Professional Documents
Culture Documents
2006revmainfraction PDF
2006revmainfraction PDF
M
ain (fractionator) column
water wash systems are Condenser
Condenser
sometimes needed when
producing heavy naphtha product to
ensure the FCC feed rate and gasoline
quality can be met throughout the run.
Reflux
Heavy naphtha product draws are used Reflux
to segregate the high sulphur portion of
the gasoline or to reduce the liquid load
through the gas plant. This is becoming
more prevalent due to the production of
propylene for petrochemical feedstocks. Heavy naphtha
Consequences include a lower main product
Heavy naphtha
column overhead temperature, higher PA return Heavy
wet gas rate and reduced gas plant naphtha PA
propylene recovery. Lowering the
overhead temperature can lead to
ammonium chloride deposits on the
trays or in the packing. These salts must
periodically be removed; otherwise, FCC
capacity will be reduced. Heavy naphtha
Heavy naphtha
pumparound &
pumparound
product
Heavy naphtha product
draws and pumparounds
Figures 1 and 2 show two heavy naphtha
product draw systems. The product in
Figure 1 is withdrawn from the same
location as the pumparound, which is
the most common arrangement. Figure 1 Typical heavy naphtha draw Figure 2 Alternative flow scheme
Pumparound temperature is set by the
heavy naphtha product rate. As the permits a higher product draw rate dewpoint, which depends on the
overhead product naphtha rate decreases without lowering the pumparound draw quantity of water present in the column
and the heavy naphtha product draw temperature. The internal liquid rate overhead vapour and operating
increases, the draw temperature drops. above the pumparound is sometimes pressure. High concentrations of water
When cold-feed preheat or gas plant less than the targeted heavy naphtha reduce the dewpoint temperature. Water
C3/C4 splitter and stripper reboiler product yield. In these instances, it is content of the overhead vapour depends
services use the heavy naphtha necessary to use a dual draw system, on the feed nozzle atomising steam,
pumparound heat, a reduction in the with the majority of product yielded reactor stripping steam and main
draw temperature can create problems in above the pumparound and a smaller column steam, with rates varying
each of these systems. Existing amount from the pumparound draw dramatically between units.
exchanger surface areas or pump tray. This maximises the pumparound Column overhead vapour HCl and
capacity are often insufficient to meet temperature. ammonia concentrations play a central
the required duties. It is common during role. FCC feeds containing high chlorides
revamps to have to add pump capacity Salt formation are mainly unhydrotreated atmospheric
and increase the exchanger surface area Localised temperatures, HCl and and vacuum residue containing residual
due to higher product draw rates. ammonia concentrations, and water inorganic salts (MgCl, CaCl and NaCl)
However, in many cases, modifying dewpoint all contribute to salt from the crude unit desalters, and
the flow scheme eliminates or formation. Ammonium chloride salts purchased gas oil contaminated with
minimises the pumparound system are deposited after condensed water has seawater. As overhead vapour HCl and
investment. Heavy naphtha product can absorbed the ammonia and HCl, and ammonia concentrations increase, salt
be withdrawn above the pumparound subsequently the water vapourises. forms at higher temperatures. Severely
(Figure 2), allowing existing equipment Water forms when localised hydrotreated feeds contain small
to be reused without modifications. This temperatures are below the water amounts of nitrogen compounds and
w w w. e p t q . c o m P T Q Q3 2006 00
saudi 5/7/06 21:12 Page 2
240
Overhead vapour
215
90
130 100
Reflux 90
160
260
200
Oil and trace
water
Temperature, F
Temperature, F
almost no chlorides. Therefore, overhead endpoint. A question often asked is present. This is done by sampling the
vapour ammonia and HCl concentra- What is the maximum percentage of draw stream and visually checking for
tions are low. High chloride feeds FCC gasoline that can be withdrawn as hydrocarbons. Since there is little water
generate large amounts of HCl, so the heavy naphtha? The answer depends present, this stream will be more than
column overhead temperature may need on the rate of salt deposition that is 90% hydrocarbon. This ensures water is
to be as high as 265F to avoid salt tolerable. If the rate of salt laydown is removed without having to install an
formation, whereas low chloride feeds high, there needs to be an effective way interface detector on the main column.
