Lecture 5

Refinery Distillation

L5 - 1

Distillation

In the atmospheric crude oil distillation tower, crude oil is

separated into various products
LPG and Naphtha
Kerosene
Diesel
Gas oil
Feed

Steam

Reduced crude
(Atmospheric residue)

Atmospheric crude tower

L5 - 2

Distillation

Crude oils are characterised by true boiling point (TBP) curves

TBP curve of feed and products

TBP curve of crude oil feed

900
800

800

700

700

600

600

500

500

400

400

300

300

200

200

100

100

20

40

60

80

100

Residue

HN
LN
0

20

40

60

80

100

Volume percent vaporised

Volume percent of whole crude vaporised

L5 - 3

HD

LD

Distillation

Crude oil mixtures are divided into a finite

number of pseudo-components
900
800

& Each pseudo-component is

treated as a pure component
with known properties.

700
600

& Commercial simulators

translateboiling point curves into
pseudo-component sets
automatically.

500
400
300
200
100
0

L5 - 4

20

40

60

80

Volume percent vaporised

Distillation

100

Traditional crude oil distillation tower with side strippers

VAP
WATER
DIST

VAP Overhead Vapour

DIST Distillate
HN Heavy Naphtha
KE Kerosene
LD Light Distillate
HD Heavy Distillate
AGO Atmospheric Gas oil
RES Residue
ST Steam

HN

KE
STEAM
LD
STEAM
HD

Furnace
Feed

STEAM
AGO
STEAM
RES

Crude preheat train

L5 - 5

Complex structure.
Highly interlinked sections.
Many side exchangers and
side columns.
Stripping steam is used to
perform separation in
some sections.
High energy consumption.

Distillation

The design of crude distillation column

1. Experience, experimental data, and empirical correlations
(e.g. number of stages in each section, or the steam flows).
2. Shortcut models (e.g. the Fenske method and Jakob
correlation).
3. Rigorous simulation (i.e. pseudo-component method and
stage-by-stage calculation).
The design is usually carried out from bottom section upwards.
Therefore, interactions between sections may not be taken into
account.
L5 - 6

Distillation

Design parameters of crude distillation column

Preheating duty
Steam flow in each section
Pump-around duties
Reboiler duties
The number of stages in each section
These parameters interact strongly with each other. All of them
must be considered simultaneously.

L5 - 7

Distillation

When considering the design of the crude tower and heat

recovery system, the design is traditionally carried out in a
sequential manner.
Sequential approach to design
LN

HN

LD
Steam
Feed
Steam
RES

Stage 2
Heat recovery system design

Stage 1
Column design

Some interactions between the heat exchanger network

and the column are not taken into account during the
design process.
L5 - 8

Distillation

Simultaneous approach to design

Water
LN

Interactions

UPA
HN
MPA

LPA
Feed

Steam
LD
Steam
HD
Steam
RES

Heat recovery system design

Column design

The heat recovery system needs to be considered at the

same stage as the column design.

L5 - 9

Distillation

Integrated crude oil distillation design

Pinch analysis provides guidelines for column modifications in
order to improve heat recovery.
Column modification

Improve heat recovery

Water
LN
PA3

UTILITY PROFILE

HN
PA2
LD
PA1
Feed

EXPAND

Steam
HD
Steam

Enthalpy

RES

Ref: K. Liebmann, PhD Thesis, UMIST, 1996

L5 - 10

Distillation

The complex column is decomposed into the

equivalent sequence of simple columns.
Water
LN

PA3
HN

Decompose

3 PA3

PA2
LD
PA1
Feed

Steam
HD
Steam

2 PA2
Feed
PREH1

HN
LD

Steam2
HD

1 PA1

RES

Water
LN

Steam1
RES

The design of complex columns becomes more systematic.

L5 - 11

Distillation

The design procedure of Liebmann is based on a set of guidelines

and insights from pinch analysis.
Column Design
Heat Integration

Yes

Scope for Improvement ?

No

Final Design

Two-step approach: Manual iterations are required.

Rigorous model of distillation column: Convergence
problems may occur.
L5 - 12

Distillation

We need
A simultaneous approach to take account of all column
design parameters and heat recovery issues.
A method for optimising the design.
A short-cut model for columns using stripping steam to
use within the optimisation framework.

