PETROLEUM

ANALYSIS

WITH
FOR

REFINING

OF

OPERATION

S-SHAPED
CRUDE

EQUIPMENT

OF

TRAY

OIL

ATMOSPHERIC

ELEMENTS

TOWER

IN L A R G E

UNIT

DISTILLATION

G. P . P i k a l o v ,
A. P. Pikalov,
P. I. Korotkov,

UDC 665.63.542.48

Yu. K. Molokanov,
A. D. Rudkovskii,
and N. V. Kazharskaya

An a n a l y s i s of the o p e r a t i o n of l a r g e crude oil distillation units with t o w e r s having S - s h a p e d t r a y

e l e m e n t s h a s d e m o n s t r a t e d the f e a s i b i l i t y of i n c r e a s i n g the t o w e r loads b y 30-40% [1-3]. The institute
VN]:Pineft' [All- Union S c i e n t i f i c - R e s e a r c h and Design Institute of the P e t r o l e u m - Refining and P e t r o c h e m i c a l
Industry] h a s completed the design f o r r e c o n s t r u c t i o n of a l a r g e crude oil distillation unit at the Novopolotesk
P e t r o l e u m Refinery, with the a i m of i n c r e a s i n g its c a p a c i t y b y 33%.
H e r e we a r e p r e s e n t i n g r e s u l t s f r o m an operating t e s t on the a t m o s p h e r i c t o w e r T - 2 , with a d i a m e t e r
of 7 m, equipped with 38 t w o - p a s s t r a y s with S - s h a p e d e l e m e n t s , installed at a spacing of 800 ram; r e c o m mendations a r e given f o r i m p r o v e m e n t s in the o p e r a t i n g indices of such t o w e r s . A d i a g r a m of the t o w e r is
shown in Fig. 1, and the b a s i c indices of the t o w e r ' s fractionating capability a r e given in T a b l e 1.
The r e c o n s t r u c t i o n design provided f o r additional m i d - t o w e r circulating reflux
i n t e r e s t of i m p r o v i n g the distribution of loads up and down the tower. The heat of the
at the expense of a t h i r d p a r a l l e l s t r e a m of crude. By the circulating r e f l u x s t r e a m s ,
withdrawn, d i s t r i b u t e d in the following m a n n e r among the individual c i r c u l a t i n g reflux
P T s O - m i d d l e , 10.5; P T s O - 2 , 24.3 G c a l / h .

( P T s O - middle) is in the
P T s O - m i d d l e is c r e a t e d
55.3 G c a l / h of heat is
s t r e a m s : P T s O - 1 ; 20.5;

During the t e s t period, the unit was p r o c e s s i n g crude f r o m the D r u z h b a pipeline, to which a g a s c o n densate was added in amount of 7% r e l a t i v e to crude. The T - 2 t o w e r feed was topped crude, amounting to 90%
of the total c r u d e entering the unit. The yields of products f r o m T - 2 t o w e r (in % r e l a t i v e to original crude)
w e r e : naphtha (IBP-180~
11.5%, k e r o s i n e (180-220~
9.0%, d i e s e l fuel (220-350~
23%. The t o t a l yield
T A B L E I. Indices of F r a c t i o n a t i n g C a p a bility of T - 2 T o w e r
Fraction
'

Indices

Dislillation (GOST
2177-66), C
IBP
lb%
50%
90%
Content of fractions accord-'
ing to TBP curve, %
below 140~
below 180~
below 220~C
below 280:C
below 350 C
below 360~C
Difference in di~tillatLon
teraperatures, C
It~-EP
10%-90%
hvezage reflux ratio

56
86
26
64
80

148
160
188
210
224

205
225
280
334
354

230
-a
---

i0.2 3,9
98 20,5
82,2

--[0,4

---

--

1,5

1,3

52,4

)2,5
)4,2

1~

9
10

--

T r a n s l a t e d f r o m Khimiya i Teldmologiya Topliv i Masel, No. 3, pp. 4 4 - 4 7 , March, 1979.

208

0009-3092/79/0304-0208 $07.50 9 1979 Plenum Publishing C o r p o r a t i o n

/g

~n~

-:3-

Steam ~ - - ~

e.!

