Beruflich Dokumente
Kultur Dokumente
UNIT
About Instructor
Current job position: CDU/KTU Process Lead
Working
W ki
experiences:
i
5 years in
i BSR,
BSR 12 years in
i Petroleum
P t l
Industry.
COURSE OBJECTIVES
When you complete this module you will be able:
To
T analyze
l
the
th operation
ti off the
th desalter
d
lt and
d th
the corrosion
i monitoring.
it i
To be aware of fundamental process control and the impact of each
controller on the process and on the characteristics of the cuts produced.
To learn about potential deficiencies and troubleshooting of CDU;
COURSE OUTLINE
Total duration: 5 days;
Lecture:
L t
3 days
d
(BSR)
(BSR);
Practice on dynamic simulator: 2 days;
COURSE ASSESSMENT
Lecture:
The multiple-choice (knowledge based questions) section of the test
is scored based on the number of questions you answered correctly;
Multi-choice test : 40 questions
Passing grade: 36/ 40;
No additional points are subtracted for questions answered
incorrectly;
Even if you are uncertain about the answer to a question, it is better
t guess than
to
th nott to
t respond
d att all.
ll
Dynamic simulator:
Passing
P
i
grade:
d Implement
I l
t an extract
t t operation
ti
procedure
d
f 10
for
minutes and troubleshoot successfully 2 scenarios in simulator;
OUTLINE
1. Crude Distillation
2 Operation of Crude Distillation Unit
2.
3. Crude Oil Desalting
4 The Pumparound
4.
5. Vapor Flow
6. Fractionation
7. Condenser and Tower Pressure Control
8. Air Cooler Fin-Fan Cooler
9. Vacuum Distillation
REFINERY CONFUGURATION
REFINERY CONFUGURATION
REFINERY CONFUGURATION
LRU: LPG
Recovery Unit
1. INTRODUCTION OF CDU
Crude distillation unit (CDU) is the first processing unit in virtually all petroleum
refineries also known as Topping unit,
refineries,
unit or atmospheric distillation unit.
unit
Designed to handle a variety of crude oil types based on light crudes/heavy crudes
and/or
d/
sweett crudes/heavy
d /h
crudes
d
scenarios.
i
S
Seasonal
l temperature
t
t
variation
i ti
should be incorporated in the design because changes in the cut point of
gasoline can vary by 20oC between summer and winter.
The unit should run satisfactorily at about 60% of the design feed rate (turndown
capacity).
p
y of the CDU: 10,000 BPSD ((1400 metric tpd)
p ) 400,000 BPSD ((56,000
The capacity
metric tpd). A good size CDU can process about 200,000 BPSD.
1. INTRODUCTION OF CDU
What is the role of CDU in the refinery?
Distills the incoming crude oil into various fractions of different
boiling
g ranges,
g
each of which are then p
processed further in the other
refinery processing units.
Provides removal of contaminations in crude oil (salts, solids,
metal,) which have negative impacts on operation/performance of
downstream units.
1. INTRODUCTION OF CDU
Typical products:
C1 - C2
C4
Gases: C1
C1-C2
Light straight run naphtha (also called light gasoline or light naphtha): C6-C10, 2090oC.
C
Heavy gasoline (also called military jet fuel): C6-C10, 130-210oC.
Kerosene (also called light distillate or jet fuel): C11-12, 150-270oC.
Middle distillates called diesel or light gas oil (LGO): C13-C17, 230-320oC.
Heavy distillates called atmospheric gas oil (AGO) or heavy gas oil (HGO): C18-C25,
320-380oC.
Crude column bottoms called atmospheric residue or Topped crude.
2. PROCESS DESCRIPTION
Process flow diagram of a typical CDU
Dewatering,
Sediments
settling by
gravity
Typically
50m,
3050 Diameter of the
trays column varies
120150oC
Remove heat,
Provide external
reflux
Salt/water/solids
removing by
electric fields
called: Flash
drum
4050% of crude
will be vaporized
in Flash-zone
330385oC
Stripping lighter
components by
reducing partial
press.
