Refinery Distillation

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 Distillation
Distillation A major refinery process for separating
constituents from liquid mixture by vaporization of
mixture to group of components

Continued importance with modernization and new

units construction

Liquid mixture vaporized yielding vapor phase

containing mixture of controllable composition different
from original mixture
Present global ADU and VDU capacity are ~86 and ~
28 million bpcd Indian refining capacity is ~ 2.8
mmbpsd
 Crude Oil
Mixture of large number of hydrocarbons

Except first few hydrocarbons all other

hydrocarbons exhibit isomerism

Hydrocarbon types: Paraffins: n- / i- Cn H2n+2

e.g. Propane, butane, iso-butane , C5 to C15 liquids
Beyond C30 mostly solids
Naphthenes: Cycloalkanes / saturated ring
structure Cn H2n e.g. Methyl cyclopentane
Aromatics: Benzene ring & derivatives, BTX
CRUDE OIL IS LIKE WINE

SWEET SOUR HEAVY

CRUDE MAY BE
 FUEL GAS
LIGHT ENDS
NAPHTHA
CRUDE OIL RAW DIESEL
GAS OIL
RESIDUE
 Asphalts, resins & bitumen
Asphalts, resins and bitumen
Asphalts high molecular weight complex molecules
soluble in aromatic solvents and CS2

Resins mostly compounds of highly condensed ring

structures,containing O, S and N and sometimes
inorganic

Bitumen made of asphalts, resins and mineral oil

Three components comprise colloidal system
Asphalts suspended in oil and resins contribute to
stability of system.
 CRUDE OIL
CLASSIFICATION
Petroleum classified in three types
Paraffinic base
Mixed base
Naphthenic base
Also on basis of residuum ( material left behind
after distillation of fractions)
Residue containing more than 5% paraffins
paraffinic base
Residue containing less than 2% paraffins
naphthenic base
Residue containing 2-5% paraffins mixed base
 Crude Oil Reserve in
thousand million barrels
743
800

600

400

104 117 144

200 41 60

0
1 2 3 4 5 6

1- Asia Pacific 2- North America 3- S. & Cent. America 4-Africa

5- Europe 6- Middle East Source BP Review of World Energy 2007
Distillation of Crude Oil
Distillation of Crude Oil
 DISTILLATION
Boiling Range C Products

-10 to 5 LPG
5-70 Light naphtha / Gasoline
70-140 Naphtha / Petrochemical feed
140-240 ATF
140-300 Kerosene
250/300 to 370 Diesel
370-400 LVGO
400-550 HVGO
550+ SR

REFINING OBJECTIVE
High volume fuels and lube production

Flexibility to use different crude stocks

Environmental issues considered

Maximization of high value distillates

and minimize bottom of the barrel /
fuel oil
 REFINERY TYPES
SIMPLE
Process range of crudes to middle distillates
CDU, VDU; FCCU/Hydrocracker; CRU; H2
plant
---COMPLEX
Processing variety crudes, High value added
products, Mother unit to nearby petrochemicals
CDU, VDU, Visbreaker, Lubes, FCCU, Delayed
Coker, Wax, CRU, Sulphur, Bitumen Plant
-- INTEGRATED
Refining, Petrochemicals and Power Plant
CDU, VDU, Visbreaker, CRU, FCCU, Coker,
Aromatics (BTX), Steam Cracker e.t.c.
IOCL GUWAHATI REFINERY LPG
STAB.
UNIT LIGHT GASOLINE Gasoline
ISO SIV

KERO KEROSENE
TRTMT

HVY KEROSENE DIESEL/

C KEROSENE
CRUDE D DHDT ATF
U GAS OIL

LPG
MS

Indmax Diesel
ATM
RESIDUE
DELAYED
COKER
COKE
 IOCL MATHURA REFINERY

LPG H2 Plant
ST RUN NAPH MS
N
MSQP
NAP CRU
S REFORM
C
HVY L NAPH

FCC LT GASO
DHDS LHT NAPH
NAPH DIESEL
D ATF HVY NAPH
NAPH OHCU KERO
KERO
DHDT DIESEL
U DIESEL
AGO
FCC TCO
V LPG
AR D VGO
FCCU
U
VR VB NAPHTHA
LIQ VBU
FUEL VR
BBU VB TAR

