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03 Crude Units PDF
03 Crude Units PDF
Chapter 4
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
Gases
Sulfur
Plant
Polymerization
Sat Gas
Plant
Gas
Fuel Gas
Butanes
Alkyl
Feed
Gas
Separation &
Stabilizer
LPG
Alkylation
Polymerization
Naphtha
Isomerization
Light Naphtha
Alkylate
Isomerate
Aviation
Gasoline
Automotive
Gasoline
Reformate
Naphtha
Hydrotreating
Heavy
Naphtha
Sulfur
LPG
Naphtha
Reforming
Solvents
Naphtha
Atmospheric
Distillation
Crude
Oil
Jet Fuels
Kerosene
Kerosene
Desalter
Distillate
Hydrocracking
AGO
LVGO
Vacuum
Distillation
Fluidized
Catalytic
Cracking
Gas Oil
Hydrotreating
Cat
Naphtha
Solvents
Distillate
Hydrotreating
Cat
Distillates
Treating &
Blending
Heating Oils
Diesel
Fuel Oil
HVGO
Cycle Oils
Residual
Fuel Oils
DAO
Solvent
Deasphalting
Visbreaking
Vacuum
Residuum
Coker
Naphtha
Heavy
Coker
Gas
Oil
SDA
Bottoms
Asphalts
Naphtha
Distillates
Fuel Oil
Bottoms
Lube Oil
Lubricant
Greases
Solvent
Dewaxing
Waxes
Waxes
Coking
Light Coker
Gas Oil
Coke
Page 3
Topics
Crude Stills
Historically the oldest refining process
Only the first step in crude oil
processing
Purpose
To separate crude oil into narrow
boiling point fractions
That more closely resemble final
products or
Atmospheric Column
Vacuum Column
Reduced pressure to keep temperatures
below 650F
TBP EP (oF)
Light Naphtha
(LSR Gasoline)
80 to 90
180 to 220
Heavy Naphtha
180 to 220
330 to 380
Middle Distillate
(Kerosene)
330 to 380
420 to 520
AGO
(Atm Gas Oil)
420 to 520
650
LVGO
(Light Vac Gas Oil)
650
800
HVGO
(Heavy Vac Gas Oil)
800
950 to 1100
Vacuum Resid
950 to 1100
Modification of figure in Increasing distillate production at least capital cost, Musumeci, Stupin, Olson, & Wendler, PTQ, Q2 2015
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
10
Semi-preflash column
Some fractionation
Final fractionation done in
top of main fractionator
Optimising preash for light tight oil processing, Lee, PTQ, Q3 2015
11
Require flexibility
o
o
o
Desalter
Temperature carefully selected do not let
water vaporize
Lighter crudes (> 40API) @ 250F
Heavier crudes (< 30API) @ 300F
BFDs from:
Refining Overview Petroleum Processes & Products,
by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD-ROM, 2000
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
13
Crude Desalting
Breaking the crude oil/water emulsion important to minimize downstream
problems
Performance of additives
may be crude specific
Picture from:
Removing contaminants from crude oil
McDaniels & Olowu, PTQ Q1, 2016
14
15
but no reboiler.
Feed preheat exchanger train
All of the heat to drive the column
comes from the hot feed.
As much as 50% of the incoming
crude may be flashed.
Overflash
o
Pumparounds
Move cooling down column.
Liquid returned above draw tray
Side draws
Side strippers
Clean up side products
Stripping steam
Reduce hydrocarbon partial pressure
Condensed & removed as a second
liquid phase.
16
Condenser
Typically 0.5 to 20 psig.
Balancing act
Low pressures reduce compression on
overhead system
High pressures decrease vaporization but
increase flash zone temperatures & furnace
duty; affects yields
Pumparounds
Reduces overhead condenser load & achieves
more uniform tower loadings
Provides liquid reflux below liquid draws
17
Vacuum Distillation
18
19
Feed
Atmospheric residuum
No reboiler
Stripping steam may be used
Needed for deep cuts (1100F)
Products
May have multiple gas oils
Usually recombined downstream to FCCU
after hydrotreating
Vacuum resid
Blended asphalt, heavy fuel oil
Further processing thermal, solvent
o
20
21
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23
24
25
27
28
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Analysis overlay scaled product yield curves on top of feeds yield curve
Scale distillation curves represent the volume removed
Cut point temperature represents the feeds TBP corresponding the cumulative volume
removed
Tail represents the light fractions amount above the cut point & the heavy fractions
amount below the cut point
Overlap represents the range between light fractions end point & the heavy fractions initial
point
End point may be represented by 99%
Initial point may be represented by 1%
30
31
32
33
34
Summary
Reported refinery capacity tied to charge
to crude distillation complex
Increase capacity with Pre-flash column
35
Supplemental Slides
Crude distillation unit costs
Page 36
36
Page 37
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Page 38
38
Features
Foster Wheeler
Shell Global Solutions
TECHNIP
Uhde GmbH
Vacuum distillation
39
Feed
Vapor, liquid, or intermediate quality
Introduced in vapor space between trays
Internals
Trays to contact rising vapors with falling liquids
40
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http://www.termoconsult.com/empresas/acs/fractionation_trays.htm
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
42
http://www.ec21.com/product-details/Tower-Internals--3942077.html
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
43
Typical No. of
Actual Trays
20 30
57
7 10
20 40
25 35
35 40
38 45
75 90
55 70
25 35
110 130
200 250
70 80
20 24
20 24
35 50
57
37
30
12
7 10
45 50
35
7 10
10 12
50 55
60 70
35
68
50 60
1
12
2
2
13 17
2
23
35
57
24
23
35
35
24 35
57
35
68
7 10
Viscosity
Maxwell
cP
Ave Viscosity of
liquid on plates
0.05
0.10
0.15
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.50
1.70
104
86
76
63
56
50
46
43
40
38
36
30
28
Drickamer &
Bradford in
Ludwig
Molal Ave
Viscosity of
Feed
98
79
70
60
50
42
36
31
27
23
19
17
7
5
44
Myth of high cutpoint in dry vacuum units , S. Golden, T. Barletta, & S. White, PTQ, Q2 2014
Updated: August 11, 2016
Copyright 2016 John Jechura (jjechura@mines.edu)
45