Crude Unit Overview - 3crude Distilation PRESENTATION

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Typical Crude Tower Products Typical Crude Tower Products
950 to 1100 Vacuum Resid
950 to 1100 800
HVGO
(Heavy Vac Gas Oil)
800 650
LVGO
(Light Vac Gas Oil)
650 420 to 520
AGO
(Atm Gas Oil)
420 to 520 330 to 380
Distillate
(Kerosene)
330 to 380 180 to 220 Heavy Naphtha
180 to 220 80 to 90
Light Naphtha
(LSR Gasoline)
TBP EP (F) TBP IBP (F) Cut
Overview Overview
Crude Stills
Historically the oldest refining process
Only the first step in crude oil processing
Purpose
To recover light materials
Fractionate into sharp light fractions
Configuration May be as many as three columns in
series
Crude Stabilizer/Preflash Column
Reduce traffic in the Atmospheric Column
Atmospheric Column
Vacuum Column
Reduced pressure to keep temperatures below
650F
Typical Configuration Typical Configuration
Atmospheric Column w/o Atmospheric Column w/o Preflash Preflash
Modification of drawing in:
Refining Overview Petroleum Processes & Products,
by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD-ROM, 2000
Overview Overview
Crude Stills
Purpose
series
Atmospheric Column
Vacuum Column
650F
Column Configuration
Condenser
Partial condenser if no
Stabilizer Column.
Total condenser if Stabilizer
Column to remove light
ends.
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.
Pumparounds to move the
cooling down the column.
Liquid returned above the
draw tray.
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
Multiple side draws & strippers
to clean up side products.
Stripping steam to reduce
partial pressure hydrocarbons.
Condensed & removed as a
second liquid phase.
Conditions set so it doesnt
condense within the column.
Can lead to foaming.
Must be treated as sour
water.
Final heating in a direct fired
heater.
Inlet typically 550F.
Heated no higher than 750F
Minimize thermal cracking.
Actual heat exchange is with
streams from within the tower.
Recovery of heat important to
distillation economics.
Final cooling done with air
coolers or cooling water.
distillation economics!
distillation economics.
Final cooling done with air
coolers or cooling water.
First absorb part of the
overhead condensation load
Exchange with one or more of
the liquid sides streams,
beginning with the top
(coldest) side stream.
Desalter
Point must be carefully selected
care taken not to let the
water vaporize
Lighter crudes (> 40API) @
250F
Heavier crudes (< 30API)
@ 300F
Balance temperature & pressure
Desalter
All crudes contain salts
May be sodium chloride,
magnesium chloride, etc.
Salt present in the
emulsified water
Treated in the field with
heat & chemicals to
break oil water
emulsions.
Crude Electrostatic Desalting Crude Electrostatic Desalting
Drawings from:
Desalter
Salt can cause damage to
equipment
Scale in heat exchangers
Drastically reduce heat
transfer
Hydrogen chloride formation
can lead to corrosion
Metals that can poison
refinery catalysts
Desalter
Remove salts & dissolved
metals & dirt
Oil mixed with fresh wash
water & demulsifiers.
Mixed & heated followed by
settling
Separated in an electrostatic
settling drum
Desalter
Added wash water as much as
10% of crude oil charge
About 90% of the water can
be recovered
Effluent water must be treated
for benzene recovery
Wash Zone
Couple trays between flash zone
& gas oil draw.
Reflux to wash resins & other
heavy materials that may
contaminate the products.
Pumparounds
Reduces overhead condenser
load & achieves more uniform
tower loadings
Provides liquid reflux below
liquid draws
Side Draws & Strippers
Cut point related to final
boiling point of draw stream
Side strippers remove light
component tail & return to
main column
Steam strippers traditional
Reboiled strippers reduce
steam usage &
associated sour water
Trays & Pressure Profile
Typically 32 trays in tower
0.1 to 0.2 psi per tray
Condenser & accumulator
3 to 10 psi across condenser
Liquid static head in
accumulator
Typically 6 to 16 psi across
entire column.
Overview Overview
Crude Stills
Purpose
series
Atmospheric Column
Vacuum Column
650F
Vacuum Distillation Vacuum Distillation
Drawings from:
Vacuum conditions to keep operating
temperatures low
Large diameter column
Very low density gasses
Condenser for water vapor
Liquid reflux from pumparounds
No reboiler
Stripping steam may be used
Needed for deep cuts (1100F)
Feed
Atmospheric residuum
All of the vapor comes from the heated
feed stream
Under vacuum (0.4 psi)
Separate higher boiling materials
at lower temperatures
Minimize thermal cracking
Products
May have multiple gas oils
Separate products to increase the
heat recovery in the column
Products recombined downstream
Usually FCCU via hydrotreating
Vacuum resid
Blended asphalt, heavy fuel oil
Further processing thermal,
solvent
Choice depends on products &
types of crude
Deep Cut System
1100F+ cut temperature & stripping
steam
Steam reduces hydrocarbon partial
pressures
Pressure profile
Flash zone: 30 mm Hg abs
Hydrocarbon partial pressure
10-15 mm Hg abs
Top of tower: 15 mmHg abs
Dry System
1050F+ cut temperature & no
stripping steam
Smaller tower diameters
Reduced sour water production
Pressure profile
Flash zone: 20-25 mm Hg abs &
750 to 770F.
Top of tower: 10 mm Hg abs
Steam Ejectors & Vacuum Pumps
Vacuum maintained on tower overhead
Steam systems considered more
reliable
Waste steam is sour & must be
treated
Combinations systems Last steam
stage replaced with a vacuum pump

Crude Unit Overview - 3crude Distilation PRESENTATION

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