BITUMEN
 RELIANCE JAMNAGAR REFINERY COMPLEX
LPG
Sat LPG
C3/C4
MEROX Normal N- Butane
Sat Gas
Butane
Concn
Recovery
Naphtha

Kero
MEROX
Unsat gas LPG Propylene
FCCU
Heavy kerosene conc. MEROX Recovery

C Diesel
CRUDE D DHDT H2

C5 - C10
U HAGO

H2 PLANT
Gasoline LPG
MEROX
V
ATM D
Residue U C5 -C6
LIGHT
NAPH
HDT

HEAVY
Delayed VGO
NAPH
Coke to PP Coker HDT
HDT

Diesel
TBP TEMPERATURE (DEGC)
600

500

400

300

200

100

10 30% 50% 70% 90%

CUMULATIVE VOLUME DISTILLED (%)

Temperature Typical Composite Curve of Crude

Volume
Fractionator Conceptual Model

HGO

LGO

KERO

Hy. NAP

Lt. NAP

Volume %
 LIGHT ARABIAN CRUDE OIL
TYPICAL CHARACTERISTICS
Gravity degree. API 34.5
Specific Gravity 0.8524
Hydrogen Sulfide, ppm 2
Pour Point, degree. C 26
Viscosity at 21.degree. C 8.9 (55 SUS)
Salt, Lb./1000 Bbl. 3
Vol. % Propane 0.17
C4 1.23
C5 2.9
C6 3
C 7+ 93.33
 Material Balance
Comparison between HS and LS crude
Bonny Light Crude Arab Mix
Stream Wt,% Wt,%
Off gas 0.0557 0.022
LPG 1.32 1.38
Naphtha 12.75 11.13
Kerosene 26.75 21.55
Diesel 30.69 18.8
HVGO 24.53 25.15
SR 3.91 22
Total 100.0 100.0
 Distillation

Binary distillation separation of only two

chemicals. Example separating ethanol form
water.
Multicomponent distillation separation of
mixture of chemicals. Example petroleum
refining. Crude oil complex mixture of
hydrocarbons with thousands different molecules.
Nearly all commercial distillation multicomponent
distillation.
 Distillation
Rectification / stripping
Flash Distillation
Differential Distillation
Steam Distillation
Vacuum Distillation (VDU)
Azeotropic distillation
 Stripping remove light material from heavy product.

Rectification remove heavy material from a light product

Fractionation remove light material from heavy product

and heavy material from light product same time

Complex fractionation multiple products from single /

complex towers with recycle streams. Example of
multiple product tower refinery crude distillation tower
making cuts of naphtha (gasoline), kerosene (jet fuel),
and diesel from same tower.
 Fractionation refers to units that have both reboiler
and condenser. Facilities attached to bottom of tower
to put heat in tower and to top of tower to take heat
out of tower.This normally called distillation

Stripping unit has no method at bottom of the tower

to put heat in. External stream supplied from outside
to strip material from liquid.

Distillation equipment - two major categories, trays

and packing
 Azeotropic & extractive distillation - addition of
mass separating agent (MSA) modify thermodynamic
behavior Many azeotropic and extractive distillation
configurations in use.
Azeotropic distillation - MSA forms minimum boiling
azeotrope with some feed component. Azeotrope taken
overhead MSA rich phase decanted and returned to
column as reflux.
Extractive distillation uses MSA that increases
volatility difference between compounds to be separated.
Example - sulfolane to increase relative volatility
difference between similar molecular weight aromatic
and paraffinic hydrocarbons.
 Rectification / Stripping
Enrichment of vapor stream passing through column in
contact with reflux called rectification

Reflux liquid stream concentrated in low boiler returned

at top of column called reflux. Without reflux no
rectification possible

In fractionating column all plates above feed injection

constitute rectification section

Feed plate and all plates below feed constitute stripping

section
 Distillation
Vapor formed by boiling liquid mixture-
different in composition from boiling liquid