Fig. 1. D i a g r a m of T - 2 a t m o s p h e r i c tower
b e f o r e and a f t e r r e c o n s t r u c t i o n : 1) pump; 2)
heat exchanger; 3) a i r - c o o l e d exchanger; 4)
stripping tower; 5) w a t e r s e p a r a t o r . S t r e a m s
shown as solid lines a r e b e f o r e reconstruction,
those shown as dashed lines a r e a f t e r r e c o n struction. I) Topped crude; II) r e s i d u a l fuel oil;
IID naphtha; IV) kerosine; V) d i e s e l fuel; VI-VII)
P T s O - 1 , 2; VIII) P T s O - m i d d l e . [The l e t t e r s TsO
denote circulating reflux; the significance of the
P is not known - T r a n s l a t o r . ]
of light p e t r o l e u m products, including the naphtha f r o m the T - 1 tower, was 53.5%, and the gas yield
was 2%.
Steam feed to the tower included the following: 1% to the d i e s e l fuel stripping t o w e r and 1.44% to the
bottom of the T - 2 tower. The absolute p r e s s u r e in the t o w e r was 2.2 k g f / c m 2. The v e r t i c a l t e m p e r a t u r e
distribution in the t o w e r was as follows: feedstock at inlet to tower 360~ t o w e r top 140~ takeoff of k e r o s e n e
f r o m tower 200~ takeoff of diesel fuel 298~ t o w e r bottom 340~ PTsO t e m p e r a t u r e s (takeoff/feedback) as
follows: P T s O - 1 154/70~ P T s O - m i d d l e 228/70~ P T s O - 2 252/86~
Calculated f r o m the operating t e s t
data w e r e the m a s s and heat balances, r e f l u x ratio, number of t h e o r e t i c a l t r a y s , and hydrodynamic c h a r a c t e r i s t i c s of t r a y operation. The p e r c e n t a g e vapor flashed off at the inlet of the topped crude to the t o w e r was
d e t e r m i n e d by a p r o c e d u r e set forth in [4]. In calculating the hydrodynamic indices, use was made of equations
given in [5, 6]. The basic p a r a m e t e r s of multicomponent distillation, i.e., the minimum operating reflux ratio,
the optimum r e f l u x ratio, and the n u m b e r of t h e o r e t i c a l t r a y s f o r the sections of the tower, w e r e d e t e r m i n e d
by a p r o c e d u r e set forth in [7]. Special f e a t u r e s involved in calculating the basic p a r a m e t e r s of distillation in
a complex t o w e r for crude oil separation a r e given in [8].
The composition of the vapor feed (composition of the load) f o r calculation of each section was assumed
on the basis of the m a s s balance of the c o r r e s p o n d i n g section of the tower and was d e t e r m i n e d f r o m the equation
of the working line,
.

x~o

(1)

where R is the r e f l u x ratio in the lower part of the section; Xiw and XiD a r e the concentrations of the i - t h
component in the reflux and r e c t i f i e d product f r o m the section, r e s p e c t i v e l y ,
In calculating the bottom sections (kerosene and diesel fuel), it was assumed that the composition of the
vapor leaving the section is equal to the composition of the rectified product f r o m these sections.
The r e s u l t s f r o m calculation of the basic distillation p a r a m e t e r s a r e p r e s e n t e d in Table 2, and t h e
hydrodynamic indices (actual and calculated) in Table 3.

209

TABLE 2. B a s i c Distillation P a r a m e t e r s of
Sections in T - 2 A t m o s p h e r i c T o w e r
Indices

Reflux ratio
minimum lh-nin
optimum Royt
workin~
9 Numberoftheoretical
trays
minimum Nmin
working
optimum Nopt
Actual number of
trays
Numbe~ of rectifying trays
Number of trays m zone
_ofPTsO
Tray efficiency,%

