ARTICLE

pubs.acs.org/IECR

Selecting the Optimum Predistillation Scheme for Heavy Crude Oils

Yanhong Wang,† Yanjie Hou,‡ Hong Gao,† Jinsheng Sun,†,* and Shimin Xu†
†
School of Chemical Engineering and Technology, Tianjin University, No. 92 Wei Jin Road, Tianjin 300072, P. R. China
‡
Ethylene Glycol Factory, Jilin Petrochemical Co., Jilin 132000, China

ABSTRACT: The problem of designing a crude distillation unit (CDU) is not only a distillation design. It has the added complexity
that the properties of crudes are different around the world, sometimes from heavy to light. In this work, we focused our attention on
designing a predistillation scheme suitable for heavy crude oils by thermodynamic analysis. The exergy efficiencies and losses were
analyzed to evaluate available schemes indicating that the two-preflash-drums case, with the highest exergy efficiencies, lowest exergy
losses, and lowest furnace duty, is the best choice for heavy crude oils. In addition, the method of selecting the optimum process for
energy saving may benefit the process optimization of other distillation units.

1. INTRODUCTION furnace temperature. However, this study was limited because

Since the early 1970s, energy conservation has been a major
area of research in chemical engineering. Crude distillation is an
energy-intensive process. It was reported that the energy require-
ment for it was an amount of fuel equivalent to 25 30% of the
total crude processed.1 Therefore, it has received significant atten-
tion for better energy integration by revamping existing plants and
generating improved designs in running crude refineries.
In typical refineries, the crude distillation unit (CDU), which
is located at the beginning of the flow, consists of heat furnaces,
distillation towers, and a heat exchanger network (HEN). In the
past two decades, major studies focused on improving the energy
efficiency of the HEN. The pinch method was the most popular
strategy in the early 1980s,2 and then optimized designs for
distillation process along with supplementary considerations
were put forward. Brugma proposed one popular strategy,
employing predistillation devices, a drum or a column, which
was widely used in several industrial sites.3 Fan Xiaomei also gave
detailed descriptions of four predistillation unit (PDU) schemes
and compared their advantages and disadvantages.4
It is doubtful that predistillation devices can be used to achieve
substantial energy conservation. In particular, we will discuss the
meaningful works of Ji and Bagajewicz5 as well as that of Golden.6
The former work includes the preflash drum or the prefractiona-
tion column in a design method for the whole system including
the main column. They made a detailed analysis explaining the
effect of the lightest compounds of the crude, called carrier-effect,
in improving the separation of the gas oil fraction and also
compared different carrier gases to improve the gas oil yield. In
another study,7 they considered the preflash and the main
column system with the vacuum column, concluding that the
whole system has an energy request slightly smaller than the base
design without the PDU.
The position of Golden6 on the performance of the predis-
tillation device is more critical. He analyzed many parameters
that influence the performance of the main column, like the flash
drum temperature, the flashed vapor feed location, the effect of
flashed crude entrainment in the vapor stream, and the quench
effect of the flashed vapor in the main column with a fixed outlet
the feedstock conditions of the two cases were different.
Exergy analysis has been demonstrated to be a feasible method
for selecting optimal designs. Some researchers have paid their
attention to exergy analysis in the assessment of the environ-
mental impacts of thermal and other industrial processes.8 13 In
a more recent study, Al-Muslim et al.14 16 compared one- and
two-stage atmosphere distillation units (ADU) using this meth-
od. In those studies, they extended the thermodynamic analysis
to investigate the effects of key system parameters in terms of
column temperature and pressure on system energy and exergy
efficiencies under various conditions. Furthermore, they investi-
gated the reciprocal effect of reference temperature (varying
from 15 to 40 °C) on the exergy efficiencies and losses in one and
two stage ADUs.
This paper will, mainly by means of thermodynamic analysis,
study and select the predistillation scheme for heavy crude oils.
On the basis of a real CDU, nine PDU schemes were summarized
and evaluated. It is meaningful because real plant data were
utilized, and the optimal predistillation scheme for heavy crude
oils was proposed.
2. REAL PLANT PROCESS DESCRIPTION AND
SIMULATION
The real plant process considered in this study is located at
China Offshore Bitumen Co., Ltd., with a nominal capacity of
1 000 000 ton/year. Basically, the process consists of three units:
PDU, ADU, and the vacuum distillation unit (VDU), two crude
oil furnaces, and a HEN, feeding with a heavy crude oil, density of
0.965 g/cm3.
2.1. Description of the Plant. Figure 1 illustrates the heavy
crude oil model under study. HEN is not shown, but its effect
on utilizing the high temperature of product streams to pre-
heat the crude oil is considered. The operating parameters and
the product specification of the model were summarized in
Received: November 30, 2010
Accepted: August 11, 2011
Revised: July 26, 2011
Published: August 11, 2011