More volatile ( Low boiler) tend to concentrate

in vapor. High boiler ( less volatile) tend to
concentrate in boiling liquid

At all column levels low boiler diffuse from

liquid to vapor and high boiler from vapor to
liquid.
 Flash Distillation
A definite amount of liquid is vaporised in still.
Vapor and residual liquid held in close intimate
contact, at end of operation vapor in equilibrium
with residual liquid

Vapor separated and condensed

Continuous process
 Distillation
In differential distillation vapor generated by
boiling liquid is withdrawn as soon as it is
formed and condensed

Relative volatility is the ratio of vapor pressure

For a two component system if pa and pb are the

vapor pressure of pure A and B
Steam / Vacuum Distillation
Problems appear in distillation of reduced crude, lubes,
glycerine, fatty acids, aniline, turpentine oil etc:
1. B.P. of material high, decomposes thermally before
reaching b.p.at atmospheric pressure

2. Vaporization temperature difficult to reach and direct

fire dangerous or detrimental to quality

Solution to lower distillation temp. to vaporize liquid

without degradation by operating in vacuum
Steam distillation older method Vaporized in stream of
inert carrier vapor whose liquid phase immiscible with
material
 Distillation range
Boiling range of crude give indication of
quantities of various products present

Various types of distillation curves (ways of

relating vapor temperature and percentage
vaporised) are available

Major types are:

TBP curves
Equilibrium or flash vaporization curves
ASTM or non-fractionating distillation curves
True Boiling Point distillation most useful
type of distillation
 TBP DISTILLATION
Test enlightens refiners with possible
information regarding % quantum of
fractions, base of crude and key
characteristics of cuts

Information supplied forms basis of design

of distillation columns.
Temperature Typical Composite Curve of Crude

Volume
 EQULIBRIUM FLASH
VAPORISATION (EFV)
Vapor kept cohesively with liquid at some
temperature and a sudden release of pressure
quickly flashes or separates the vapor from the
mixture

Experimentally this type of distillation may not be

suggested as cumbersome and costly

Inter conversion from one type of distillation to

other always possible.( TBP TO EFV)
 ASTM Distillation
No deliberate attempt to fractionate

Vapor temperature does not represent true or

actual boiling point of the material situated at
that percentage in the crude oil.

ASTM designation D-86 applied to gasoline,

naphtha, kerosene, etc. is the best known
nonfractionating distillation for products.
 UNIT CAPACITY
Design capacity : present requirement,future
expansion
No. of streams hrs. per year
Turndown of maximum capacity
No. of trains
FEED / PRODUCT SPECS
Feed: feed TBP, light ends & characteristics,
pure component analysis, crude assay
Products: Composition, cut range, desired
quality
 Product Separation
Crude contain innumerable components falling in
small close boiling cuts.

Individual separation not possible.

Design based on TBP/ASTM data.

Increasing closeness of boiling points of two
successive cuts, separation difficult task.
Expressed as difference between ASTM 50% boiling
points of two successive cuts Larger difference
renders separation better
 Separation
What defines a good separation ?

Relationship between ASTM distillation temperatures at

95%vol and 5%vol of two adjacent fractions, light
and heavy, respectively
ASTM 5% vol Temp (heavy fraction, e.g. LGO)
95%vol Temp (light fraction, e.g. kerosene) = T

if T > 0 and high, called ASTM

gap (good separation)

if T < 0, bad separation

 ASTM Gap
Defined as difference between 5% boiling point
of heavy fraction and 95% boiling point of
preceding lighter cut.

Ta = 5% BOILING POINT OF HF
Ta
Tb = 95% BOILING POINT OF LF
Tb ASTM GAP = Ta - Tb
 TBP OVERLAP

If ASTM gap not available TBP overlap taken

into account.
TBP overlap difference between FBP and IBP
of successive fractions

LF
TBP OVERLAP

HF

Volume % distilled
What influences good separation in a
distillation column:
No.of plates
Reflux Ratio
Steam Injection - particularly for better separation of
heavy fractions

Fractionation in light end towers:

Measured by distribution of key components in

distillate and bottoms
 Typical Main Fractionator
Main column provided with:

Valve trays in top section,

Valve trays in KERO / LGO section,

Structured packing in HGO section,

Valve trays Over-flash section.