2. PROCESS DESCRIPTION
Typical designs of crude distillation column have the trays distribution between
products:
3. OPERATION OF CDU
Fractionation:
Operation
p
of crude distillation column involves
a process of fractionating a mixture of
thousands
of
compounds
p
into
several
required fractions.
The degree
g
of fractionation in a crude
unit is determined by the gap or overlap
between two adjacent
j
fractions ((side stream
products).
GAP?
OVERLAP?
3. OPERATION OF CDU
Gap: Difference between (the 5% ASTM D86 boiling point of the heavier product and the 95%
ASTM D86 boiling point of the lighter product) is possitive. A gap indicates good fractionation.
Overlap: Difference between (the 5% ASTM D86 boiling point of the heavier product and the
95% ASTM D86 boiling point of the lighter product) is negative. An overlap indicates that
some of the light product is still in the heavier product and vice versa.
3. OPERATION OF CDU
Cut points (TBP cut-points):
Cut point is the temperature on crude oil cumulative TBP curve,
curve which defines the yields of
specific cuts
The cut points in the CDU are controlled by the overhead vapour temperature
which
determines how much vapour goes to the condensers to produce light naphtha and by the
flow rate of the various products straight from the column or the side stream
strippers.
The amount of light naphtha is determined by the dew point of the naphtha at its partial
pressure, which is close to the overhead temperature.
The atmospheric residue level control inside the column determines its flow rate and thus its
initial cut point.
3. OPERATION OF CDU
Changing the draw-off rate of any product affects the cut points of the heavier
product below it. For example, lowering the kerosene flow rate will lower its end
point, but will also modify the initial cut points of the LGO and HGO and the
initial cut point of the atmospheric residue.
residue
The residue flow rate, the internal reflux rate, the draw-off temperatures and the
pump-arounds are also affected by changing the draw-off rate of a product.
If the cut point of one stream is changed through a change in its withdrawal rate,
the flow rate of the heavier product next to it should be changed in the reverse
and by the same amount in order to make the changes in the desired stream
only.
3. OPERATION OF CDU
The side stream rate also affects the temperature at the withdrawal tray and
l
lowers
th internal
the
i t
l reflux
fl coming
i outt off that
th t tray.
t
The internal reflux rate affects the degree of fractionation. It can be
increased by increasing the heater outlet temperature, and by lowering the
pump-around
pump
around duty in the lower section of the column.
When less heat is removed by the lower pump-around, more vapours will be
available up the column and more internal reflux is produced as the vapours
are condensed.
3. OPERATION OF CDU
Degree of fractionation:
The
fractionation
quality
q
y
between
two
consecutive
products
p
is
affected by several factors such as the vapour and liquid flow rates in the
column zone between these two streams, the number of trays, and the
heat extracted by the pump-around.
Fractionation quality is formulated in terms of gap or overlap of the
products For perfect fractionation,
products.
fractionation zero gap and overlap are required.
required
This means that the EBP of the light cut would be the IBP of the heavier
cut and so on.
3. OPERATION OF CDU
Overflash:
In order to fractionate the crude oil into the various p
products,, it has to be
heated to a temperature between 330 and 385oC, depending on the
crude composition.
The partially vaporized crude is transferred to the flash zone of the
column located at a point lower down the column.
The furnace outlet temperature should be enough to vaporize all
products withdrawn above the flash zone plus about 35 vol% of the
bottom product
3. OPERATION OF CDU
What is Overflash?
Overflash is the ratio of the volumetric flowrates of liquid flowing from the tray above
the flash zone down to the tray below flash zone and the feed.
feed
Flash
zone
Wash zone: the tray section located between the flash zone and gas oil draw tray.
3. OPERATION OF CDU
Functions of overflash:
Providing liquid wash to the vapours going up the column from the flash zone, and improving fractionation
on the trays above the flash zone, thereby improving the quality of the HGO and reducing the overlap with
the bottom products below the flash zone. This necessitates that there must be few trays in the region
between the flash zone and the HGO draw off.
The over-flash provides heat input to the column in excess to that needed to distill the overhead products. It
also prevents coke deposition on the trays in the wash zone.
zone
3. OPERATION OF CDU
Controlling the quantity of overflash:
Adjusting the gas oil drawing: higher rate of drawing, lower rate of overflash.