can operate as low as 235F without rapid to remove it; otherwise, the tray will Even though the draw stream contains
salt formation. plug, eventually causing flooding. 90% hydrocarbon or more, it will be less
Reflux temperature and rate influence Refiners yielding 20% or more of the than 10 gallons per minute for most
the rate of salt deposition because they gasoline as heavy naphtha will likely units. This stream can be cooled and
set localised temperatures. Reflux have high rates of salt deposition unless routed to the main column overhead
temperatures vary from 75120F, the feed has no chlorides. Those main receiver, where the oil and water are
depending on ambient conditions and columns that have operated problem- separated. The rate is so low that it does
the condenser system design. Reflux rate free for years at 215F or lower have not materially change the sulphur
depends on column heat balance. well-designed water draw trays and good content in the main column overhead
Overhead vapour temperature may be operating procedures. One refiner has product stream.
240300F, yet the liquid temperature been operating at below 190F for
leaving the top tray may be only 150- several years (Figure 4), but Water washing: abnormal
180F. High rates and cold reflux reduce continuously withdraws water during operations
the local temperature. Recognising the normal operation. Hence, salts never Water washing will cause significant
difference between localised liquid build up on the trays. Yet, it is essential upsets if the system is poorly designed,
temperatures on the top trays and that all free water be withdrawn; process routing is incorrect or the
measured vapour temperatures is otherwise, water containing HCl and procedure is not done properly. During
essential to understanding the ammonia will flow down the tower. This the water washing procedure, water and
mechanism of salt formation. is difficult to remove when it deposits oil will be withdrawn from the column
Heat is exchanged when cold reflux below the water draw tray. at 150190F. If this stream is routed
and hot vapour mix on the tray. Figure 3 directly to the main column overhead
depicts the change in liquid temperature Normal operations receiver without cooling, it will flash,
across a one-pass tray. In this case, reflux During normal operation, the targeted generating a higher wet gas compressor
enters at 90F, heat (and mass) is heavy naphtha product rate is set by load. During water washing, this stream
exchanged between the vapour and controlling the overhead temperature. needs to be piped upstream of the
liquid, and liquid leaves at 160F. A Lowering the overhead temperature overhead condensers (Figure 5).
portion of the vapour entering the top produces more heavy naphtha product Proper operating procedures are
tray is condensed. Localised temperatures with localised temperatures low enough essential, because water washing forces
below the water dewpoint contribute to to condense water even during normal an abnormal operation on the main
salt formation because the water absorbs operation. Ideally, this water is column. First, the column overhead
HCl and ammonia from the vapour. withdrawn continuously to minimise temperature must be reduced, and then
Water eventually vapourises because the amount of salt deposited. When the sufficient water added to the reflux so
temperatures increase as liquid flows column is designed with a proper water water is present on the water draw tray.
down the column, and salt is deposited. draw one or two trays below the top Water draw tray temperatures need to be
tray, it is possible to continuously low enough so that sufficient water is
Column overhead temperature remove free water. present to remove the salt. When the
Column overhead temperature is set by Operating with a continuous draw is water draw tray product is routed to the
operating pressure, the amount of water quite simple. Draw rate is set high main column condensers, the main
and overhead naphtha product enough to ensure hydrocarbon is always column overhead receiver temperature
00 P T Q Q3 2006 w w w. e p t q . c o m
saudi 5/7/06 21:12 Page 3
Condenser 175
75
Reflux
Water -
intermittent
use 185
Oil
Oil and
continuous
water
Oil and water to
overhead
condensers -
intermittent
Temperature, F
00 P T Q Q3 2006 w w w. e p t q . c o m