Structured packing in bottom stripping section and
OVHD vapour partially cooled / condensed in Air condenser
~ to 65 C, further cooled in trim coolers Condensed gasoline
at 45 C collected in reflux vessel

Pumps take suction from reflux drum. Part of gasoline

pumped as reflux back to column under flow control by
FICand part pumped to Naphtha caustic wash under flow
control by other FIC cascaded with LIC-2501 of V. The
overhead temperature controlled by TICcascaded with
reflux flow FIC
 Typical Main Fractionator
First side stream Kerosene withdrawn from tray no. 10. Part
goes by gravity to KERO stripper where lighter ends stripped-
off by steam. Has packed bed of structured packing.
Vapor return from stripper back to column at tray no 10
Stripped bottoms picked up by pumps and sent to rundown
under flow control by FIC via heat exchangers E- and finally
through a cooler E
Balance kerosene drawn from main column pumped by
Circulating Reflux (pump-around), exchanging heat with the
incoming crude in the heat exchangers E A hand control valve
HCV is provided in bypass line of E to adjust the exit
temperature.
Kero CR returns to tray no.-7
The flow of Kero CR back controlled by FIC
 Typical Main Fractionator
LGO & LGO CR drawn from tray 19 and pumped
by pumps to heat exchangers E
LGO product ex E goes to AC under flow control by
FIC. LGO CR ex E goes back to the main column
under the flow control FIC cascaded
A hand control valve HIV provided in bypass of E
to adjust exit temperature . LGO CR returns to Tray
-17
HGO & HGO CR drawn from chimney tray below
structured packing bed of 1326 mm (above tray no.
22), and pumped to heat exchangers E
 Typical Main Fractionator
HGO product from Ex goes to AC under flow control
FIC HGO CR ex -E goes back to the main column
under flow control by FIC. hand control valve HCV-
provided in bypass of Ex to adjust exit temperature of -
E.
HGO CR returns to column above HGO packing bed.
column bottoms (RCO) pumped directly to furnace F-
under column bottom level control LIC cascaded with
furnace pass flow controls FIC
RCO heated to around 406 C and flashed into Vacuum
Column
 PRE-FLASH DRUM

TO STABILISER

PREHEATED CRUDE

CRUDE COLUMN
 PRE-FLASH DRUM

Higher crude preheat temperature

Used if high light ends. Temperature ~ 1800c

5% to 6% vaporisation

Used in revamps for capacity enhancements

Reboiler/steam stripped

costlier than single column

 Parameters
Pre-heat train
Heater outlet temperature
Flash zone temperature
Overflash
Column/flash zone pressure
Type of condenser (partial/total)
Location and number of pump arounds
Stripping steam
No. of trays
Flash zone temperature enough to vaporise
products plus overflash
 PRE-HEAT TRAIN
Optimised for operating/capital cost

Crude/vacuum units integrated, suitable for

light/heavy crude, suitable for summer/winter operation

Overhead condenser (low level heat recovery) piping

for adjusting desalter temperature minimum
vaporisation at heater inlet typical temperature at
heater inlet (2500c to 3000c)
 CRUDE HEATER
MASS VELOCITY : 190 TO 350 LBS / SEC/FT2

AVERAGE RADIANT HEAT : 32500 kcal/hr. m@

FLUX
TYPE : VERTICAL CYLINDRICAL / BOX
TYPE
TUBE MATERIAL : 5 CHROME, 0.5 MOLY

AIR PREHEATER : CAST / PLATE

EFFICIENCY : 85% TO 90%

ACID DEW POINT : FLUE GAS TEMP. 250C ABOVE

ACID POINT
 Atmospheric Distillation
Column
Typical 40 to 50 actual trays
No. of trays from bottom
4 to 6 bottom stripping
4 to 6 flash zone/heavy gas oil
4 to 6 heavy gas oil/light gas oil
4 to 6 light gasoil/kerosene
4 to 8 kerosene/heavy naphtha
4 to 8 heavy naphtha/light naphtha
2 to 3 pump arounds each
Top temperature: 80 to 100 above water dew point (1200 to
1300C typical)
Flash zone below cracking temperature: 3850C typical
 Crude Distillation
Pump around
Typically at product draw tray
return 2 to 3 trays above
60 to 800c temperature drop
Stripping steam
Bottom: 18 to 24 kg /std m3 of RCO
Side strippers: 12 to 18 kg /std m3 of
stripped product

 t-130 C
p-40psig

t-118C,
70psig,

260 C, 45psig

170 psig 379 C


 Crude oil heated in series of heat exchangers & oil picks
heat from circulating hot oil streams from fractionating
column and vacuum column

