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DistillationColumnDesign
Thedesignofadistillationcanbedividedinthefollowingsteps.
Specifythedegreeofseparation:Setproductspecification.
Selecttheoperatingconditions:Operatingpressure.
Determinethestageandrefluxrequirement:Thenumberofequilibriumstages.
Selecttypeofcontactingdevice:Platesorpacking.
Sizethecolumn:Diameter,numberofrealstages.
Designthecolumninternals:Plates,Distributors,PackingSupportsetc.
Mechanicaldesign:VesselandInternalfittings.
ArrangementofTowers
Threetypesofarrangements(Howheatisremoved)
1. TopTrayReflux:Refluxisonlyattoptrayonly
RefluxiscooledandsentintotheTower.
Heatinput:ThroughTowerbottom.
Removal:atthetop.
Thusrequireslargetowerdiameter.
Improperrefluxandpoorqualityoffraction.Economicutilizationofheatisnotpossible.
2. Pumpbackreflux.
3. PumparoundReflux.
PumpbackReflux:
Fig:2.25VacuumDistillationUnitOverview[7]
Refluxisprovidedatregularintervals.
This helps every plate to act as a true fractionator.( because there is always good amount of
liquid).
Towerisuniformlyloaded,henceuniformandlesserdiametertowerwilldo.
Heatfromexternalrefluccanbeutilisedasitisatprogressivelyhighertemperatures.
Howeverdesignofsuchtoweriscostly,butprovidesexcelletservice.
Mostcommoninrefineries.
TopTrayreflux
PumpAroundReflux:
Fig:2.26TopTrayreflux[1,2]
Inthisarrangementrefluxfromalowerplaeistaken,cooledandfedintothecolumnatahigher
sectionby2to3plates.
Thiscreateslocalproblemofmixingunevencompositionofrefluxandliquidspresentonthetray.
Designers treat all the plate in this zone as one single platre, the result gives large number of
platesandhightowerheight.
Fig:2.27AtmosphericDistillationUnitMiddle[8]
Fig:2.28TypicalConfigurationofSingleFeedandMultipleFeedintoDistillationUnit[1,2,11]
SomeBasis
SectionabovefeedpointRectifying/EnrichmentSection
SectionbelowFeedStrippingSection
RefluxratioR=Flowreturnedasreflux/Flowoftopproductdesign
MinimumrefluxRmin:Refluxbelowwhichstagerequiredisinfinity.
Optimumrefluxratiotypicallylinesbetween1.2to1.5timestheminimumrefluxratio.
RelativeVolatilityij=Pi/Pj=Ki/Kj
y=X/(1+(1)x)forcontructionofyxdiagram.
Fig:2.29StageEquationsForDistillationUnit
MeshEquations
MaterialBalance
Vn+1Yn+1+Ln1Xn1+FnZn=VnYn+LnXn+snXn............Equ1
EnergyBalance
Vn+1Hn+1+Vn1Hn1+Fhf+qn=VnHn+Lnhn+Snhn.........Equ2
EquilibriumRelation:
Yi=KiXi........Equ3
SummationEquitation:ForLiquid&Vaporcomposition
These Four equations are the called MESH EQUATION i:e Material Equilibrium, Summation and Heat
(Energy)Balance Equation.MESH Equation can be written for each stage and for reboiler and
condenser.TheSolutionofthesetofequationsformsthebasisofrigorousmethods.
BasicProcesses
SeparationbyBoilingpointdifference.
CrudeAssayprovidesestimatesofvariousproductsobtainablefromaparticularcrude.
Table:2.9[1,2]
TypicalProducts
TBPCUTRANGE
UnstabilizedNaphtha
IBP120oC
HeavyNaphtha
120oC140oC
Kerosene
140oC270oC
LightGasOil
270oC330oC
HeavyGasOil
330oC370oC
ReducedCrudeOil
370oC+
Fig:2.30[1,2]
Fig:2.31AtmosphericDistillationUnitBottom[9]
Fig:2.32VacuumDistillationUnitOverhead[10]
ProcessDesignBasics
Heatandmaterialbalancecalculations
Computehydrocarbonmaterialbalanceforfeedandproducts.
Steamratestostrippingsectionsandsteamdistributionsbetweenoverheaddistillatesvaporsand
liquids.