L5 - 13

Distillation

To design the crude oil distillation tower, we will

decompose it into a sequence of simpler columns
Hypothetical condenser
4
3 PA3
2 PA2
Feed

1 PA1
PREH1

Water
LN

HN

Feed

LD

Steam

Steam2
HD

Steam1
RES

Refluxed Stripper

The column with stripping steam is modelled as a refluxed

stripper with a hypothetical condenser.
L5 - 14

Distillation

Characteristics of a refluxed stripper

Temperature

Simple column :
Temperature profile is
monotonic along the column.

Feed

Steam

Refluxed stripper :
A temperature peak occurs
at the feed stage. This is
caused by the cooling effect
in the stripping section.

Stage Number

The Fenske-Underwood-Gilliland short-cut method cannot be

applied directly to refluxed strippers.
L5 - 15

Distillation

Shortcut Design Procedure :

Based on Underwood equation
Step 1 : Estimate minimum vapour flow
Step 2 : Calculate top and bottom product
conditions (temperature, pressure)
Step 3 : Estimate the number of stages

L5 - 16

Distillation

Step 1 : Estimate minimum vapour flow

Different steam flows

(1-q)F

V Vs

Different values of partial

pressure at feed stage

F
qF

L'

V'

Different q-values
Different minimum vapour flows

Given the steam flow rate, the Underwood equation can be

used to estimate minimum vapour flow above feed stage.
L5 - 17

Distillation

Step 1 : Calculate Vmin (continued)

Specify steam flow
Assume partial pressure of feed at feed stage
Feed flash calculation to estimate q-value
Underwood to estimate minimum vapour flow
Update new partial pressure at feed stage
partial
pressure
changed?

Yes

No
Vmin above feed and non-key distribution
L5 - 18

Distillation

Step 1 : Minimum vapour flow (continued)

The constant molar overflow assumption
For wide boiling mixtures, minimum
vapour flow is not constant through the
column section.
Vmin from the Underwood is the value at
the top pinch zone of the column.
Minimum vapour flow at the top of the
column determined by enthalpy balance:

Top Pinch

Enthalpy balance
Determine condenser duty
Enthalpy balance
Calculate minimum vapour flow at the
top of column.
L5 - 19

Composition estimated
by Underwood equation

Distillation

Step 2 : Calculate top and bottom temperatures

Distillate

Specify R/Rmin

Qc

Usually between 1.1 and 2.0

Underwood underestimates Rmin.

Enthalpy balance
Calculate condenser duty
and top stage temperature

Feed

Enthalpy balance
Calculate bottom stage temperature
and bottom vapour flow rate.

Steam
Bottom product

L5 - 20

2
Distillation

Step 3 : Estimate number of stages

Distillate

Rectifying section  NR

QC

Gilliland correlation.
NR

Stripping section  NS

Vapour flow changes

through section.
Gilliland correlation does
not work.
Consecutive flash from
bottom stage until vapor
flow reaches the value
below the feed stage.

L5 - 21

Feed

NS

Lf

Vf + Vs

L-

Vb + Vs
Steam (Vs)
Bottom product (B)

Distillation

Optional equipment: Pump-around/Pump-back cooler

Pump-around

Pump-back

Draw liquid from a particular stage, cool

and feed back onto some stage above.

Draw liquid from a particular stage, cool

and feed back onto some stage below.

Function of pump-around/pump-back
Reject heat at higher temperature.
Reduce the internal flows in the top sections.
L5 - 22

Distillation

Modelling of pump-around/pump-back cooler

Water

Cut
Steam

Feed

Water

Steam

Feed

Link
Steam

Steam

Pump-around/pump back cooler is installed at the top of the column section.

L5 - 23

Distillation

Pump-around/Pump-back Models
Pump-around

Pump-back

V*+VS

V*+VS
L*

L*

PA
V+VS

V+VS

PB

L
2

Calculation Procedure:
1) Calculate total cooling duty in absence of pump-around/pump-back.
2) Specify degree of thermal coupling, L*/Lo

where Lo is liquid flow at the top in the absence of pump-around/ pump-back.

L*/Lo < 1 represents partial thermal coupling.