Column fractionates heated crude in presence of

stripping steam

Produce series of products differing in boiling range

Number of products from column depending on crude

processed and products desired by refinery
 Crude column atmospheric gas oil, diesel oil,
kerosene and naphtha as side cut

Gasoline as overhead and reduced crude as

bottoms product

Reduced crude to vacuum column &

separated light VGO, HVGO as side cut
products & asphalt as bottoms
 Pressure on crude heat exchanger train and
on desalter

Equipment cost lower as crude pressure

lower

Conventional desalter designed to hold 150

psig. the present invention allow desalter as
90 psig

Reduces crude side P across heat

exchangers reducing power required for
crude feed pump
 In conventional crude unit, exchangers in
series , P high

Parallel exchanger trains utilized for

pressure drop is lower

Hot crude oil passed in desalter to remove

salt & water soluble contaminants hot crude

 Desalted hot crude heated by heat in series /

parallel heat exchangers heated by circulating
diesel stream, atmospheric gas oil product
stream, and the circulating atmospheric gas oil
stream of crude column

Hot crude oil sequentially heated in exchange

with circulating heavy gas oil and asphalt
product of vacuum column.
 Finally, hot crude oil passed in crude column heater
where picks up final amount of required heat by
means of convection and radiation produced
through the combustion of gas or oil in the heater

Heat exchange conducted in series, large pressure

drop experienced and typical for discharge pressure
of crude oil pump be from 125 to 200 psig. or even
higher

High crude oil pressure is a detriment to the crude

oil fractionation process
 Innovation
Pressure on the crude oil side of the heat exchangers
maintained < hot oil side of exchangers ?

Any leaking heat exchanger leak refined hot oil stream

in unrefined crude oil

No contamination of refined hot oil stream allowing

crude unit continue regardless of leaking exchanger

Shutdown of plant to repair / replace leaking

exchanger bundle scheduled at more suitable time
 Process to provide economical heat exchanger design,
allowing crude side be established by heat transfer
and distribution considerations

In prior processes crude pressure higher than hot oil

pressure, design send crude through exchanger tubes
where strength greater

Cold crude put on shell side for best heat exchange

Process of present invention allows this since crude

side pressure lower than hot oil side in inventive
process.



 Distillation, absorption & extraction - mass transfer
operations wide use in oil refining, chemical &
petrochemical industries

Equipment for mass transfer to take place column or

tower

In column, liquids and vapours contact each other.

Cmponents from one phase transferred to other

Interphase diffusion of components increased with

contacting surface area increase
 Columns classified under broad headings--packed
and plate-type

Packed columns use meshes or rings, plate columns

utilise plates or trays, spaced apart by distance,
serve as phase contacting area

Trays carry phase contacting devices of 3 main

types, with many variants of each

Bubble caps and sieves traditionally used as

vapor/liquid contactors.

Bubble caps have limited efficiency and expensive


 Bubble cap have riser acting as liquid seal
through which vapor rises. Vapor proceed
through reverse path, dispersed in liquid via
slots in cap

Alternative to bubble caps and sieves - valve

tray. Consist of orifice in tray with moveable
cap valve fitted directly above, providing
variable open area.


 Sieve tray, liquid maintained on surface by
kinetic energy of vapor

Sieves used due to simple manufacture and

maintenance

Less efficient than bubble caps

Valve trays alternative to bubble caps and

sieves tray
 Valves consist orifice in tray with moveable
cap valve above it, providing variable open
area.

