Atmospheric Crude Tower R1-1

R1 Atmospheric Crude
Tower

R1.1 Process Description..................................................................... 2

R1.2 Setup........................................................................................... 5

R1.3 Steady State Simulation............................................................... 8

R1.3.1 Simulate the Pre-Fractionation Train..........................................9
R1.3.2 Install Atmospheric Crude Fractionator.................................... 11

R1.4 Results....................................................................................... 16

R1-1
R1-2 Process Description

R1.1 Process Description

Figure R1.1

After passing through a preheat train, 100,000 barrel/day of

29.32o API crude is fed into a pre-flash separator operating at
450o F and 75 psia. The vapour from this separator bypasses the
crude furnace and is re-mixed with the hot (650 o F) pre-flash
liquids leaving the furnace. The combined stream is then fed to
the atmospheric crude column.

R1-2
 Atmospheric Crude Tower R1-3

The column operates with a total condenser, three coupled side

strippers, and three pump around circuits.

Figure R1.2

A naphtha product is produced overhead, a kerosene product is

produced from the first side stripper, a diesel product is
produced from the second side stripper, and an atmospheric gas
oil (AGO) is produced from the third side stripper. Both the AGO
side stripper and the diesel side stripper are steam stripped,
while the kerosene side stripper has a reboiler.

The following Assay data is used to characterize the oil for this
example:

Assay Liq Volume % Boiling Temperature (F)

0.0 15.0
4.5 90.0
9.0 165.0
14.5 240.0
20.0 310.0
30.0 435.0

R1-3
R1-4 Process Description

Assay Liq Volume % Boiling Temperature (F)

40.0 524.0
50.0 620.0
60.0 740.0
70.0 885.0
76.0 969.0
80.0 1015.0
85.0 1050.0

Bulk Properties
Standard Density 29.32o API

Light Ends Liq Volume %

Methane 0.0065
Ethane 0.0225
Propane 0.3200
i-Butane 0.2400
n-Butane 0.8200
H2O 0.0000

There are two basic steps in this process simulation:

1. Setup. The component list must include C1 to C4 light ends
components as well as the hypocomponents that will be used
to represent the C5+ portion of the crude oil. The Oil
Characterization procedure in HYSYS will be used to convert
the laboratory data into petroleum hypocomponents.

Any other library components required for the overall

simulation (for example, H2O) should be selected as well.

2. Steady State Simulation. This case will be modeled using

a Pre-Fractionation Train consisting of a Separator and
Heater. The Outlet stream will then fed to an Atmospheric
Crude Fractionator. The results will be displayed. Dynamic
Simulation - The steady state solution will be used to size
all the unit operations and tray section. An appropriate
control strategy will be implemented and the key variables
will be displayed on a strip chart.

R1-4
 Atmospheric Crude Tower R1-5

R1.2 Setup
1. In the Session Preferences property view, set the unit set to
Field units.
2. In the Component List property view, select the following
components: methane, ethane, propane, i-butane, n-
butane, and water.
3. In the Fluid Package property view, define a fluid package
with Peng-Robinson as the property package.

Oil Characterization
Click the Oil Environment icon to enter the Oil Characterization
Environment, using the fluid package you just created. Three
Oil Environment icon
steps are required for characterizing the oil:
1. Define the Assay.
2. Create the Blend.
3. Install Oil in the Flowsheet.

Define the Assay

1. On the Assay page of the Oil Characterization property view,
click the Add button. This will create a new assay, and you
will see the Assay property view.
2. Change the Bulk Properties setting to Used.
3. Complete the Input data for the Bulk Properties as shown
below:

Figure R1.3

4. Since the TBP data is supplied, select TBP from the Assay
Data Type drop-down list.

R1-5
R1-6 Setup

5. Select Liquid Volume% from the Assay Basis drop-down

list.
6. Click the Edit Assay button and enter the data as follows.

Figure R1.4

7. In the Assay Definition group, click the Light Ends drop-

down list and select Input Composition.
8. In the Input Data group, click the Light Ends radio button.
9. Enter the light ends data as follows.

Figure R1.5

R1-6
 Atmospheric Crude Tower R1-7

10. Upon completion of characterizing the assay, select the

Calculate button. HYSYS will calculate the Working Curves,
which can be viewed on the Working Curve tab.

Figure R1.6

You can scroll through this table to view all 50 points of the
Working Curve.
11. Close the Assay property view.

