © 2009 - IFP Training - 12 13 woe 15, 6 16 7 sons AD sol 21 28 26 27 01/12/2009oO1- PRODUCT CUT POINTS IN MULTIPLE DRAW OFF COLUMNS. 1. - CUT POINT DEFINITION ‘All modem refineries have several multiple draw off columns. They process a variety of feeds such as ~ crude oils, which may be pure or mixtures, in atmospheric distillation colurnns, = atmospheric distillation residue in vacuum dis n columns, = complex mixtures of hydrocarbon effluents from conversion processes such as catalytic. cracking, hydrocracking and visbreaking, which are subsequently separated in fractionation columns by a process allied either to atmospheric distilation or to vacuum distilation These feeds are composed of a very large number of components of which only the most volatile fractions can be identified. Light hydrocarbons, from C1 to C5 can be easily identified by ‘chromatographie analysis, but the same does not apply to the heavier hydrocarbons. ° ere2 tight engs 100 200 | 300 400 by their boiling point | 500 SU ae i 600 700 bp °C Weight % over feed nee orcozec The composition of @ feed is therefore characterized by TBP. distilation. The different components of the feed are identiied by their true boiling points. This analysis glves the composition of the processed feed based on the true boiling points of its components. The result may be shown as a rectangular band representing the feed in relation to a boiling point scale whose graduations correspond to the different components. This is illustrated by the diagram opposite. The boling points are shown in increasing order from top to bottom. The distilation products will thus appear on the diagram from top to bottom in decreasing order of volatility © 2009 - IFP TrainingWhen applied to the separation of a crude oil in an atmospheric distillation column, this representation illustrates the material balance of the column. The feed is divided into different cuts, in decreasing order of volatity, as follows: = overhead cut (ight ends and gasoline) = kerosene = light gas oil ~ heavy gas oll = atmospheric residue ‘The product may be listed in this order, one after the other, stating from the top. Each cut is thus bounded by a theoretical frontier in the form of a horizontal segment which represents the frontier boiling point temperatures on the temperature scale, The latter are often referred to as cut point temperatures, or simply cut points. The figure below illustrates this definition with respect to the previously mentioned fractionation and shows the four cut points noted ty to t4' = tis the cut point between gasoline and Kerosene and is normally in the range 145-185°C = t2iis the out point between kerosene and light gas oil and is normally in the range 220-230°C = {3 /s the cut point between fight gas oil and heavy gas oil and is normally in the range 300°C depending on the nature of the crude and the desired quality of the light gas oll cut = tq s the cut point between heavy gas oil and residue and represents the limit of atmospheric distillation, t's normally in the 380°C range. oe Over head cut | Over head cut 07 | flow rate yas roy _lightend + gasoline) Eas Kerosene |) L pte 24 fowrets |< Kerosene Lightgasol | & “0 flow rate | 3 eater ] Light GO Se # Hea gas | 9 flow rate u at © a Heavy GO 5 Crude oil 70 Zz Oe © eo nel 90 a a Atmospheric 8 bp'c. 100 residue bl 0829 AA © 2009 - IFP Trainingone AA CUT POINTS AND PRODUCT CHARACTERISTICS In industry, the detailed characteristics ofthe feeds to be processed in multiple draw off columns are generally not known. Consequently, the products have to be analyzed in order to determine the ‘cut points. The results of some standard tests are very sensitive to variation in cut points and are a ‘good means of control. These tests may be performed by continuous analyzers which rapidly provide information on the regulation conditions ofthe equipment. the tt cut point between gasoline and the kerosene cut is cirectly related to the end point orto the 95% ASTM distillation point of gasoline. An inorease in the overhead cut flow rate therefore leads to a higher tt value (lower cut point