Adjusting the furnace outlet temperature: at the same rate of gas oil drawing,
drawing higher
outlet temperature produces higher rate of overflash.
Adjusting Bottom stripping steam quantity: at the same rate of gas oil drawing, higher
Bottom stripping steam quantity produces higher rate of overflash.
In some designs,overflash is drawn from a tray like an external stream and routed back
t the
to
th flash
fl h zone.In
I this
thi case it is
i possible
ibl to
t directly
di tl measure the
th quantity
tit off overflash.
fl h
Factors affecting overflash:
Switch different crude oils.
Stripping steam quantity.
Furnace outlet temperature.
Distillate draw quantity.
Unit throughput
3. OPERATION OF CDU
The furnace outlet temperature is controlled to keep coking inside the
furnace tubes and in the column flash zone to a minimum. However, the
composition of the crude plays a part in determining the
maximum
temperature allowed.
Paraffinic crude oils cracks more readily than an aromatic or asphalt-base
asphalt base
crude. Therefore, the furnace outlet temperature for paraffinic crude oils is
lower than that for other crude types.
3. OPERATION OF CDU
Column pressure :
The pressure inside the CDU column is controlled by the back pressure of the overhead
reflux drum. For design, the overhead drum pressure is estimated first. This is the bubble point
pressure of the top product at the maximum cooling water temperature. The flash zone pressure is
then
h equall to overhead
h d drum
d
pressure plus
l pressure drop
d
i the
in
h ovhd
hd condenser,
d
overhead
h d lines
li
plus
l
the pressure drop in the trays.
The Top tray pressure is 0.20.7
0 2 0 7 bar gauge (310
(3 10 psig) higher than the reflux drum.
drum
The flash zone pressure is usually 0.340.54 bar (58 psi) higher than the top tray (0.10.3 psi/tray).
Flash zone pressure should at the minimum possible level. This will maximize the crude vaporization
or, if less than maximum vaporization is desired, will minimize the operating temperature level.
3. OPERATION OF CDU
Overhead temperature:
The column top temperature is equal to the dew point of the overhead vapor.
This corresponds to the 100% point on the EFV curve (equilibrium flash
vaporization curve, giving the temperature at which a required volume of
distillate will be vaporized) of the top product at its partial pressure calculated on
the top tray.
p
must be controlled to be 1015oC higher
g
than the
The overhead temperature
dew point temperature for the water at the column overhead pressure so that no
li id water
liquid
t is
i condensed
d
d in
i the
th column.
l
Thi is
This
i to
t preventt corrosion
i
d
due
t
to
the hydrogen chloride dissolved in liquid water (hydrochloric acid).
3. OPERATION OF CDU
Overhead temperature:
Example:
If the overhead stream contains 8.5 mol% water at a pressure of 34.7 psia (2.36 bars),
calculate the overhead temperature
p
for safe operation.
p
Solution:
Calculate the saturation temperature of water at the partial pressure of water in the
overhead vapour.
Water partial pressure = 0.085
0 085 x 2.36
2 36 = 0.2
0 2 bars;
Refer to steam table, saturated steam temperature at 0.2 bars = 61oC;
Safe
S f overhead
h d operating
ti temperature
t
t
= 61 + 10 = 71oC.
C
3. OPERATION OF CDU
Preflash column and Crude column capacity:
A crude column is typically designed for 80-90% loading, which means that the
unit can be operated at 10-20% throughput more than the design value (margin).
The capacity of the column is limited by the vapour flow rate with a velocity between
2.5 and 3.5 ft/s (0.76 and 1.07 m/s).
The vapour flow rate increases as the vapours rise from the flash zone to the
overhead. To keep the vapour velocity within the limits mentioned above, the pumparounds, which are installed at several points along the column, extract heat from the
column. This results in condensing the rising vapours and reducing the vapour
velocity.
3. OPERATION OF CDU
Preflash column and Crude column capacity:
To expand crude capacity, the most used technique is to introduce a pre-flash column before
the crude heater.