Valves having advantages of both

Flexibility of trays in efficient operation in

wide range Valve trays P between sieves
and bubble caps

In VDU P be low. High capacity as large

vapor volumes. Valves widely used.
 Construction of tray
Each valve contains two part assembly having
angled riser and angled orifice cap

Riser acts as valve guide

Depending on pressure drop restrictions, various

heights of orifice cover and riser can be used

Valve incorporates dimples, that eliminate

cap/tray deck contact completely minimizing
sticking.
 Three legs welded to underside of each orifice cover
positioned in riser and legs bent to 90 degree at ends so
as cap retained in riser.

Vapour rises from below tray passing up angled riser.

Minimum head of liquid equal riser height maintained

on tray. Vapor meets liquid where inter phase
contacting, diffusion take

At high vapor loads orifice cover start lifting and

increasing contact area between vapor and liquid.
 At low vapor flows liquid prevented from dumping
down through valve because riser may serve to
reduce weeping to large extent during normal
operation

Valve being symmetrical, vapor eject in liquid from

all sides of each valve efficiently breaking up liquid
ensuring good distribution & mixing of vapor in
liquid

Valve according to present method redirect vapor

through angle > 90 degree, unlike conventional
valves
Improved efficiency of liquid mixing on tray lead to
higher tray efficiency
 Valve tray superior to sieve due to reduction in
weeping and dumping, particularly at low vapor

Excessive weeping lead cause for loss of

fractionation efficiency

In sieves, liquid prevented from weeping through

holes by velocity of vapor above certain
minimum

Weeping occur if vapor rate not achieved

 Valves operate over wide range preventing
weeping through holes at low vapor velocities

Liquid on tray weep through valve fully

opened Weeping occur when valve shut due to
imperfection of fit / dimples on cap preventing
sticking to tray

Moveable valve cap positioned above riser on

each aperture
 Valve cap comprising
(a) upper section adapted to seat over
aperture when cap in closed position

(b) outwardly and downwardly elongated

sloping sides to cover sloping sides of riser
when valve in closed position
 Active area on the tray
panel for mass transfer.
downcomer and carried
Here liquid vapor phase
upward to upper tray
contact to form froth
through free area
Downcomer for
transporting liquid from
tray to tray. Receive
mixture at top from active
aarea
Source K J Pai, L &T rea to send clarified liquid
from bottom to lower tray
Vapor disengages in the
downcomer to be carried
upward to upper tray through
free area
Free area is for vapor liquid
disengagement

Source K J Pai, L &T

Source K J Pai, L &T
Source K J Pai, L &T
Source K J Pai, L &T
 Reversal area

Annular area
CCap
Slots
Riser
area
Riser
Source K J Pai, L &T
Source K J Pai, L &T
Source K J Pai, L &T
 Flow Regimes On Trays
Bubble Regime : Gas bubbles in liquid

Spray Regime : Liquid droplets in vapor

Froth Regime : Vigorous bubbles in two-phase

mobile froth

Emulsion Regime : Vapor emulsified as small bubbles

in high liquid flow
 Froth Regime
Chain of bubbles move around mobile froth
covered by droplets

For rise in vapor rate, vapor jets form at

perforations and there is mixed bubbling and
jetting action

At higher vapor rate froth slowly converts to a

spray regime Due to wide operating range it is
commonest regime and of industrial importance
 Emulsion Regime
At high liquid rates compared to vapor rates,
horizontal momentum of liquid shears vapor
bubbles converting them to small sized bubbles
emulsified in liquid continuous phase

Regime behaves liquid-like

In industrial practice, emulsion regime seen in

columns operating under high pressure and high
liquid rates
 Spray Regime
Seen in columns operating in vacuum

If liquid loads high, one sees froth regime under

these conditions

In distillations over 15 bar emulsion regime likely to

occur

Most low and medium pressure columns operate in

froth Regime as it cover wide L/V range
 Depending on rise in either vapor or liquid rate
froth regime converted to Spray or Emulsion
regime respectively

Emulsion Regime has negligible entrainment but

prone to foaming

Trays operate better at higher pressure in Froth

compared to Emulsion regime

Entrainment expectedly severe in Spray Regime

Vacuum columns designed with generous tray
spacing and usually >= 600 mm
 Flooding
Excessive accumulation of
liquid in column leads to
flooding which may be by