on the diagram) and to a rise inthe ASTM fina dstllation temperatures. the t2 cut point between kerosene and light gas oil can be identified by ASTM distilation and also by low temperature operability characteristics. The temperature at which crystals disappear (freezing coin!) is an indication of the Keroseneflight gas oil frontier, even if this characterstcis also influenced by the cut point between gasoline and kerosene. the t3 cut point between the two gas oils, and also the t4 cut point between heavy gas oil and atmospheric residue, are characterized by the ASTM final dstilation points and by their low temperature operability properties, particulary the cloud point. Like the freezing point, the cloud point is influenced by both the highest and the lowest cut point temperatures. It should also be noted that the t4 cut point is related to residue characteristics, ie. viscosity and especially specific gravity. Product characteristics do not depend solely on the material balance, that is on the cut points used. Two supplementary factors affect product quality the separating power in each zone of the distillation column, which determines the quality of the different separations and the distinction between each cut. This factor influences the ASTM distillation curves and it generally results in gaps or overlaps. At constant flow rates, that is at constant cut points, a change in the separating power perceptibly modifies the ASTM final distillation point of a cut. The effect is nevertheless much less pronounced than that caused by changes in the material balance. the effectiveness of the stripping operation, which influences the concentration in volatile ‘compounds in the streams and modifies their flash point and the beginning of their ASTM distillation curve, ASTM EP = ASTM End Point gasoline Kerosene cut point Kerosenefight gas oil cut point ASTM EP for gasoline - flash point for kerosene ASTM EP and freezing point for Kerosene - low temperature operability for ight gas oll light gas oiv/heavy gas oi! cut point ASTM EP and low temperature operability for light heavy gas oilfresidue cut point gas oil - low temperature operabilty for heavy gas oll ASTM EP and low temperature operability for heavy 99s ol - specific gravity and viscosity for residue © 2009 - IFP TrainingIl- CUT POINTS AND CONTROL SYSTEMS For a given feed, we know that the product flow rates at the distillation column outlet govern the cut points. Consequently itis the control systems that determine product flow rates and that enable modification and adjustment ofthe cut points used. There are different control systems that influence the flow rates of the product streams. They often involve ‘control of both flow rate and temperature, ‘An example of the control system commonly used with atmospheric distillation columns is given in Figure 1 in the appendix. Ae 00829. ALA OVERHEAD CUT RATE - OVERHEAD GASOLINE/KEROSENE CUT POINT a Temperature control ‘The overhead cutis the lightest product obtained by distillation. It leaves the top of the column in the vapor state, or the intermediary drum in the case of a two-stage condensation system. The principle most commonly practiced is therefore to control the dew point temperature of the cut which 0, the calculation gives the value ofthe gap. It (15, heavy cut-t,,, light cut) <0, the calculation gives the value of the overlap. + Standard fractionation quality t Say eee t (°C) | ASTM distillation (°C) cure cut t Cut point {t] ii | ifi | = iyi | 5 ec * NO” Weight % - [i 100 % vol dst. Boiling LC temperature [95%] | [5% + Perfect fractionation quality ——— + t c °c (21) ery dstioton ened fy curve ou | rt | t + — tren | | Ator GAP maxi oe. | Ti : Light j cut Vi a Weight % o% 100 % vol. dist ee 0% 100% (95%) (5%) temperature coe AA © 2009 - IFP Training7 * Bad fractionation quality pes Heenan ie ay Light il | ASTM distillation Heavy (Pe) cut cue Cut point {t] | : | Jovene < : NCI weight mi & 100 % vol. dist 9% PcoaenK. Baling el temperature 5%] But this method is not possible for the separation between the heavy gas cil and the atmospheric residue. In this