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Industrial & Engineering Chemistry Research ARTICLE

Figure 1. Distillation unit configuration of the real plant.

Table 1. Basic Data of Fractionating Towers in the Heavy Table 3. Products Quality Index of the Heavy Crude Oils
Crude Oils Distillation Unit Distillation Unit
parameter AC VC substance weight % target (°C)

number of trays 48 (actual trays) 32 theoretical trays top oil of PC 100 195
feed tray 46 30 top oil of AC 100 195
furnace temperature °C 365 365 DST 5# oil 90 345
column top 103 1 atmosphere cut 2 100 346
pressure KPa vacuum cut 2 95 425
condensing 40 vacuum cut 3 100 483
temperature °C

amount of time and good technical knowledge of the plant. The

cut 01 withdraw tray 16 01 withdraw tray 3
simulation procedure can be described in the following three
02 withdraw tray 28 02 withdraw tray 10
principal steps: (1) definition of the flow sheet; (2) definition of
02 steam stripping 03 withdraw tray 17
the operative variables; (3) choice of the thermodynamic model.
return tray 24 04 withdraw tray 23
ASTM D86 data and flow rates of products of the plant and
simulated were compared in Figures 2 and 3, respectively. Other
Table 2. Basic Data of Pumparounds in the Heavy Crude Oils important parameters are the internal data in the AC and VC
Distillation Unit (Tables 4 and 5). It can be seen that the simulated data agreed
well with the plant data, confirming the validity of this model.
AC VC Subsequently, this model can be used to analyze other cases in
our study.
Parameter PA01 PA02 PA03 PA01 PA02 PA03

withdraw tray 4 20 32 3 5 12
return tray 3 17 29 1 4 11 3. DESCRIPTION OF THE PDU SCHEMES
mass flow rate t/h 14 20 15 19 41 53 The purpose of PDU is to remove the light compounds from
return temperature °C 85 180 260 64 123 180 the crude before it enters the furnace. The vapor stream obtained
from PDU can then be introduced at the furnace outlet or in an
appropriate location of the main column. In this way it is possible
Tables 1 3. The components can be described as follows: (1)
to reduce the heat duty of the furnace and the feeding flow rate of
light products obtained in the preflash drum sent to the
upper section of the atmosphere column (AC); (2) three pump- the furnace before the CDU, as well as to improve the hydraulic
arounds and two side-streams in the AC; (3) three pumparounds performance of the HEN.17,18
and four side-streams in the vacuum column (VC). In Table 6, the available PDU schemes were summarized and
2.2. Simulation Model. To find the exact side cuts, tempera- compared, and nine schemes were presented as seen in Figure 4
ture, pressure, enthalpy, and entropy, the simulation of the to Figure 12. Case 0 is the conventional two-stage CDU evapo-
available schemes should be conducted. To make a comparison ration design. There is no predistillation device in this model and
among different PDU schemes it is necessary to start a simulation can be used as contrast test (Figure 4). A detailed description of
from the real plant. The aim is to make the simulation as close as this design can be found elsewhere.19 The VDU is not presented
possible to the real plant behavior. Developing a good simulation in those Figures because it is the same as the previous two-stage
is a difficult task for substantial plant data, demanding a large evaporation design.
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Figure 2. ASTM D86 data of the products comparison between the plant and simulated data.