Hydrocarbonmaterialbalancesaroundproductstrippers.
Atmospheric EFV Temperatures for products corresponding to the estimated strip out for each
product.
DrawTraylocations,NumberoftraysineachsectionsandtotalnumberoftraysintheTower.
Heatinputtothebasesectionofthetowerfromfeedandbottomsstrippingsteam,heatoutflow
inthebottomsliquidandexternalheatquantitiesattheflashzone.
ProductYieldDetermination
SeparationCriteria
SeparationCriteria
DegreeofSeparation
Definedintermsofproductpuritiesorcomponentrecoveries.
Greaterthedegreeofseparation,greaterwillberecoveryofthelightcomponentinthedistillate
andtheheavycomponentinbottoms.
Degreeofdifficultyofseparation:Definedastherelativedifficultyencounteredinseparating
the two compounds, regardless the purity requirements set by process specifications~ inversely
proportionaltotherelativevolatilitybetweenthetwocomponents.
ASTMGapandOverlap
Fractionationisthedifferencebetween5%ASTMcurveofHeavycutandthe95%pointonthe
ASTMcurveofalightercutoftwoadjacentsideproduct.
PositivedifferenceiscalledGap.
Negativedifferenceiscalledoverlap.
ASTMBoilingrangegivesgeneralcompositionoffractions.
595GAP:Definestherelativedegreeofseparationbetweenadjacentfractions.
Determined by subtracting 95 vol.% ASTM Temperature of a fraction from the 5 Vol. % ASTM
temperatureoftheadjacentheavyfraction.
(595)Gap=(t5HT95L)ASTM
5H=5%OFTHEHEAVIERFRACTION
95L=95%OFTHELIGHTERFRACTION
TBPCUTPOINT=(TOH+T100L)/2
TBPOverlap=[T100LTOH]
TBPCUT,GAP&OVERLAP
Fig:2.33TBPCut,Gap&Overlap[1,2]
Generalobservationforseparation
Foragivensystem
No.oftraysrequiredincreasesmarkedlyaspurityrequirementincreases,butrefluxrequirements
increasesonlyasmallamount.
Tray and reflux requirements increases as relative volatility decreases i.e separation becomes
moredifficult.
SeparationCriteria
Forafixednumberoftrays,refluxreqirementisdirectlyproportionaltothedegreeofdifficultyof
separation.
Qualitatively
CrudeColumnDesign
INPUTREQUIRED
CrudeTBP(essential)
Density/APIgravity(essential)
MolecularWeight(optional)
Viscosity(optional)
SPECIFICATIONREQUIRED
ColumnPressure
Productspecificationcanbegivenintermsoffixdrawordistillationpoint.
Pumparounddutiesneedtobespecified.
Columntoptemperaturecanbespecified.
Processdesign
PrepareTBPDistillationandequilibriumFlashVaporisationcurvesofcrudetobeprocessed.
Using crude assay data construct TBP curves for all products except gas and reduced crude.
ConvertthesetoASTM&EFV.
ConvertTBPdatatoEFVcurves.
Preparematerialbalanceofcrudedistillationcolumn,onbothvolumeandweightbasis.
Fractionationrequirements:ASTMgapandoverlap
KnowinggapsasthedesignparameterscorrelatedeviationorgapwithFfactor(productofnumberof
platesbetweentwoadjacentsidedrawsoffstreamandinternalrefluxratio.
PackiesMethod
TBPVSASTM50%B.P
Fig:2.34TBPVSASTM50%B.P[1,2]
RelationBetweenTBPandASTM50%BoilingPoint
IBPANDFBPOFASTM&TBP
Fig:2.35IBPANDFBPOFASTM&TBP[1,2]
RelationBetweenIBPandFBPofASTMandTBP
Fig:2.36RelationBetweenIBPandFBPofASTMandTBP[1,2]
EXAMPLE
Inarefinerysidestreamoperationthefractiontobecollectedisdiesel.Thedieselenteringtheside
stripper is 4000 bbl/h, the 50 percent point of the cut is 275 oCandcontainedwith Kerosine whose
midboilingpointis145 oC.Ifthestripperishaving4platesfindtheactualamountofdieselcoming
outofthestripperiftheASTMGAPis20oC.