Section
I
diesel
naphtha kem~ne fuel

2,90
2,38

1,89

2,67
1,87

1,72

0,3

0,97
2,95
2,34

1,68
3,45
3,56

0,53
1,97
2,22

192

121010

1.53
0,61

--

32~7

43,2

19,7

F r o m the r e s u l t s obtained in this w o r k we can m a k e the following s t a t e m e n t s . The c l o s e n e s s of s e p a r a tion with distillations in a c c o r d a n c e with GOST 2 1 7 7 - 6 6 m e e t s the r e q u i r e m e n t s of the r e f i n e r y ; however,
the T B P distillation data indicate a c o n s i d e r a b l e o v e r l a p of adjacent cuts (see T a b l e 1). F o r example, the
k e r o s i n e cut contains 20.5% f r a c t i o n distilling below 180~ and the content of k e r o s e n e f r a c t i o n s dwelling
below 220~ in the d i e s e l fuel cut is m o r e than 10%.
The significant content of f r a c t i o n s distilling below 180~ in the k e r o s i n e cut is p a r t l y explained b y the
fact that no s t e a m is fed to the s t r i p p i n g section. If c l o s e r fractionation of the k e r o s i n e is n e c e s s a r y , it will
be d e s i r a b l e to provide the s t r i p p i n g t o w e r with a r e b o i l e r , using the w a s t e heat f r o m the d i e s e l fuel o r r e s i d u e
streams, or high-pressure steam.
The h y d r o d y n a m i c calculations show that in the naphtha and k e r o s i n e s e c t i o n s the t r a y s a r e o p e r a t i n g
with v a p o r v e l o c i t i e s c o n s i d e r a b l y below the allowable l i m i t s . Such o p e r a t i n g conditions a r e p a r t i c u l a r l y u n f a v o r a b l e f o r t r a y s of this type, since the e n t i r e s t r e a m of liquid m o v e s o v e r the S - s h a p e d e l e m e n t s , and an
e x c e s s i v e d e c r e a s e in v a p o r v e l o c i t y m a y be the s o u r c e of liquid weeping and lower t r a y efficiency. In this
connection, attention is drawn to the r a t h e r nonuniform distribution of v a p o r and liquid loads through the i n dividual sections of the tower. F o r optimization of the p r o c e s s r e g i m e , a design calculation study was made
on the a t m o s p h e r i c tower, with the a i m of a m o r e u n i f o r m distribution of loads and c l o s e n e s s of distillate
s e p a r a t i o n throughout the e n t i r e o p e r a t i n g height of the tower.
As input data we u s e d the indices of the p r o c e s s r e g i m e obtained in the operating t e s t on the unit; as the
b a s i s f o r the distribution of the reflux heat between P T s O - 1 and P t S O - 2 we u s e d the operating indices of a
unit, of s i m i l a r type and capacity, at the K i r i s h i r e f i n e r y , the o p e r a t i o n of which g i v e s a c l o s e r s e p a r a t i o n of
distillate f r a c t i o n s without any additional i n t e r m e d i a t e circulating reflux. The withdrawal of heat in this unit
is a c c o m p l i s h e d b y P T s O - 1 , 2, as specified in the t y p i c a l unit design.
T h e s e calculations showed that, with a v a p o r velocity in the t o w e r amounting to about 80% of the m a x i mum, the d e v e l o p m e n t of reflux in the u p p e r p a r t of the t o w e r by the u p p e r P T s O - 1 m a k e s it p o s s i b l e to
r e c o v e r a p p r o x i m a t e l y 77% of the entire amount of heat withdrawn f r o m the column, and the development of
reflux b y the l o w e r P t s O - 2 can give 23% r e c o v e r y . This gives a m o r e f a v o r a b l e v a r i a t i o n of load with r e s p e c t
to t o w e r height, and f e w e r t r a y s a r e involved in the c i r c u l a t i n g reflux loop, so that it is p o s s i b l e to i m p r o v e
the c l o s e n e s s of distillate s e p a r a t i o n .
Such a d i s t r i b u t i o n of heat withdrawn by P T s O - 1 and P T s O - 2 , with the t o w e r capacity specified b y
design, is in c o m p l e t e a c c o r d with the p o s s i b i l i t i e s of its r e c o v e r y in heating crude oil. Thus, the r a t i o n a l
r e d i s t r i b u t i o n in the heat exchange s y s t e m of the heat in the distillate and r e s i d u e s t r e a m s , as well as the
r e p l a c e m e n t of cold w a t e r b y hot spent w a t e r in washing out the salts, m a k e s it p o s s i b l e to i n c r e a s e the heat
r e c o v e r y and p r o v i d e heating of the c r u d e oil to 220~ ahead of the topping t o w e r T - 1 [9-11].
E x p e r i e n c e in the o p e r a t i o n of analogous crude oil distillation units indicates the d e s i r a b i l i t y of m a x i m u m d e v e l o p m e n t of r e f l u x in the u p p e r p a r t of the a t m o s p h e r i c tower, which will m a k e it p o s s i b l e to i m p r o v e
the c l o s e n e s s of d i s t i l l a t e s e p a r a t i o n [2]. In combination with the supply of heat to the l o w e r p a r t of the t o w e r

