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Crude Oil Distillation

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Crude Oil Distillation Crude Oil Distillation Chapter 4 Gases Polymer- Sulfur Sulfur ization Plant LPG Sat Gas Gas Plant Butanes Fuel Gas Alkyl LPG Feed Alkylation Gas Polymerization Separation & Naphtha Stabilizer Isom- erization Light Naphtha Alkylate Aviation Isomerate Gasoline Automotive Gasoline Reformate Naphtha Solvents Heavy Naphtha Hydro- Naphtha Reforming treating Naphtha Atmospheric Distillation Jet Fuels Kerosene Crude Desalter Kerosene Oil Distillate Cat Solvents Hydro- AGO Naphtha Distillate cracking Treating & Hydro- Heating Oils Blending treating Gas Oil Fluidized Cat Diesel LVGO Hydro- Catalytic treating Cracking Distillates Vacuum Distillation Fuel Oil HVGO Cycle Oils Residual Fuel Oils DAO Solvent Deasphalting SDA Coker Asphalts Bottoms Naphtha Naphtha Visbreaking Heavy Distillates Fuel Oil Coker Bottoms Gas Vacuum Lubricant Residuum Oil Lube Oil Solvent Greases Dewaxing Waxes Waxes Coking Light Coker Gas Oil Coke Updated: July 12, 2018 2 Copyright © 2017 John Jechura ([email protected]) Atmospheric & Vacuum Distillation in U.S. EIA, Jan. 1, 2018 database, published June 2018 http://www.eia.gov/petroleum/refinerycapacity/ Updated: July 12, 2018 3 Copyright © 2017 John Jechura ([email protected]) Topics Crude Stills Configuration — May be as . Historically the oldest refining many as three columns in process series . Only the first step in crude oil . Crude Stabilizer/Preflash Column processing • Reduce traffic in the Atmospheric Purpose Column . Atmospheric Column . To recover light materials . Vacuum Column . Fractionate into sharp light fractions • Reduced pressure to keep blow cracking temperatures Product Yield Curves – Cut Point, Overlap, & Tails Updated: July 12, 2018 4 Copyright © 2017 John Jechura ([email protected]) Configuration: Atmospheric Vacuum Preflash Updated: July 12, 2018 Copyright © 2017 John Jechura ([email protected]) Atmospheric & Vacuum Tower Complex Updated: July 12, 2018 6 Copyright © 2017 John Jechura ([email protected]) Atmospheric & Vacuum Tower Complex Modified drawing from: “Revamping crude and vacuum units to process bitumen,” Sutikno, PTQ ,Q2 2015 Updated: July 12, 2018 7 Copyright © 2017 John Jechura ([email protected]) Atmospheric Column with Preflash Modification of figure in “Increasing distillate production at least capital cost,” Musumeci, Stupin, Olson, & Wendler, PTQ, Q2 2015 Updated: July 12, 2018 8 Copyright © 2017 John Jechura ([email protected]) Preflash Options – Tight Oil Example with no AGO “Optimising preflash for light tight oil processing,” Lee, PTQ, Q3 2015 Updated: July 12, 2018 9 Copyright © 2017 John Jechura ([email protected]) Feed Preheat Train & Desalter Feed Preheat Train Desalter . Initial heat exchange with streams from within . Temperature carefully selected — do not let the tower water vaporize • Heat recovery important to distillation economics! • Lighter crudes (> 40oAPI) @ 250oF o First absorb part of the overhead • Heavier crudes (< 30oAPI) @ 300oF condensation load . All crudes contain salts (NaCl, MgCl, …) o Exchange with one or more of the liquid sides • Salt present in the emulsified water streams, beginning with the top (coldest) side stream • Treated in the field with heat & chemicals to break oil water emulsions. • Require flexibility • Salt can cause damage to equipment o Changes in crude slate o Scale in heat exchangers o Temperature at desalter o HCl formation can lead to corrosion o Limits on two‐phase flow through network o Metals can poison refinery catalysts . Final heating in a direct fired heater . Remove salts & dissolved metals & dirt • Heat enough to vaporize light portions of the crude but temperature kept low to minimize • Oil mixed with fresh wash water & demulsifiers. thermal cracking . Separation in electrostatic settling drum o Inlet typically 550oF, outlet 600 to 750oF. Wash water up to 10% of crude charge o Heavier crudes cannot be heated to the • ~ 90% of the water can be recovered higher temperatures . Effluent water treated for benzene Updated: July 12, 2018 10 Copyright © 2017 John Jechura ([email protected]) Crude Electrostatic Desalting Drawing by Milton Beychok http://en.citizendium.org/wiki/File:Desalter_Diagram.png BFDs from: Refining Overview – Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD‐ROM, 2000 Updated: July 12, 2018 11 Copyright © 2017 John Jechura ([email protected]) 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 Updated: July 12, 2018 12 Copyright © 2017 John Jechura ([email protected]) Direct Fired Heater Ref: “Useful tips for fired heater optimisation” Bishop & Hamilton, Petroleum Technology Quarterly, Q2 2012 Updated: July 12, 2018 13 