SOLUTION
CalculateFFactorfromPackiemethodforsidestreamstripper.
ASTMT50%=275145=130oC(254oF)
ASTMGAP=20oC=36oF
F=(L/D)NT=>L/D=5/4=1.25
V=L+D=4000
HenceD(Actualamountofdiesel)=1778bbl.
Calculationofminimumnumberofstage
FenskeequationisusedforNm
Calculationofminimumrefluxratio
UsingUnderwoodEquation:
q=heattovaporize1moleoffeed/molarlatentheatofvaporization.
=Rootofunderwoodequation.
CalculateRmusingErbarMaddox(orGilliland)correlationcalculateRactual.
CALCULATIONOFREFLUXRATIO
Fig:2.37CALCULATIONOFREFLUXRATIO[1,2]
Kirkbrideequationisusedforfeedtraylocation.
log[Nr/Ns]=0.206log[(B/D)(Xf.LK/Xd.HK)2].........KrikbrideEquation
Where
Nr=Numberofstagesabovethefeed,includinganypartialcondenser.
Ns=Numberofstagesbelowthefeed,includingthereboiler.
B=Molarflowbottomproduct.
D=Molarflowtopproduct.
Xf.HK=concentrationoftheheavykeyinthefeed.
Xf.LK=concentrationofthelightkeyinthefeed.
Xd.LK=concentrationoftheheavykeyinthetopproduct.
Xb.LK=concentrationofthelightkeyinthebottomproduct.
Insimulationmethod,itisknownasshortcutmettod
OptimizationCriteriainDesign
Fig:2.38[1,2]
Maximizationofdistillates.
Maximizationofdesiredproduct(s).
Qualityofreducedcrude.
Overflashcontroltooptimizeenergy.
Optimizationofpumparoundinyield.
Optimizationofparticularproduct(s).
FlashZoneoperatingconditionsFZtemperatureislimitedbyadventofcracking.
FZ pressure is set by fixing the reflux drum pressure and adding to it to the line and tower
pressuredrop.
Over flash:Over flash is the vaporisation of crude over and above the crude overhead and side
streamproducts.
Over flash is generally kept in the range of 36 liquid volume %. Kept at minimum value as a
Largeroverflashconsumeslargerutilities.
Overflashpreventscokingofwashsectionplatesandcarryoverofcoketothebottomsidestreamsby
and the tower bottom by providing reflux to the plates between the lowest sidestream and the flash
zone.
FlashZoneTemperature
CrudeTBPprovidesestimateoftotaldistillate.
EFVcruveofthecrudeisderivedfromtheTBPandconvertedtotheflashzonepressure.
Overflashquantityisselectedincludedthismaterialbalanceandheatbalancearountthebottom
sectionincludingfeedsectionisdonetofixtheflashzonetemperature.
Flashzonetemperaturethusfixedensuresdesiredtotaldistillateyield.
ProductYieldDetrmination[1,2,6]
From ASTM curve:1 ATM EFV curve are develoved and extrapolated to() 50% VOL% vaporized
asaninitialestimate.
Stripping steam to the stripper is set at about 10LB/BBL of stripped product bubble point of
unstrippedsidestreamisestimated.
Fig:2.39
EFVTEMPVSDRAWTRAYTEMP
Fig:2.40EFVTEMPVSDRAWTRAYTEMP[1,2]
FLASHZONE
Fig:2.41FLASHZONE[1,2]
D=Sumofallstreams.
V=%OFVAPORISATIONinFlashzone.
Lo=Overflash.
SF=Totalamountofhydrocarbonsstrippedoutbysteam.
ThusV=D+LoSF
Fromtheflashcurve(EFV)ofthecrude,thetemperatureatwhichthisvaporisationisachievedat
theFZPressureisdetermined.
ThisTshouldnotexceedthemaximumpermissibletemperature.IfdoesquantitiesofOverflash
andstrippingsteamarechangeduntilapermissibletempisobtained.
StrippedoutHCFraction(Sf)dependsonamountofstrippingsteam.
W=LofzVso,(W=Vol.%Feedleavingthebottom).
Lofz=Lo(Overflash)+W
V=Lo+100W/(1Sf)vol.%ofoffeedflashedatFZinlet.