1 Spray entrainment

2 Blow flooding

3 Downcomer choke flooding

4 Downcomer backup flooding

 Jet Flooding
Jet Flooding highly excess entrainment of liquid
droplets to tray above Spray / froth occupy all space
between trays

Downcomer operates, load increased by recirculating

entrained liquid flooding it

Column performance deteriorate before jet flooding

occurs as efficiency lost by liquid entrainment
especially in vacuum distillation

Jet Flooding common at low liquid load in low

pressure columns around 5 atm& vacuum columns
 Blow Flooding
Form of entrainment flood Little liquid on tray floor
appearing to be dry

With low liquid level no downcomer seal so vapor

travels up downcomer

Vapor velocity in downcomer based on downcomer

area exceeds limit, liquid not to travel down column

Stable operation not achieved As with jet flooding,

column performance deteriorates before blow
flooding occurs
 Downcomer Choke Flooding
Froth, aerated liquid enters
downcomer & establish zone for
vapor disengagement

Vapor returns to tray space above

and clear liquid flows to tray
below

When downward velocity of froth

in downcomer , at top, so high that
little / no vapor disengagement
occurs

Low liquid volume fraction fill

throughout downcomer causing
backup flood
Downcomer Backup Flooding
Vapor liquid disengagement
take place in downcomer
Various components of
downcomer backup exceed
available height in downcomer
and froth backs up on tray above
Downcomer Backup Flooding
occur when height of dispersion in
downcomer > downcomer height
Liquid height defined by condition
that hydrostatic liquid head be
sufficient to make liquid flow
down against tray pressure drop
 Distillation Column Flooding
Predictor
Advanced process control tools preventing flooding of
distillation column

Controls used in conjunction with licensed

multivariable predictive-control technologies or
developed in-house

Conventional control strategies predict columns

approach to flood on monitoring column P

Damage & production loss due to inaccuracies based

on raw data
 Distillation Column Flooding
Predictor
Distillation column flooding predictor, pattern
recognition identifying transient tower instability
pattern, preceding tray flooding

Process signal data obtained from existing column

instrumentation

Once pattern identified, modeled in plant distributed

control system
Control system programmed to briefly unload tower
each time pattern appears by momentarily reducing
temperature input to tower.
 Distillation Column Flooding
Predictor
Increase in column
throughput 2 - 5 %, greater
safety margin
Increase in efficiency of
refinery process increasing
production by allowing
column to run closer to flood
limit
Reduces flooding in columns
Reduces equipment damage
by column flooding
conditions
Source- George E. Dzyacky, www.2ndpoint.com
Lowers maintenance cost
 Flooding Prevention
Increase column throughput 2 to 5 percent with
greater margin of safety

Increased efficiency of refinery process,

increased production allowing column to run
closer to flood limit

Damage resulting from column flooding

conditions avoided
VACUUM DISTILLATION UNIT
NON-CONDENS.
TO VACUUM
SYSTEM

LVGO

SLOP MAX HVGO

WASH OIL
TOPPED
CRUDE

PROCESS VACUUM RESIDUE

STEAM STEAM
 Why a vacuum unit?
To vaporize and fractionate at temperature
below cracking by reducing pressure

How vacuum achieved?

steam ejector
vacuum pump

To separate reduced crude oil (RCO) in fractions

according to boiling point
 Fractions to other units for further processing
Distillates : FCC , Hydrocracker unit

Vacuum Residue : Lube processing (PDA

extraction

Dewaxing, hydroprocessing etc.) , Bitumen

Blowing Unit, Visbreaker, Delayed Coker
 FUEL BASED
Prepares feedstock to FCC, Hydrocracker
Products
Diesel
Light vacuum gas oil (LVGO)
Heavy vacuum gas oil (HVGO)
Slop distillate
Vacuum residue
LUBE BASED
Prepares feedstock to lube plant
Products
Spindle oil -- Light neutral -- Intermediate
neutral -- Heavy neutral --Vacuum residue
WET VACUUM FEATURES
Set by vapour pressure of water say at 400c
Used for lube stocks where flash points of products
to be met
Based on hydrocracker preference
Reduces heater O/ L temperature requirement due
to partial pressure of steam
Lesser ejector steam
Marginally better yield of distillates &
controllability due to steam
Dry vacuum features
Higher heater outlet temperature
More ejector steam
 Damp Vacuum TO EJECTOR