The crude oil after preheating in the hot products and pump-around heat exchangers is flashed
into a column where the lightest products are removed.
removed
The bottoms from the pre-flash column are introduced into the crude heater and then to the crude
column.
The amounts of the light ends in the crude are now less, and this reduces the vapour loading up the
column.
Although the unit throughput is increased, the furnace duty is not increased, since the crude rate
going to the furnace is not affected due to the removal of the light ends.
Pre-flash columns are also introduced in the original design of the CDU when the crude oil is light, and
when it contains a lot of light ends in the naphtha range.
3. OPERATION OF CDU
Bottom Stripping steam:
At the bottom of the stripping section, steam is injected into the column to strip out the atmospheric
residue of any light hydrocarbon and to lower the partial pressure of the hydrocarbon vapours in the
flash zone. This has the effect of lowering the boiling point of the hydrocarbons and causing more
hydrocarbons to boil and go up the column to be eventually condensed and withdrawn as side streams.
streams
The steam rate used is approximately 5-10 lb/bbl (14-30 kg/m3) of stripped product.
Side Stripping steam:
Distillate products (kerosene and diesel) are withdrawn from the column as side-streams and usually contain
material from adjacent above cuts. Thus, the kerosene cut may contain some naphtha and the light diesel
cut may contain some kerosene-range boiling material. These side cuts are steam stripped using
superheated steam, in small side-stream stripper columns, containing 4-6 trays, where lower-boiling
hydrocarbons are stripped out and the flash point of the product adjusted to the requirements.
The flash point/initial point of the stripped product can be adjusted by varying stripping steam rate.
3. OPERATION OF CDU
Pumparound :
The pumparound stream is a liquid stream withdrawn at a point below a side stream tray that is
cooled by the cold crude feed as part of the preheat exchangers train. It is then returned to the
column a few trays above the draw tray.
Purpose of a Pumparound:
First,
Fi t the
th cold
ld liquid
li id condenses
d
more off the
th rising
i i vapours thus
th providing
idi more internal
i t
l reflux
fl
to compensate for the withdrawal of products from the column.
Second, heat is removed from the column at higher
g
temperatures.
p
This is in addition to the heat removal from the condenser which
takes place at relatively lower temperatures, thus the thermal
efficiency of the column is improved and the required furnace duty is
reduced.
Third, pumparound streams reduce the vapour flow rate throughout
the column. Therefore, the required column is smaller than what
would otherwise be required if pumparound streams where not there.
4. PUMPAROUNDS
Calculate Pumparound (PA) heat removal:
Tray 10: PA drawn tray; temperature = 500 oF, flowrate =
1000 lb/h.
lb/h
Tray 9: PA return tray; temperature = 400 oF, flowrate = 1000
lb/h.
Cp (specific heat) of PA liquid = 0.7 Btu/[(lb)(F)].
Heat removed in the pumparound circuit:
Q = Ths x Cphs x Fhs = Qremoved
= (500F 400F) (0.7) 1000 lb/h = 70,000 Btu/h
Flow of liquid on the cold side of the PA heat exchanger:
Cp (specific heat) of cold
cold-side
side liquid = 0.5
0 5 Btu/[(lb)(
Btu/[(lb)(F)]
F)].
Qabsorbed = Qremoved = Tcs x Cpcs x Fcs
Fcs = 70,000 Btu/h / [(300F 200F) (0.5) ] = 1400 lb/h.
4. PUMPAROUNDS
Why do we wish to remove heat from the vapor flowing up
through tray 10?
Recovering heat to a process stream that would otherwise be lost to
the cooling tower.
Increasing the pumparound heat removal will lower the coolingwater outlet temperature. If the cooling-water outlet temperature
from the condenser was 140F. This is bad. The calcium carbonates
in the cooling water will begin to deposit as water
water-hardness
hardness deposits
inside the tubes. It is best to keep the cooling-water outlet
temperature below 125F to slow down such deposits.
Increasing pumparound heat duty will unload the overhead
condenser. This will cool off the reflux drum. A colder reflux drum will
absorb more gas into the distillate product. Less gas will be vented
from the reflux drum, and this is often desirable.