Sf=fractionofstripoutvapor(Lofz(1Sf)=W).
EXAMPLE:Itisplannedtoyieldasasidestripperfromanatmosphericcrudetower,100bblperhour
of a light distillate product having a TBP cut point range of 400525 oF (volume range 2739%, API
39.8).Theestimateddrawtraytemperatureis425oF.Theliquidistobestrippedina4traycolumn
using500oF Steam. The stripping rate is 10 lb/bbl of stripped product. Calculate the temperature of
strippedproductstrippingthebottomofthestripper.
Solution:100bblofLDtobeproducd,TBPCut2739%=12vol.%,Midvol%33
Stripoutvapor=Sf=23.8vol.%.
Feed(F)=w/1sf.
=100/(1238).
=131.2bbl/h/100BBLOFLD.
ThereforeFeedF=12X1.312=15.74%OFCRUDE.
HeatintoFZ,QFZ1=VH+WH.
SelectionofColumnPressure
Pressuretobeadequatethatdewpoint(forthecompositionoftopproduct)ismorethancoolinghot
water temperature around 45oc+T(15oc)=60oc with cooling water inlet temperature of 33oc with
condensatetemperatureof40o45ocanbeobtainedeithconsiderationof10o15oT.Thecolumn
pressuretobeadequatethatbubblespointofthetopproductis40o45o.
i.e
atcolumnpressureanddrumtempof45o
or
Picalculatedat45oCforallthecomponents.
Pi=XiPiorYiPt=XiPi
ForcrudeDistillationColumn
Thetopproductisamixtureoflightendandtopnaptha(C5140o).ThenapthaTBPissubdivided10oC
or20oCcutseg.70o80o,80o90o,90o100oetcandmidpointaretabulated.
Kvaluesestimatedfromdepriesterchart.
Table:2.10
Comp./cutrange(TBP)
B.P.T
Ki45oC,1.6
Kg/cm2g
Xi
Ki
Xi
C1
B1
K1
X1
K1
X1
C2
B2
K2
X2
K2
X2
C3
B3
C4
B4
C5
B5
70o90o
80o
90o110o
100o
110o130o
115o
130o150o
140o
Kn
Xn
Kn
Xn
ni=1KiXi
ItKiXi=1thenthepressureisOK.
Ifnot1thenrepeattrialwithanothervalueofpressuretillKiXiis1.
Same method is applied for discrete component and mixture of pure component and fixes the reflux
drumpressure.
TopTemperatureEstimation
Toptemperatureisdewpointoftopvaporatcolumntoppressure.Oncerefluxdrumpressureisfixed
PD(say)the column top pressure is estimated after adding the pressure drop across condenser/OH
line.Typically0.3kg/cm20.5kg/cm2istakenaspressuredrop.
Columntoppressure=PD+0.5
Again calculation is performed at top pressure for determining the dew point.Assume a top
temperatureandcalculate.
yi/Kitillitbecomes1.
CalculationofVapor/LiquidProfile
Fig:2.42CalculationofVapor/LiquidProfile[1,2,11]
Thisisdonebyperformingmaterialbalance&heatbalanceinenvelopes.
Atmosphericdistillationunit
TowerDia:58m.
No.ofPlates:2540(dependsonNo.ofdraws).
Maxm.Allowablepressuredropperplate:0.015kg/cm2).
PressuredropfromfurnaceoutlettoFlashzone:0.30.4kg/cm2.
Pressureattopofthetower:1.21.4kg/cm2
No.ofplatesrequiredforseparation.
LNHN(80130C):68
HNLD(180C):56
LDMD(250C):46
MDGASOIL(330C):34
FlashzonetoFirstdrawtray:3
FZTOBOTTOM:3
Refluxdrumpressure:1.11.15kg/cm2abs.
Steamrate/bblofcrude:45kgs
Refluxratios:23(forlightfractions)forHeavyfractions1.52.5.
ContactingDevice
CrossFlow
Counterflow
CrossFlow
Fig:2.43CrossFlow
CounterFlow:Packing,Heattransfertrays.
Hdry>drytraypressuredrop,inches.
Hdry=C1+C2V2/2gC
Pdry=K2(VH)2DV/DLunitfullopen.