zone the quality of the separation is controlled by a fixed flow rate of overflash. The operating value of overfash is often 2 to 8% ofthe crude mass flow rate Increasing the overflash flow rate increases the separating power. CHANGE IN THE LIQUID-VAPOR TRAFFIC. i Ee Overhead cut Kerosene Light gas oi Heavy gas oll Crude oil Atmospheric residue 0820 AA © 2009 - IFP Trainingcose AA 18 {1 should be noted that the L and V flow rates are not independent because the mass flow rates are: V = L + overhead cut + kerosene cut ie ve = overhead cut + kerosene cut This apples to all the levels in the column. The difference between the ascending vapor flow rate and the descending liquid flow rate is equal fo the sum ofthe flow rates ofthe side streams located above the point concemed. I we assume that the material balance is fixed, ie. the cut points are constant, it can be seen that in ‘order to observe the relation \V-L= overhead cut + kerosene = constant ‘ny variation in the vapor flow rate V must be accompanied by an equivalent variation in the liquid flow rate L The impact of an increase in L and V with a fixed material balance in the Kerosenellight gas cil separation zone leads to an increase in separating power. The effec is illustrated in the dagram below. Increase in oe Initia case Cay Over head cut Over head cut L ty Kerosene Kerosene L tpte—} L tse Peace) lq | EVs ed EUs ed PIT cSt orcomso bp The improved quality of separation results in a decrease in the Kerosene ASTM end point and to an increase in the light gas oil intial point. The resulting distance between the ASTM distilation curves consequently reduces the overiap or else increases the gap. The concepts of overlap and gap are used to characterize the separation qualities obtained between cuts that can be analyzed by ASTM distilation, ie. gasolines, Kerosene and gas oils. However they cannot be used to characterize separation between the last cut and residue. Instead of separation qualty, separating power is generally imposed in the heavy gas ollatmospheri residue zone by means of the overfiash flow rate, © 2009 - IFP Trainingo0H70_ AA 19 VARIABLES ACTING ON THE SEPARATING POWER, (On the basis of the preceding relations, it can be seen that at constant cut point the separating power ‘operating in each zone depends only on the flow rate of the hydrocarbon vapor circulating in the Column. The liquid flow rate is effectively the result of the vapor flow rate after the upper side streams have been drawn of. ‘Any variation likely to affect the vapor flow rate consequently influences the separating power. This applies to ~ the crude oil inlet temperature, which determines the intial vapor flow rate ensuring the reboiling of the column, The vapor flow rate generated also depends on the nature of the crude and on the pressure. The crude oil inlet temperature also largely determines the energy consumption of the atmospheric furnace, - heat rates extracted by the pumparounds, which act as partial condensers integrated within the column. An inorease in the heat rate extracted by a pumparound causes supplementary vapor condensation in the heat exchange zone and consequently leads to a reduction in the vapor-liquid traffic above the zone of interest. By acting on the heat rates extracted by the different refuxes circulating in the column, itis theoretically possible to regulate all the iquid-vapor traffics in order to obtain the desired separations and to optimize the energy balance ofthe column, Compared to the setting of the cut points which is performed from the top, the setting of the separating power in each zone involves the energy balance which can be modulated via the steam ‘low rate, The optimization of the energy balance should therefore be performed from the bottom by allowing the passage at each level of the amount of steam actually required to achieve the desired separation Regulation of Regulation of ‘material balance: from top to bottom energy balance: from bottom to top MODIFICATION OF THE CRUDE OIL INLET TEMPERATURE IN THE COLUMN The crude oil inlet temperature is regulated by the heat supplied