4. PUMPAROUNDS
Why do we wish to remove heat from the vapor flowing up through tray 10?
The pressure drop across the top few trays would increase.
increase
Increase the pumparound duty >> flow of vapor through trays 1 to 8 will
decrease >> lower vapor velocity >> reduce the tray pressure drop >>
ability
bilit off the
th vapor to
t entrain
t i liquid
li id will
ill be
b reduced
d
d >> the
th height
h i ht off liquid
li id
in the downcomer will be reduced >> tray flooding (entrainment flooding)
will be suppressed.
4. PUMPAROUNDS
Does Pumparound fractionate or enhance fractionation?
The temperature difference between tray 10 and tray 9 shows that
f ti
fractionation
ti is
i taking
t ki place
l
across the
th PA trays.
t
The temperature difference is a measure of the amount of
fractionation. The bigger this temperature difference, the more the
fractionation that is taking place across the trays.
Increases PA flow rate increases this temperature difference up to a
pointt >> e
po
enhance
a ce fractionation/tray
act o at o /t ay e
efficiency.
c e cy
However, when the PA liquid flow becomes too great. Probably, the
downcomers start to back up. Tray efficiency is impaired because of
thi downcomer
this
d
fl di
flooding.
Th temperature
The
t
t
diff
difference
b t
between
t
tray
10 and tray 9 becomes smaller. The point above which T decreases
when PA flow increases is called the incipient flood point for the
PA trays.
PA Duty
constant
in
vapour
temperature
results
in
PA Duty
constant
PA Duty
constant
its dew point and the liquid leaving each tray is at its
bubble point.
point
As the top reflux rate is increased, all the trays are
cooled The vapors leaving trays 3,
cooled.
3 4,
4 and 5 are cooled.
cooled
As a vapor at its dew point cools, the heavier
components
co
po e ts in tthe
e vapor
apo co
condense
de se into
to a liquid.
qu d The
e
remaining vapors have a lower molecular weight because
they are lighter.
PA Duty
constant
from
the
internal
reflux.
These
lighter
PA Duty
constant
6. IMPROVING FRACTIONATION
How to improve the degree of fractionation between Diesel and GO (remove the
relatively heavy GO from the Diesel and remove the lighter Diesel from GO)?
Reduce the amount of diesel product from the tower?
That could wash the heavier gas oil out of the diesel.
But it would also increase the amount of diesel in the
gas oil.
Increase heat removed in the PA?
Similar effect to above: less gas oil in diesel,
diesel but more
diesel in gas oil.
Decrease heat removed in the PA?
6. IMPROVING FRACTIONATION
How to improve the degree of fractionation between Diesel and GO (remove the
relatively heavy GO from the Diesel and remove the lighter Diesel from GO)?
D
Decrease
h t removed
heat
d in
i the
th PA?
That increases the vapor flow from tray 8.
The
Th extra
t flow
fl
rates
t off vapor flow
fl
up the
th tower
t
and
d raise
i the
th
tower-top temperature.
The
Th reflux
fl
control
t l valve
l
opens to
t cooll the
th tower-top
t
t
temperature back to its temperature set point. Then the liquid
fl
flow
rates,
t
f
from
t
trays
1 2,
1,
2 and
d 3,
3 onto
t tray
t
4 allll increase.
4,
i
If the diesel draw-off rate is maintained constant, the liquid
over-flow
fl
rates
t onto
t trays
t
5 6,
5,
6 and
d 7 will
ill increase.
i
Thi liquid
This
li id
flow is called the internal reflux.
6. IMPROVING FRACTIONATION
How to improve the degree of fractionation between Diesel and GO (remove the
relatively heavy GO from the Diesel and remove the lighter Diesel from GO)?
D
Decrease
h t removed
heat
d in
i the
th PA?
Trays 5, 6, and 7 are the trays that fractionate between diesel and
gas oil.
oil The more efficiently they work,
work the less the contamination of
the adjacent products.
To improve the separation efficiency between a light and heavy
product, the vapor flow rate through the trays is increased, and the
internal reflux flowing across the trays is increased.
increased
This improvement in the degree of fractionation developed by trays
5, 6, and 7 is a result of reducing the amount of heat duty removed
by the PA flowing across trays 8, 9, and 10.