4)Calculate hypothetical condenser duty using enthalpy balance

5)Calculate pump-around/pump-back duty and vapour flow below top
stage using enthalpy .
L5 - 24

Distillation

Simultaneous approach to design of crude oil

distillation systems
Pinch Analysis
Energy Target
Area Target

Initial design
Column
Decomposition

Final design

Cost models

Optimisation
(SQP)

L5 - 25

Distillation

Summary
Shortcut model for the design of atmospheric crude oil
distillation tower is proposed.
Different design parameters are considered.
 This allows capital and energy trade-offs to be explored.

All column design parameters and the heat recovery scheme

can be considered simultaneously.
 Pinch Analysis provides energy and area targets for the optimisation of
the atmospheric crude oil distillation tower.

We can obtain the optimum design with high potential for heat
recovery.
L5 - 26

Distillation

Working Session 5
Refinery Distillation

WS5 - 1

Distillation

Part A

Design of Atmospheric Crude Oil Distillation Tower

WS5 - 2

Distillation

Feed :

Crude assay
% Distilled

TBP ((C)

0
5
10
30
50
70
90
95
100

-3.0
63.5
101.7
221.8
336.9
462.9
680.4
787.2
894.0

100,000 bbl/day
(2,610 kmol/hr)
25 (C
3 bar
360 (C
370 (C
2.5 bar

Temperature :
Feed pressure :
Preheating temp. :
Limiting preheated temp. :
Column Pressure

Product target temperatures

Light Naphtha (LN):
40 (C
Heavy Naphtha (HN):
40 (C
Light Distillate (LD):
40 (C
Heavy Distillate (HD):
50 (C
Residue (RES ):
100 (C
Unit cost
(/kW.yr)
57.5
Flue gas
1510-150 (C
46.3
MP-Steam
185.4 (C
35.2
LP-Steam
158.0 (C
3.5
Cooling Water 20-40 (C
Utilities

Density = 865.38 kg/m3

25 pseudocomponents

Economic data
Interest rate : 10%
Plant life : 10 years
WS5 - 3

Distillation

The crude tower is decomposed into the indirect sequence.

Water
LN

PA3
HN

Decompose

3 PA3

PA2
LD
PA1
Feed

Steam
HD

2 PA2
Feed

Steam

1 PA1
PREH1

RES

HN
LD

Steam2
HD

Steam1
RES

Stripping steam is only used in columns 1 and 2.

WS5 - 4

Distillation

Water
LN

Design parameters (WS5_1.col):

Column
1
2
3
Feed
Main
Col1 Top
Col2 Top
Preheat temp. (deg.C)
360
Column Pressure (bar)
2.5
2.5
2.5
Light key
13
11
7
Heavy key
16
14
9
LK recovery in Top
0.98
0.98
0.98
HK recovery in bottom
0.98
0.98
0.98
Top stream to
T/C Column T/C Column T/C Column
Bottom stream to
Product
Product
Product
Pump-around
Yes
Yes
Yes
Degree of Therm. coupling
0.6
0.2
0.6
Temp.drop in PA (deg.C)
40
50
20
Type of Condenser
Partial
Partial
Partial
R/Rmin
1.6
1.17
1.2
Use steam
Yes
Yes
No
Steam Temp. (deg.C)
260
260
Steam Press. (bar)
4.5
4.5
Steam Flow (kmol/hr)
1200
250
Use reboiler
No
No
Yes
Top cooling to (deg.C)
Bottom cooling to (deg.C)
100
50
40
WS5 - 5

4
Col3 Top
2.5
4
6
0.98
0.98
Product
Product
No
Total
1.2
No
Yes
40
40

Distillation

1. Determine the column capital cost.

In the Steam stripping menu, the specifications for each
column can be seen by selecting the Column specifications.
Simulate the sequence by selecting the Sequence report in
the Steam stripping menu.
From the report, find the total annualised cost of merged
sequence (complex tower).

WS5 - 6

Distillation

2. Determine total annualised cost.

To perform Pinch Anlaysis, Tmin is set to 10oC. Then,
determine the energy cost, utility capital cost, and area
capital cost (1-1 exchanger) from Capital Report in the
Target menu.
Cost
Column Cost
Utility Energy Cost
Utility Capital Cost (Furnace)
Area Capital Cost
Total Annualised Cost

WS5 - 7

M/yr

Distillation

3. Plot Balanced Grand Composite Curves.

The Balanced Grand Composite Curves can be plotted by
selecting the Balanced Grand Composite Curves in the
Target menu. Determine the minimum hot utility and
minimum cold utility requirement.