Copyright © 2017 John Jechura ([email protected]) Atmospheric Distillation Summary Condenser … Pumparounds . Partial condenser if no Stabilizer Column. Move cooling down column. Total condenser if Stabilizer Column to . Liquid returned above draw tray remove light ends. Side draws … but no reboiler. Side strippers Feed preheat exchanger train . “Clean up” side products . All of the heat to drive the column comes from the hot feed. Stripping steam • As much as 50% of the incoming crude may . Reduce hydrocarbon partial pressure be flashed. Condensed & removed as a second liquid • “Overflash” phase. o Extra amount of material vaporized to • Conditions set so it doesn’t condense ensure reflux between flash zone & within the column – can lead to foaming lowest side draw • Must be treated as sour water o Typically 2 vol% of feed Updated: July 12, 2018 14 Copyright © 2017 John Jechura ([email protected]) Atmospheric Distillation Summary Wash Zone Side Draws & Strippers . Couple trays between flash zone & gas oil . Side strippers remove light component “tail” & draw. return to main column . Reflux to wash resins & other heavy materials . Steam strippers traditional that may contaminate the products. • Reboiled strippers reduce associated sour water & may reduce steam usage Condenser . Typically 0.5 to 20 psig. Trays & Pressure Profile . Balancing act . Typically 32 trays in tower • Low pressures reduce compression on overhead . 0.1 psi per tray for design & target for system operation • High pressures decrease vaporization but increase • May find as high as 0.2 psi per tray, but probably flash zone temperatures & furnace duty; affects flooding! yields . Condenser & accumulator Pumparounds • 3 to 10 psi across condenser • Liquid static head in accumulator . Reduces overhead condenser load & achieves more uniform tower loadings . Typically 6 to 16 psi across entire column. Provides liquid reflux below liquid draws Updated: July 12, 2018 15 Copyright © 2017 John Jechura ([email protected]) Vacuum Distillation Refining Overview – Petroleum Processes & Products, “Consider practical conditions for vacuum unit modeling” by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD‐ROM, 2000 R. Yahyaabadi, Hydrocarbon Processing, March 2009 Updated: July 12, 2018 16 Copyright © 2017 John Jechura ([email protected]) Vacuum Distillation – Trays vs. Packing Packing used in vacuum towers instead of trays . Lower pressure drops across the tower – vapor “slides by” liquid instead of pushing through the layer on the tray . Packing also helps to reduce foaming problems “Foaming in fractionation columns” M. Pilling, PTQ, Q4 2015 Updated: July 12, 2018 17 Copyright © 2017 John Jechura ([email protected]) Vacuum Distillation Summary Column Configuration Feed . Vacuum conditions to keep operating . Atmospheric residuum temperatures low . All vapor comes from the heated feed . Large diameter column . Under vacuum (0.4 psi) . Very low density gases . Separate higher boiling materials at . Condenser only for water vapor lower temperatures . Liquid reflux from pumparounds • Minimize thermal cracking . No reboiler Products . Stripping steam may be used . May have multiple gas oils • Needed for deep cuts (1100oF) • Usually recombined downstream to FCCU . Common problem – coking in fired after hydrotreating heater & wash zone . Vacuum resid • Fired heater – high linear velocities to • Blended — asphalt, heavy fuel oil minimize coke formation • Further processing — thermal, solvent • Wash zone – sufficient wash oil flow to o Depends on products & types of crude keep the middle of the packed bed wet Updated: July 12, 2018 18 Copyright © 2017 John Jechura ([email protected]) Vacuum Distillation Summary Dry System Steam Ejectors & Vacuum Pumps . 1050oF+ cut temperature & no stripping steam . Vacuum maintained on tower overhead . Smaller tower diameters . Steam systems considered more reliable . Reduced sour water production . Waste steam is sour & must be treated . Pressure profile . Combinations systems — Last steam stage • Flash zone: 20‐25 mmHg abs & 750 to 770oF. replaced with a vacuum pump • Top of tower: 10 mmHg abs Deep Cut System . 1100oF+ cut temperature & stripping steam . Steam reduces hydrocarbon partial pressures . Pressure profile • Flash zone: 30 mmHg abs • HC partial pressure 10‐15 mmHg abs • Top of tower: 15 mmHg abs Drawing from http://www.enotes.com/topic/Injector Updated: July 12, 2018 19 Copyright © 2017 John Jechura ([email protected]) Example Crude Preheat Trains Ref: “Improve energy efficiency via Heat Integration” Rossiter, Chemical Engineering Progress, December 2010 Updated: July 12, 2018 20 Copyright © 2017 John Jechura ([email protected]) “Composite Curve” for Preheat
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