Crude Distillation

Chapter 4

Gasses
Polymerization Sulfur Plant

Sulfur

Gas

Sat Gas Plant

LPG Alkyl Feed

Alkylation

Butanes

Fuel Gas LPG

Gas Separation & Stabilizer

Isomerization

Polymerization Naphtha Isomerate Alkylate Aviation Gasoline Automotive Gasoline Solvents

Light Naphtha

Reformate Heavy Naphtha

Atmospheric Distillation Naphtha Hydrotreating Naphtha Reforming

Naphtha

Crude Oil

Kerosene
Desalter

Jet Fuels Kerosene

Hydrocracking

AGO LVGO
Vacuum Distillation

Distillate
Gas Oil Hydrotreating Fluidized Catallytic Cracking

Cat Naptha

Solvents
Distillate Hydrotreating Treating & Blending

Heating Oils Diesel

HVGO

Cat Distillates Fuel Oil Cycle Oils Residual Fuel Oils

DAO
Solvent Deasphalting

Coker Naphtha

SDA Bottoms

Naphtha

Asphalts

Visbreaking

Vacuum Residuum

Coker Gas Oil

Distillates Fuel Oil Bottoms Lube Oil

Solvent Dewaxing

Lubricant Greases Waxes

Waxes
Coking

Coke

Typical Crude Tower Products

Cut Light Naphtha (LSR Gasoline) Heavy Naphtha Distillate (Kerosene) AGO (Atm Gas Oil) LVGO (Light Vac Gas Oil) HVGO (Heavy Vac Gas Oil) Vacuum Resid TBP IBP (F) 80 to 90 180 to 220 330 to 380 420 to 520 650 800 950 to 1100 TBP EP (F) 180 to 220 330 to 380 420 to 520 650 800 950 to 1100

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

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
Atmospheric Column w/o Preflash

Modification of drawing in: Refining Overview Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD-ROM, 2000

Typical Configuration
Atmospheric Column w/o Preflash
Column Configuration Condenser Partial condenser if no Stabilizer Column. Total condenser if Stabilizer Column to remove light ends. but no reboiler.

Typical Configuration
Atmospheric Column w/o Preflash
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.

Typical Configuration
Atmospheric Column w/o Preflash
Column Configuration Pumparounds to move the cooling down the column. Liquid returned above the draw tray.

Typical Configuration
Atmospheric Column w/o Preflash
Column Configuration Multiple side draws & strippers to clean up side products.

Typical Configuration
Atmospheric Column w/o Preflash
Column Configuration 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.

Typical Configuration
Atmospheric Column w/o Preflash
Feed Preheat Exchanger Train Final heating in a direct fired heater. Inlet typically 550F. Heated no higher than 750F Minimize thermal cracking.

Typical Configuration
Atmospheric Column w/o Preflash
Feed Preheat Exchanger Train Feed Preheat Exchanger Train Actual heat exchange is with Actual heat exchange is with streams from within the tower. streams from within the tower. Recovery of heat important to distillationof heat important to Recovery economics. distillation economics! Final cooling done with air coolers or cooling water.

Typical Configuration
Atmospheric Column w/o Preflash
Feed Preheat Exchanger Train Actual heat exchange is with First absorb part of the overhead condensation tower. streams from within theload Recovery of heat important to Exchange with one or more of the liquid economics. distillationsides streams, Final cooling done with air beginning with the top (coldest) cooling water. coolers or side stream.

Typical Configuration
Atmospheric Column w/o Preflash
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

Typical Configuration
Atmospheric Column w/o Preflash
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.

Typical Configuration
Atmospheric Column w/o Preflash
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

Crude Electrostatic Desalting

Drawings from: Refining Overview Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD-ROM, 2000

Crude Electrostatic Desalting

Desalter Remove salts & dissolved metals & dirt Oil mixed with fresh wash water & demulsifiers. Mixed & heated followed by settling Separated in an electrostatic settling drum

Crude Electrostatic Desalting

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

Typical Configuration
Atmospheric Column w/o Preflash
Wash Zone Couple trays between flash zone & gas oil draw. Reflux to wash resins & other heavy materials that may contaminate the products.

Typical Configuration
Atmospheric Column w/o Preflash
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

Typical Configuration
Atmospheric Column w/o Preflash
Pumparounds Reduces overhead condenser load & achieves more uniform tower loadings Provides liquid reflux below liquid draws

Typical Configuration
Atmospheric Column w/o Preflash
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

Typical Configuration
Atmospheric Column w/o Preflash
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
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

Vacuum Distillation

Drawings from: Refining Overview Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD-ROM, 2000

Vacuum Distillation
Column Configuration 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)

Vacuum Distillation
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

Vacuum Distillation
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

Vacuum Distillation
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

Vacuum Distillation
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

Vacuum Distillation
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

Summary
What are the important take-away messages?