6. IMPROVING FRACTIONATION
Potential of tray flooding by reducing heat removed in PA:
Reducing the PA duty increases loadings on trays 1 through 7 >> the
trays operate closer to their incipient flood point. The incipient flood point
corresponds to the optimum tray performance.
Crossing over the incipient flood point, trays 5, 6, and 7 actually start to
flood, their fractionation efficiency will be adversely affected. Then, as the
PA heat-removal duty is decreased, the mutual contamination of diesel
and gas oil will increase.
From an operating standpoint, as the PA duty is decreased, the T
between the Diesel and GO product draws should increase. When these
t
two
t
temperatures
t
start
t t to
t come together,
t
th
it assume the
its
th incipient
i i i t flood
fl d
point has been exceeded and that trays 5, 6, and 7 are beginning to flood.
of crude oil varies typically from 0.5 to 10% vol and quite
dispersed
water
phase
polar head
(hydrophilic) group
(likes water)
hydrophobic tail
(likes oil)
ELECTRICAL FIELD
+
++ ++
-- ---
++
---
+
+
--
Induced Charge
Electrostatic
Attraction
CV 02 D 6
F
d4
F = Attractive Force
C = A Constant
V0 = Voltage Gradient, volts/inch
D=D
Droplet
l t Di
Diameter
t
d = Distance Between Drops
Coalescence:
How to increase attractive force?
Increase the water droplets population.
Increase wash water rate.
What is the risk in case of over emulsion (very small water droplets)
generated in the mixing
mi ing valves?
al es?
Reduced attractive force.
Water carry over.
High salt content at the outlet.
Emulsion accumulation at the interface.
Short circuit in the grids.
KD 2 w o
V = Settling Velocity
K = A Constant
D = Diameter of Water Droplet
w = Density of Water
o = Density of Oil
= Viscosity
Vi
it off Oil
Settling:
What is the impact on the droplets settling velocity if the oil viscosity
change from 2 cP to 3 cP?
The droplet settling velocity is reduced by 1/3.
What about separation of water droplets?
The residence time may
ma be not enough
eno gh to achieve
achie e proper separation.
separation
What is the possible solution?
Increase temperature to reduce the oil viscosity.
Reduce oil flow rate.
Increase wash water rate to compensate the bad separation.
H2 O
H2HO2 O
H2 O
Crude Oil
H2 O
H2 O
H2 O
H2 O
H2 O
H 2O
Water
0 1500
0.1500
5.00
0.1450
4.00
0.1400
3 00
3.00
0 1350
0.1350
2.00
0.1300
1.00
0.1250
0 00
0.00
0 1200
0.1200
150
Crude Visc
cosity, cSt
Settling Veloc
city of Water
200
250
300
Temperature, F
Water Solubility in Crude
0.60
40 API
W
aterinC
rude, vo
l%
0.50
33 API
0.40
21 API
0.30
16 API
0 20
0.20
0.10
0.00
150
200
250
T emperature, F
300
350
through the
reflected
f
back
vapor in the
radiator.
radiator
These noncondensables mix with the steam
propane
condensing
to
vapor
propane
is
liquid
still
at
the
pressure
introduction
restriction,
of
the
this
butane
t
towers
overhead
h d vapor flow
fl
i leaking
is
l ki through
th
h the
th hot-vapor
h t
b
bypass
valve
l
between the
condenser outlet and the reflux pump suction, 1 percent of the towers
vapor flow
fl
i leaking
is
l ki through
th
h thevapor
th
b
bypass
valve
l
area, the
Aqueous system:
Incidentally, the condenser may be located above or below the
reflux drum.
drum
Both configurations
condenser.
But
if
the
condenser
is
located
below
the
reflux
drum,
reduces
the
heat-transfer
surface
area
available
for
problem
bl
with
ih
fl d d
flooded
condenser
d
pressure
controll
i
is
Condensate backup
Subcooling
g of condenser
effluent
Fouling due to low flow of
the cooling-water tubes
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