Create the Blend (Cut the Oil)

1. Click the Cut/Blend tab (Oil Characterization property view)
and click the Add button. The Blend: Blend-1 view appears.
2. Click the Data tab, then select the Assay you created in the
Available Assays column.
3. Click the Add button. HYSYS will transfer that Assay to the
Oil Flow Information table.
As a guideline, each Outlet stream from the crude column
should contain a minimum of 5 hypocomponents where the
composition is greater than 1.0%. Therefore, a total of 30
components should fulfil this requirement.
4. From the Cut Option Selection drop-down list, select User
Points, then specify the Number of Cuts at 30. HYSYS will
calculate the hypocomponents.

R1-7
R1-8 Steady State Simulation

5. Click the Tables tab to view the hypocomponents.

6. From the Table Type group drop-down list, select Molar
Compositions.
7. Close the Blend property view.

Install Oil in the Flowsheet

The final step is to install the oil in the flowsheet.
1. Click the Install Oil tab of the Oil Characterization property
view.
2. In the Stream Name cell, type Raw Crude. This is the
stream name where you would like to install the oil.
3. On the Oil Characterization property view, click Return to
Basis Environment button.
4. Click the Enter Simulation Environment button on the
Simulation Basis Manager property view to enter the Main
Environment. The Raw Crude stream has been installed.

R1.3 Steady State

Simulation
The following major steps will be taken to set up this case in
steady state:
1. Simulate the Pre-Fractionation Train. This determines
the feed to the atmospheric fractionator, and includes the
pre-flash separation, crude furnace, and mixer which
recombines the pre-flash vapour and furnace outlet stream.
2. Install the Atmospheric Crude Fractionator. Add the
column steam inlets to the flowsheet and install the crude
fractionator using the rigorous distillation column operation.

R1-8
 Atmospheric Crude Tower R1-9

R1.3.1 Simulate the Pre-

Fractionation Train
Inlet Stream
Specify the Inlet stream (Raw Crude) as shown below.

Stream [Raw Crude]

In this cell... Enter...
Temperature [F] 450.0F
Pressure [psia] 75.0 psia
Std Ideal Liq Vol Flow [barrel/day] 100,000 barrel/day

Because the composition has been transferred from the Oil

Characterization, the stream is automatically flashed.

Pre-Flash Operations
Install the Separator, Heater, and Mixer and provide the
information displayed below:

Separator [PreFlash]
Tab [Page] In this cell... Enter...
Design Inlet Raw Crude
[Connections]
Vapour Outlet PreFlash Vap
Liquid Outlet PreFlash Liq

Heater [Crude Heater]

Tab [Page] In this cell... Enter...
Design Inlet PreFlash Liq
[Connections] Outlet Hot Crude
Energy Crude Duty
Design [Parameters] Delta P 10.00 psi
Worksheet Temperature (Hot Crude) 650 F
[Conditions]

R1-9
R1-10 Steady State Simulation

Mixer [Mixer]
Tab [Page] In this cell... Enter...
Design Inlets Hot Crude, PreFlash Vap
[Connections] Outlet Atm Feed

The calculated specifications for the Pre-Fractionation Atm Feed

stream appear below.

Figure R1.7

The Pre-Fractionation train is shown as follows:

Figure R1.8

R1-10
 Atmospheric Crude Tower R1-11

R1.3.2 Install Atmospheric

Crude Fractionator
Steam and Trim Duty Streams
Before simulating the atmospheric crude tower, the steam feeds
and the energy stream (Q-Trim - representing the side
exchanger on stage 28) to the column must be defined.

An energy stream can be installed by selecting the

appropriate icon from the palette, or a material stream
converted to an energy stream on the Util page of the stream
property view.

The Q-Trim stream does not require any specifications, this will
be calculated by the Column.

Three steam streams are fed to various locations in the tower.

Specify the steam streams as shown below. Define the
composition for each as H2O = 1.0000.

Stream Name Temperature [F] Pressure [psia] Mass Flow [lb/hr]

Main Steam 375.00 150.00 7500.00
Diesel Steam 300.00 50.00 3000.00
AGO Steam 300.00 50.00 2500.00

These streams could be installed inside the Column Build

Environment as well. By taking this approach, you will need
to attach these streams to the Column Flowsheet so that
they can be used in the calculations.

Column
In this application, the Input Experts option have been turned
off, and the Column is being configured directly through the
Column property view.

