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Conventional Distillation Pre-flash Fractionation Previous Work Mission Statement Optimization Results: Light Crude Results: Heavy Crude
ASTM standard - specifies product purity Defined as a percentage of the product that boils at a specific temperature Naphtha 95% D86 182oC
Light Crude 95% D-86 Points ( C) Naphtha 182 Kerosene 271 Diesel 327 Gas Oil 410 Residue 820
Heavy Crude 95% D-86 Points ( C) Naphtha 182 Kerosene 271 Diesel 327 Gas Oil 390 Residue 1220
Minimum gap refers to the lowest temperature difference required to obtain the desired separation
Light Crude Gaps (oC) Naphtha-Kerosene 16.7 Kerosene-Diesel 0 Diesel-Gas oil -2.9
Light Crude
5.00E+03
4.00E+03
Barrels/Day
Naphtha
3.00E+03
Kerosene Diesel
2.00E+03
1.00E+03
378.00
100.00
128.00
155.00
183.00
211.00
239.00
266.00
294.00
322.00
350.00
405.00
439.00
495.00
549.00
597.00
663.00
781.00
4 trays No reboiler or condenser Inject steam to control separation Draw from column Return to tray above draw
return
draw
steam
product
Heat supply and demand are represented by areas. Supply can only cover demand on the left. Uncovered demand is satisfied by utilities (red area).
Pinch Calculator
Pinch Calculator
Tray 1
Tray 15
34 Trays Total
Concluded that pre-flash was only more energy efficient if gas oil yield was reduced Steam cannot replace all carrier effect of light components
Previous work studied pre-flash fractionation with the addition of one flash drum This work studies the effect of pre-flash fractionation with the addition of multiple flash drums in both light and heavy crude systems
In the process of investigating this, a new design was proposed Technical details of this new design cannot be made public at this time We will only disclose the impact of the new design in terms of new flow rates of products and the economics
250
200
Naphtha Kerosene
150
100
Residue
50
0 conv.
For the light crude, the new design increases gas oil yield from pre-flash design, but not from conventional
tray-10
tray-15
tray-20
tray-25
2 flash
4 flash
new design
25000
20000
15000
10000
5000
100
20
New design increases gas oil yield over the conventional case
conv.
tray-10
tray-15
tray-20
tray-25
2 flash
4 flash
new design
12200
12000 conv. tray-10 tray-15 tray-20 tray-25 2 flash 4 flash new design
Light Crude
Process 1 flash tray-15 2 flash 4 flash new design Utility Cost Increase -$690,000 $3,280,000 $7,790,000 -$1,980,000 Profit Increase -$17,220,000 -$19,520,000 -$395,350,000 -$14,270,000 Gross Profit Increase -$16,530,000 -$22,790,000 -$403,150,000 -$12,290,000
Heavy Crude
Process 1 flash tray-15 2 flash 4 flash new design Utility Cost Increase $2,120,000 $2,580,000 $2,490,000 -$1,110,000 Profit Increase -$4,310,000 -$3,080,000 -$4,400,000 $7,160,000 Gross Profit Increase -$6,430,000 -$5,660,000 -$6,890,000 $8,270,000
The new design shows noticeable energy improvement and gas oil recovery from conventional distillation for heavy crudes Further studies are warranted
1. Bagajewicz M. and S. Ji. Rigorous Targeting Procedure for the Design of Crude Fractionation Units with Pre-Flashing or Pre-Fractionation. Industrial and Engineering Chemistry Research, 41, 12, pp. 3003-3011 (2002). 2. Bagajewicz M. and S. Ji. Rigorous Procedure for the Design of Conventional Atmospheric Crude Fractionation Units Part I: Targeting. Industrial and Engineering Chemistry Research. Vol. 40, No 2, pp. 617-626 (2001).
Stephanie English Jesse Sandlin Ernest West Chris Wilson Su Zhu Dan Dobesh