Table 4. Comparison between Calibration Value and Simu-

lation Value of the CDU
calibration simulation
item parameter value value

atmospheric furnace outlet temperature, °C 365 365

atmospheric top temperature, °C 101 101
product
atmospheric cut 1 temperature, °C 221 221
atmospheric cut 2 temperature, °C 281 283
atmospheric extract 124 124
pumpround 1 temperature, °C
return 85 85
temperature, °C
flow rate, t/h 14 14
atmospheric extract 256 260
Figure 3. Flow rate of the products comparison between the plant and
simulated data. pumpround 2 temperature, °C
return 180 180
4. THERMODYNAMIC MODELING temperature, °C
flow rate, t/h 20 20
There are three governing equations that are normally used in
atmospheric extract 302 302
energy-exergy analysis of open systems, namely the conservation
equations of mass, energy, and entropy generation.20 These pumpround 3 temperature, °C
equations were applied to our steady-state steady-flow conditions return temperature, °C 260 260
for the case of negligible changes in kinetic and potential energy flow rate, t/h 15 15
with ambient conditions: T0 = 25 °C = 298.15 K, P0 = 101 kPa.
For each case, the three conservation equations were utilized to
5. PDU SCHEMES OPTIONS
calculate exergy losses and exergy efficiencies.
The total exergy of a stream of matter is simply the sum of To determine the optimal scheme for heavy crude oils, the
physical exergy and chemical exergy. Physical exergy of a stream rates of exergy losses and efficiencies were calculated according to
can be defined as the maximum work (useful energy) that can be the stream parameters extracted from the simulation results. First,
obtained from the stream by taking it to physical equilibrium the simulation was run for the real plant. Next, all the other cases
(of temperature and pressure) with the environment.21 For many were conducted. In all simulations in this paper the units were fed
identified substances, the standard chemical exergy (i.e., at with the same heavy crude oil. Except for the different PDUs, the
T0 and P0) can be found in the literature; however, for the models of ADU and VDU were under the same condition.
pseudocomponents the chemical exergy can be determined from 5.1. Simulation Results of All the Schemes. To evaluate the
heuristic empirical expressions that are a function of the elementary simulation results, the total yield of CDU and ASTM D86 distillation
composition and the heating value of each pseudocomponent.22 curves of the side stream products were compared with data from
In the literature and some applications, the net heating value of the the real plant data. To have a very good agreement, it is necessary to
pseudocomponents could be used as a first approximation of their make a series of simulation tests by adjusting the operative variables,
chemical exergy.23 such as furnace temperature, heat-removing, etc.
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Table 5. Comparison between Calibration Value and

Simulation Value of the VDU
item parameter calibration value simulation value

vacuum furnace outlet temperature, °C 365 365

vacuum top temperature, °C 54 64
product
vacuum cut 1 temperature, °C 157 145
vacuum cut 2 temperature, °C 235 249
vacuum cut 3 temperature, °C 283 297
vacuum cut 4 temperature, °C 307 317
vacuum return temperature, °C 64 64
pumpround 1
vacuum return temperature, °C 123 123
pumpround 2 flow rate, t/h 41 41 Figure 5. Scheme of one preflash drum, top feeding.
vacuum return temperature, °C 180 180
pumpround 3 flow rate, t/h 53 53

Table 6. Comparison between Different Cases

prefractionation preflash

case number of number of number of flashed vapor feed

number columns sides drums location

0 0
1 0
2 0
3 0
4 1
5 1
6 1
7 1
8 1
0
1 top
1 bottom
2
0 0
1 0
0 1 top
0 2 Figure 6. Scheme of one preflash drum, bottom feeding.
0 1 bottom

Figure 4. Flow sheet for two-stage evaporation.