TrayPressureDrop
HT=Hdry+How+Hw
PT=Pdry+0.4(gpm/lwi)2/3+0.4HW
PumparoundDuties
Pumarounddutiesneedtobemaximizedforenergyefficiencypointofview.
This is limited by Gap/Overlap specification between adjacent products and minimum internal
refluxspecification.
Pumparounddutiesaremaximizedandrefluxratioisbroughtcloseto1.5to1.8.
VacuumColumn
(T)Hy.DieselPA:70oC90oC
(T)LVGOPA:50oC
(T)HVGOPA:55oC
Stagesinvacuumcolumn:
TopPA=1stage.
TopHy.DieselLVGO=23stage.
LVGOPA=1stage.
LVGOHVGO=1stage.
HVGOPA=23stage.
Wash=23stage.
Washliquidatbottomofwashbed0.3M3/hr/M2columnC.Sarea.
ThermodynamicsBK10/GSI.
TransportPropertyPETRO.
DensityAPI.
VacuumDistillationUnit[1,11]
The primary objective of a vacuum distillation is to produce either feedstock for FCCU or HCU.
ThistypeofvacuumdistillationunitsaretermedasFuelTypeVacuumUnit.
TheotherkindofvacuumdistillationunitisaLubeTypeVacuumUnitanddeployedforproduction
offractionsforLubeOilBasestocks.
In a Fuel Type Vacuum distillation Unit the VGO TBP cut point is controlled for Maximizing
profitability while containing the level of contaminants acceptable by downstream secondary
Units.
VACCUMDISTILLATION
Fig:2.44VACCUMDISTILLATION[1,2]
VacuumDistillationunit:cont
Fig:2.45VacuumDistillationunit[1,2]
DifferentConfigurationofVacuumColumn
1. Dry(nostripping,nocoilsteam).
2. Wet(Precondenserlimitingcolumnoverheadpressuretocoolingwatertemperaturelimitations).
3. Dumpcolumnwithoutstripping(noprecondenser,coilsteamusedtoadjustflashzoneoilpartial
pressure).
4. Dumpcolumnwithstrippingsteam(noprecondenser,coilandstrippingsteamused).
DifferentConfigurationofVacuumColumn
Thefirstoneoperatestypicallyat812mmHg(a)attop.Thevapourdirectlygoestoejectors.
The second type operates at 6070 mm Hg (a) at top and have a precondenser, the non
condensablearepulledbyejector.
Thethirdtypeofoperationisdoneat1825mmHg(a)attop.
Withoutstrippingsteamhasaboosterejectorfollowedbycondenser.
Thisfourthtypeagainoperateswithatoppressureof1825mmHg(a)andusesstrippingsteam
and Coil steam both. This type is considered best to increase cut point of VGO limiting the
contaminantslikeV,Nietc.inVGOwithsamenumberofstagesinwashsectionascomparedto
otherconfigurations.
References
1. Rao, B.K.B.(1990). Modern Petroleum Refining Processes (2nd Edition Ed.) Oxford & IBH
Publishers.ISBN8120404815.
2. James H. Gary and Glenn E. Handwerk (2001). Petroleum Refining: Technology and Economics
(4thed.).CRCPress.ISBN0824704827.
3. http://www.simtronics.com/catalog/spm/spm2700.htm
4. http://www.alfalaval.com/industries/Oilrefinery/crudedistillationunit/Pages/crudedistillation
unit.aspx
5. James. G. Speight (2006). The Chemistry and Technology of Petroleum (4th ed.). CRC Press.
ISBN0849390672.
6. RezaSadeghbeigi(2000).FluidCatalyticCrackingHandbook(2nded.).GulfPublishing.ISBN0
884152898.
7. http://www.simtronics.com/catalog/spm/spm2700Large.htm?full/spm2700f.gif.
8. http://www.simtronics.com/catalog/spm/spm2700Large.htm?full/spm2700d.gif
9. http://www.simtronics.com/catalog/spm/spm2700Large.htm?full/spm2700e.gif
10. http://www.simtronics.com/catalog/spm/spm2700Large.htm?full/spm2700g.gif.
11. Kister,HenryZ.(1992).DistillationDesign(1stEditioned.).McGrawHill.ISBN0070349096.