WS5 - 8

Distillation

Part B

Optimisation of Heat-integrated Crude Tower

WS5 - 9

Distillation

1. Selecting the optimisation variables:

The design parameters from Part A will be used as the initial
parameters in the optimisation.
The optimisation variables for the atmospheric crude tower
are shown below. The details can be seen in the
Optimisation Variables in the Steam Stripping menu.

WS5 - 10

Column1
Preheating temperature
Degree of thermal coupling
Temperature drop across pump-around
Stripping steam flow

Column3
R/Rmin
Degree of thermal coupling
Temperature drop across pump-around

Column2
Degree of thermal coupling
Temperature drop across pump-around
Stripping steam flow

Column4
R/Rmin

Distillation

2. Optimisation of atmospheric crude tower.

The optimisation can be performed by selecting Optimise
Sequence in the Steam Stripping menu.
Determine the column capital cost, energy cost, utility capital
cost, area capital cost, and total annualised cost for the
optimum design.
Plot Balanced Grand Composite Curves, and determine the
minimum hot utility and minimum cold utility requirement.
Cost
Column Cost
Utility Energy Cost
Utility Capital Cost (Furnace)
Area Capital Cost
Total Annualised Cost
WS5 - 11

M/yr

Distillation

Working Session 5
Solution

Sol5 - 1

Distillation

Part A

Design of Atmospheric Crude Oil Distillation Tower

Sol5 - 2

Distillation

Details of Total Annualised Cost for Atmospheric Crude Tower

Cost
Column Cost
Utility Energy Cost
Utility Capital Cost (Furnace)
Area Capital Cost
Total Annualised Cost

Sol5 - 3

Distillation

M/yr
0.2885
3.1378
0.3391
1.0177
4.7831

Balanced Grand Composite Curves of Atmospheric Crude Tower

400

300

Minimum hot utility: 55.0 MW

200

Minimum cold utility: 39.3 MW

100

0
0

10

20

30

40

50

60

Enthalpy (MW)
Sol5 - 4

Distillation

Part B

Optimisation of Heat-integrated Crude Tower

Sol5 - 5

Distillation

The optimum design parameters (WS5_2.col)

Column
1
2
3
Feed
Main
Col1 Top
Col2 Top
Preheat temp. (deg.C)
366.7
Column Pressure (bar)
2.5
2.5
2.5
Light key
13
11
7
Heavy key
16
14
9
LK recovery in Top
0.98
0.98
0.98
HK recovery in bottom
0.98
0.98
0.98
Top stream to
T/C Column T/C Column T/C Column
Bottom stream to
Product
Product
Product
Pump-around
Yes
Yes
Yes
Degree of Therm. coupling
0.57
0.16
0.36
Temp.drop in PA (deg.C)
12.2
19.2
12.2
Type of Condenser
Partial
Partial
Partial
R/Rmin
1.6
1.17
1.05
Use steam
Yes
Yes
No
Steam Temp. (deg.C)
260
260
Steam Press. (bar)
4.5
4.5
Steam Flow (kmol/hr)
975.7
198.5
Use reboiler
No
No
Yes
Top cooling to (deg.C)
Bottom cooling to (deg.C)
100
50
40

Sol5 - 6

4
Col3 Top
2.5
4
6
0.98
0.98
Product
Product
No
Total
1.05
No
Yes
40
40

Distillation

Details of Total Annualised Cost of the Optimum Design

Cost
Column Cost
Utility Energy Cost
Utility Capital Cost (Furnace)
Area Capital Cost
Total Annualised Cost

Sol5 - 7

Distillation

M/yr
0.3353
2.5908
0.3183
0.8333
4.0777

Balanced Grand Composite Curves of the Optimum Design

400

Optimum Design
Initial Design

300

Minimum Hot Utility: 43.1 MW (78%)

200

Minimum Cold Utility: 27.8 MW (71%)

100

0
0

10

30

Enthalpy (MW)
Sol5 - 8

Distillation

40

50

60