210

TABLE 3. Hydrodynamic C h a r a c t e r i s t i c s of
T - 2 A t m o s p h e r i c T o w e r Operation, f o r T e s t
Regime (values in n u m e r a t o r ) and Calculated
R e g i m e (values in denominator)
Tray number (from top)
Indices
3

Volumetric vapor

rat9 under tray,

Vapor velocity under

tray, m/sec
.min!mun~_ calcu-

lated with working

12

15

t9,0

21

24

925

0,428

0,360

0.494
1,074
44

0,650
0,900

range of 2.5

actual
maximum [6]
Spedfic liquid load
~n31(m, h)
Ratio of valmr load

46

Height of backup of
liquid above weir,
into liquid head

4O

Tray resistance, mm
Hg
Height of froth in
downcomer, mE

4,1

m maximum, %

64
72,2
51
6,2

452

487

s t r i p p e r s through r e b o i l e r s , this can give a substantial i m p r o v e m e n t in distillate separation in an a t m o s p h e r i c

crude oil distillation tower.
Inadequate distillate separation in the stripping section of the tower is r e l a t e d to the small amount of
s t e a m supplied to the tower bottom (1.44% instead of the 1.75% specified by design). Owing to the low vapor
flux in the lower part of the tower, the contact between these v a p o r s and the large volume of liquid is not as
efficient as it should be.
On the basis of the studies r e p o r t e d here, we have established the optimal operating indices f o r the T - 2
t o w e r in a t m o s p h e r i c distillation of crude oil. Depending on the composition of the feedstock being p r o c e s s e d
and the r e q u i r e d yields of light products, it is possible to s e l e c t the most rational s c h e m e for supplying and
r e c o v e r i n g heat in a complex tower.
LITERATURE
1.
2.
3.
4.
5.
6.
7.
8.
9.

10.
11.

CITED

G . P . Pikalov, A. I. Skoblo, et al., Khim. Tekhnol. Topl. Masel, No. 4, 34 (1972).

G . P . Pikalov, A. I. Skoblo, et al., Khim. Tekbnol. Topl. MaseI, No. 7, 34 (1972).
G . P . Pikalov, Neft. Gazov. P r o m s t . , No. 5, 41 (1974).
A . I . Skoblo Basic E l e m e n t s of P r o c e s s Design Calculations f o r P e t r o l e u m Distillation Units [in R u s sian], AZGONTI, Baku (1939).
I . A . Aleksandrov, Distillation and Adsorption Equipment [in Russian], Khimiya, Moscow (1971), pp.
117-119.
Yu. K. Molokanov et al., N e f t e p e r e r a b . Neftekhirn. (Moscow), Nos. 11-12, 34 (1964).
Yu. K. Molokanov, T. P. Korablina, et al., Khim. Teldmol. Topl. Masel, No. 2, 36 (1971).
Yu. K. Molokanov and G. P. Pikalov, Khim. Tekhnol. Topl. Masel, No. 5, 43-45 (1977).
O . A . Ktatorov, P. L Korotkov, et al., E x p e r i e n c e in Design, C o m m e r c i a l Operation, and I n c r e a s e s in
Capacity of L a r g e Units f o r P r i m a r y Crude Oil Distillation [in Russian], TsNIIT]~neftekhim, Moscow
(1975), p. 73.
G. P, Pikalov, Neft. Gazov. P r o m s t . , No. 3, 34 (1976).
A . D . Rudkovskii, V. G. Teteryuk, and G. P. Pikalov, Combatting L o s s e s of Crude Oil and P r o d u c t s in
the Novopolotsk P e t r o l e u m R e f i n e r y [in Russian], TsNIITFmeftekhim, Mosco W (1977), p. 15.

211