to the crude oil in the atmospheric The change in the quality of a crude oll also leads to a significant moditication teed to tad td in the cut point determined by the rate CRUDEOL,| _#7Va | of vaporization in the expansion zone. Ip to a light one we observe that under the same conditions in the expansion zone, the surplus vaporization due to the lightening of the crude oil greatly B exceeds the change in composition a— BA Assuming that the vapor flow rate ofthe crude oil is more or less equivalent to all the side streams, this change resuts in a cut point ty distinctly higher fora light crude oil. This can be seen in the diagram below. 00820. (ty Lt provanee © 2009 - IFP Training29 This phenomenon, as illustrated on the crude oil separation diagrams, shows the gain obtained, in constant cut points between the draw offs, with respect fo the last side stream and the residue. CRUDE OIL 4 CRUDE OIL 2 [ Over head cut Le tebe ‘ —< Over head cut Kerosene Light GO Cae eats 00820 AA bp °C, CUTS rs eer This vaporization behavior during a change in composition is used in vacuum columns to lower the furnace outlet temperature when recycling a distilate cut © 2009 -IFP Training pecoameATMOSPHERIC DISTILLATION —Control set up — —Figure 1 — Flare Fuel gas, Rian Gear iB 00620.AA © 2009 - IFP TrainingoO34 VACUUM DISTILLATION OF ATMOSPHERIC RESIDUE — Control set up — cose AA © 2009 -IFP Training32 FLUID CRACKING FRACTIONATOR | — Control set up — — Figure 3 — reagan Gas) Gear 0829 AA © 2009 - IFP Training33 CHANGE IN THE CUT POINT — Figure 4— MAXIMUM LIGHT GAS REFERENCE CASE ee | Flow rates kglh Overhead cut 74566 74571 | Kerosene 37 488 37 480 | Light gas oil 26610 52281 Heavy gas oil 38 091 12400 Residue 115611 115621 Product quality Overhead cut - Kerosene = 18 0.833 0.848 Light gas oil: dy | Flash point 95°C 102°C Pour point 17°C -7°C Cetane index 56 | 54 %S 09 1.23 5 0.872 0.887 Heavy gas oil: d Flash point rare 143°C Pour point +6°C + 18°C %S 17 1.98 Temperatures °C Top 1744 1746 Kerosene 2110 2118 | Light gas ol 267.4 24 Heavy gas oil 3174 334.3 Residue 346.9 346.9 ‘ABT Light Heavy Light Heavy gascl —gascil_| gasol —gasoil Pp 236 286 - = 5% 248 298 260 323 10% 251 301 263 329 30% 262 315 276 347 50% | 269 326 289 357 70% 276 339 305 365 90% 289 363 329 377 95% 300 376 oat 388 | 100% 314 393 387 403 00828 AA © 2009 - IFP Training34 VARIATION OF THE CRUDE INLET | TEMPERATURE IN THE COLUMN REESE Eee eee eee ere eeee ee — Figure A Tintet | Reference = % Tintet case Feed inlet temperature (°C) 385.3 3504 345.65 | Flow rates kgih Overhead cut 74.540 74617 Kerosene cut 37 474 37493 Light gas oi 26 605 26617 Heavy gas oil 37 898 38 332 Residue 115 844 115 302, %Vaporized = owt 85.29 63.78 6233 Gap Overhead cutlkerosene 204 197 189 Kerosenellight gas cil 74 6 44 Light gas oilheavy gas oil -24 -32 Heavy gas oilresidue -39 54 ASTM Overhead cut PL 5% 48.3 48 = FP. 185.3 185.5 1857 Kerosene PL5% 189.2 188.8 188.3 FP 250.8 251 2514 Light gas oil -PT5% 248.8 279 246.9 FP. 3143 314.3 144 Heavy gas oil PL 5% 3345 332.2 3293 FP 391.7 393.4 404.2 Temperatures °C First drum B 102 142 1423 1426 Columns overhead mar | ATA 174 Kerosene za | oat 209.7 | Light gas oil 292674 265.2 Heavy gas oll 319 3174 3159 Residue 351 346.9 342.6 nee AA © 2009 - IFP Trainingcn AA 35 VARIATION IN THE HEAT RATE EXTRACTED BY PUMPAROUNDS — Figure n°6 — Qgci = 4500 thin instead of 6000 thin LPA return temperature with a constant flow rate of the LPA overhead reflux condensation Separation sharpness, GAP overhead kerosene GAP kerosene-LGO GAP LGO-HGO GAP HGO-Residue Temperatures Drum Top Kerosene co Heo Treturn : 208 ci: 10280 we ec -280 > -44.2°0 142.3°C > 744°C > anc 274 a74c (© 2009 - IFP Training 226.7°C 41670 thin 2 arc -28°C = 442°C 141.8°C 175°C 213.4°C mec 379°CO36 —Figure 7 — gets oops cy (409) 1604550 ge co. ‘eno prin) ano 0084 = =| ‘ceo, Hnen.y 6uis9 usnt Tf ose feb yar au, aunanse ° i weg 5 Cage > [a - Gan i i yo apnig, : Eo i vile ‘ytevi 0009 = YI [xe } ooze | wuieow asog = VN => \ I *¢ ‘0058 we] Cam a (spimpanseg CO) ‘wean oor = PHO , 7 HG) Werees @ HY Gap oI © 2009 - IFP Training 082s ALAO