Figure 7. Scheme of two preflash drums.

The results are shown in Figures 13 and 14. Good agreement considerable effect on energy saving. Case 3 had a slightly decreased
between the simulated data and plant data was obtained. Based furnace duty compared to the other cases.
on these results, Figure 15 shows a comparison of the furnace 5.2. Exergy Analysis. As it is well-known, energy cannot be
duty of all the cases. Furnace duty was almost equal for all the created nor destroyed but only transformed (it is the first law of
cases except for Case 7 and Case 0, which had significantly higher thermodynamics). However in all real processes its quality
furnace duties. Therefore, it is reasonable to say that PDU has a decreases, that is, energy is degraded (it is the second law of
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Figure 11. Scheme of a prefractionation column with two preflash

Figure 8. Scheme of a prefractionation column. drums.

Figure 9. Scheme of a prefractionation column with one side. Figure 12. Scheme of prefractionation column with one preflash drum,
bottom feeding.

Figure 10. Scheme of a prefractionation column with one pre-

flash drum.

thermodynamics) and the increasing relevance of the second law

Figure 13. The simulated D86 distillation curves of the products.
is the result of two significant changes produced at the interna-
tional level in energy policies.
Exergy analysis is an effective tool both for achieving efficient principles together with the second law of thermodynamics. A
energy utilization with reduced environmental and sustain- thermodynamic analysis was conducted for CDU. In the analy-
ability impact and for providing optimum designs and operation tical procedure, we simultaneously considered PDU, ADU,
for using the conservation of mass and conservation of energy VDU, and the entire process.
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Industrial & Engineering Chemistry Research ARTICLE

Figure 14. Yield comparison between the plant and simulated data.
Figure 17. Exergy efficiencies of PDU.

Figure 15. Simulated furnace duties.

Figure 18. Irreversibility rate of ADU.

Figure 16. Irreversibility rate of PDU.

Figure 19. Exergy efficiencies of ADU.
5.2.1. PDU. The parameters studied are shown in Figures 16
and 17. The highest energy efficiencies and the lowest exergy prefractionation columns had higher physical exergy losses than
losses occurred in case 1 and 2. It is noticed that the cases with the other cases. This is because more trays in the prefractionation
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Industrial & Engineering Chemistry Research
Figure 20. Irreversibility rate of VDU.
Figure 21. Exergy efficiencies of VDU.
Figure 22. Irreversibility rate of the whole process.
column lead to an increase of the temperature difference.
Additionally, the chemical exergy losses followed the same trend
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Figure 23. Exergy efficiencies of the whole process.
as the physical exergy losses, due to fewer light components in
the heavy crude oils, which will lead to less gas produced from
preflash drums.
5.2.2. ADU. Figures 18 and 19 show the rate of exergy losses
and efficiencies for all cases. The chemical exergy losses of case 0
were outstanding. This is again because the main separation took
place in ADU. The chemical exergy losses of cases with preflash
drums were higher than that of the others associated with fewer
light compounds in the heavy crude oils. Thus, ADU became the
main preliminary separation device. Considering only the effect
of PDU on ADU, case 5 is the optimal solution.
5.2.3. VDU. There was no significant change with regard to the
chemical exergy losses (Figures 20 and 21). The lack of a
significant change in VDU can be explained from the steady
feed composition as a result of the ending position in the chain of
the process equipments. The optimal solution, with regards to
VDU, was case 3.
5.2.4. The whole process. As illustrated in Figures 22 and 23, the
chemical exergy losses were nearly equivalent, but for the physical
exergy losses, case 3 is the lowest point with high exergy efficiencies.
It can be concluded from the above observations, cases 1, 2, 3,
and 5 were optimal considering a separate unit. However, when
the whole process was analyzed, case 3 was selected as the
optimal design. Furthermore, the furnace duty of case 3 is also the
lowest. This means that not only does it need less fuel, but also
the fuel is used more efficiently. This is because two preflash-
drums were adopt in case 3 design, which can flash more vapor,
and then make the temperature and flow rate evenly distributed
in AC and VC. This again emphasized the fact that low exergy
losses were encountered in applications where there is a low
temperature difference.
6. CONCLUSIONS
In this article, nine PDU schemes were summarized and
discussed, and an optimum scheme for heavy crude oil is
proposed. First, they were simulated at the same feeding condi-
tions with the product specification maintained consistent with
real plant data. Via exergy analysis, case 3 is chosen as the
optimum scheme, which has two preflash-drums. It presents high
exergy efficiencies, low exergy losses and furnace duty. Moreover,
because of the different feeding locations of the two flash vapors,
temperature and gas/liquid flow rate in AC can be evenly dis-
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Industrial & Engineering Chemistry Research ARTICLE