R1-11
R1-12 Steady State Simulation

The main column, Atms Tower, is represented by the following:

Number of stages is 29 ideal stages (not including the
condenser).
The overhead condenser operates at 19.7 psia and the
bottom stage at 32.7 psia.
The condenser experiences a 9 psi pressure drop.
The temperature estimates for the condenser, top stage,
and bottom stage are 100oF, 250oF and 600oF,
respectively.
Condensed water is removed via a water draw from the
three-phase condenser.

HYSYS comes with a 3 Stripper Crude Column template. A

Refluxed Absorber template could also be used, but this would
add the procedure of installing Side Strippers and Pump
Arounds.

For this example, install the 3 Stripper Crude Column custom

template.
1. Select the Custom Column icon in the Object Palette, then
click the Read an Existing Column Template button. The
Available Column Templates finder property view appears.
Custom Column icon
2. In the Files of type drop-down list, select Column
Templates (*.col).
3. From the list, select the 3sscrude.col template file, then
click the Open button.
The 3sscrude.col template installed 40 trays, 29 in the Main
Tray section, 3 trays in each of the 3 Side Strippers (1
reboiled and 2 steam stripped), a reboiler, and a condenser.

R1-12
 Atmospheric Crude Tower R1-13

4. In the Column Property view, connect the Inlet and Outlet

streams to the column sub-flowsheet as shown (Design tab,
Connections page).

Figure R1.9

5. Modify the Draw and Return stages of the Pump Arounds and
Side Strippers on the corresponding page of the SideOps
tab.

Figure R1.10

R1-13
R1-14 Steady State Simulation

6. In the Atmos Tower Column property view, specify the

column information below.

Column [Atms Tower]

Tab [Page] In this cell... Enter...
Parameters Condenser Pressure 19.7 psia
[Profiles]
29_Main TS Pressure 32.7 psia
Condenser Temperature 100F
1_Main TS Temperature 250F
29_Main TS Temperature 600F

Field units are used for column preferences.

Specifications
On the Monitor page of the Design tab, make the following
changes and input the values into the default set of
specifications supplied with the pre-built 3-Side Stripper
Column.
1. Change all the Pump Around delta T specifications to a
Duty specification.
2. Delete the Kero SS BoilUp Ratio and the Residue Rate
specs.
Open the specification property view by clicking the View
button, then click Delete to delete the specification.
3. Specify the Reflux Ratio spec to have a value of 1. Clear
the Reflux Ratio Active checkbox and make it an Estimate
only.
4. Change the following default specifications by selecting the
specification in the table and clicking the View button.
Change the Flow Basis to Std Ideal Volume before entering
values.

Specification Flow Basis Spec Type Spec Value

Kero_SS Prod Flow Volume 9300 barrel/day
Diesel_SS Prod Flow Volume 1.925e+04 barrel/day
AGO_SS Prod Flow Volume 4500 barrel/day
PA_1_Rate(Pa) Volume 5.000e+04 barrel/day
PA_1_Duty(Pa) Duty -5.500e+07 Btu/hr

R1-14
 Atmospheric Crude Tower R1-15

Specification Flow Basis Spec Type Spec Value

PA_2_Rate(Pa) Volume 3.000e+04 barrel/day
PA_2_Duty(Pa) Duty -3.500e+07 Btu/hr
PA_3_Rate(Pa) Volume 3.000e+04 barrel/day
PA_3_Duty(Pa) Duty -3.500e+07 Btu/hr
Naptha Prod Rate Volume 2.300e+04 barrel/day

5. On the Specs page of the Design tab, add the following new
specifications by clicking the Add button in Column
Specifications group.

Specification Type Variable (Field) Value

Column Liquid Flow Name Overflash Spec
Stages 27_Main TS
Flow Basis Std Ideal Vol
Spec Value 3500.00 barrel/day
Column Duty Name Kero Reb Duty
Energy Stream Kero_SS_Energy @Col1
Spec Value 7.5e+6 Btu/hr
Column Vapour Flow Name Vap Prod Flow
Stage Condenser
Flow Basis Molar
Spec Value 0.00 lbmole/hr

The final specification table will appear as shown below:

Figure R1.11

6. Once you have provided all of the specifications, run the

column.

R1-15
R1-16 Results

R1.4 Results
Workbook Case (Main)
The material stream results for the Workbook Case[Main]
appear below.

Figure R1.12

R1-16
 Atmospheric Crude Tower R1-17

Workbook Case (Atms Tower)

The material stream results for the Workbook Case [Atms
Tower] appear below.

Figure R1.13

R1-17