tributed, and this also avoids the reduction of carrier-effect and (10) Ayres, R. U. L.; Ayres, W.; Martinas, K. Exergy, waste account-
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’ AUTHOR INFORMATION 2003, 125, 199–207.
(15) Al-Muslim, H.; Dincer, I.; Zubair, S. M. Thermodynamic
Corresponding Author analysis of crude oil distillation system. Int. J. Energy Res. 2005,
*E-mail: jssun2006@vip.163.com. Tel./Fax: +86-22-27891755. 29, 637–655.
(16) Al-Muslim, H.; Dincer, I; Zubair, S. M. Effect of reference state
on exergy efficiencies of one- and two-stage crude oil distillation units.
’ ACKNOWLEDGMENT Int. J. Therm. Sci. 2005, 44, 65–73.
The authors acknowledge the support provided by the China (17) Harbert, W. D. Pre-flash saves heat in crude unit, Hydrocarbon
Offshore Bitumen Co., Ltd. Process. 1978, July 123 125.
(18) Feintuch, H. M.; Peer, V.; Bucukoglu, M. Z. A pre-flash drum
can conserve energy in a crude preheat train. Energy Progress. 1985,
’ NOMENCLATURE 5, 165–172.
E = energy rate, kw (19) Bagajewicz, M.; Ji., S. Rigorous procedure for the design of
h = specific enthalpy, kJ/kg conventional atmospheric crude fractionation units. 1. Targeting. Ind.
Q = heat transfer rate, kw Eng. Chem. Res. 2001, 40, 617.
Ξ = exergy, kw (20) Al-Muslim, H. Energy and Exergy Analyses of Crude Oil
ε = specific exergy, kJ/kg Distillation Plants. M.Sc. Thesis, KFUPM, Dhahran. 2002.
Ψ = exergy efficiency (21) Rivero, R. Tridimensional Exergy Diagram. In Energy Systems
NHV = net heating value, kw and Ecology; Szargut, J., Kolenda, Z., Tsatsaronis, G., Ziebik, A., Eds.;
Polish Ministry of National Education American Society of Mechanical
P = pressure, kPa Engineers: Cracow, Poland, 1993; Vol. 1, pp 305 312.
T = temperature, °C (22) Szargut, J; Morris, D. R.; Steward, F. R. Exergy Analysis of
Thermal. Chemical and Metallurgical Processes; Hemisphere Publishing
Subscripts
Corporation: New York, ISBN 0 89116 574 6, 1988.
i = component (23) Rivero, R.; Rendon, C.; Monroy, L. The exergy of crude oil
j = component mixtures and petroleum fractions: Calculation and application. Int. J.
Appl. Thermodyn. 1999, 3, 115–123.
Abbreviation
CDU = crude distillation unit
PDU = predistillation unit
ADU = atmosphere distillation unit
VDU = vacuum distillation unit
PC = predistillation column
AC = atmosphere column
VC = vacuum column

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