NO PRE CONDENSER

25 MM HG

LVGO

STEAM

VACUUM
HEATER HVGO
RCO

SLOP DISTILLATE
40 MMHG
6

1 TRAYS

STEAM
 47

Source N. P. Lieberman et al, Encyclopedia of Chemical processing and Design, Ed. J. J, Mcketta
 Vacuum Distillation
DRY DAMP WET
Top pressure mmHg a 8 25 75
Flash zone pressure mmHg a 24 42 95
Heater outlet temp.0C 395 405 420
Column dia Highest Int Least
Steam Nil Int Highest
Economics normally in favor of damp vacuum
 Pressure profile based on selection of vacuum
(dry / wet / damp)
Ejector suction pressure fixed
Line loss: 1-2 mm Hg
Precondenser loss: 3-5 mm Hg
Arrive column top pressure
Add 3-5 mm Hg per packed bed(1 mmHg/m of
packing)
Add 1-1.5 mm Hg per chimney tray & demister
Add 1.0 mm Hg /1.5m for grid
Add 2 - 3 mm Hg / tray for valve tray
 NO. OF THEORITICAL
TRAYS
Use two for each heat transfer zones (pump
arounds)
Between diesel & LVGO- Two
Between HVGO & slops (wash zone) - Two
max. three (more than 3, can lead to coking)

Stripping steam
Injected in heater
Injected in column bottom ( max. 36 kg/hr. /
std m3 of VR)
 Leakage
AIR Leakage
Lb/hr = 6 * sqrt (bbls/day) / 1000
Cracked gases
lb/hr = c * (bbls / hr)
c = 1.2 for 8000 F flash zone &
decrease 50% for each 250 F drop

Dissolved gases
lb/hr = 11.5 * (bbls /day)
 Typically packed with random structured packing
(new design)
Sections Purpose
# 1 Diesel Fractionation

# 2 LVGO Heat transfer

# 3 HVGO Heat transfer for fuel refinery
# 4 wash zoneFractionation
Typical pump arounds drop 600c to 800c at draw
tray at HVGO / LVGO / diesel draw off
 For heat transfer beds, use spray
distributors
At turndown spray headers, distribution is
poor, needs at least 0.5 kg/cm2 p at
turndown; at design flow p = 2.0 kg/cm2
For mass transfer, preferably use gravity
trough type distributors
wash zone chimney tray should be welded
(leak tight) as liquid load is very low
Wash rate at top of wash zone min. 0.3 -
0.5 gpm/ft2 and at bottom 0.1 - 0.2 gpm/ft2
Entrainment in wash zone is high (30% &
higher)
 Packing
Maximize surface area for contact per unit volume
Random packing efficiency > with dropping size
Structured packing efficiency > as it is denser
Uniform spreading to efficiently vapour-liquid
contact
Pall ring better than Raschig ring
Punched structure more spreading of cylinders
surface area

Pall ring
Raschig
 Packing
Minimizing vapor and liquid mal-
distribution of in bed
Later generation of packing provide
better fluid flow through them
Efficient & maximum drainage of
stagnating pockets which waste packing
surface giving rise to greater localized
residence and limit polymerization
Maximizing packing surface wetting
Maximizing void space per unit volume
Greater void space > capacity
 Packing
Minimizing frictional losses means improving
fluid flow resulting in higher capacities
Easy vapor-liquid disengagement desired
Higher Mechanical Strength
Minimum Cost
Higher Fouling Resistance
Low Liquid Hold-up
Random or Dumped Packing
Specific geometric shape dumped in column
shell
Large variety of them extensively used over
wide range of operating conditions
Compare well in mass transfer stages
More suited for high pressure & high liquid
load conditions
 Structured packing
Crimped layer of wire mesh or corrugated sheets
stacked in column
Early seventies and extremely useful in high
vacuum services with very low pressure drop
requirement .
In such service no equal in either trays or random
packings
Grids
Systematically arranged packings
Use open lattice structure
Extremely robust, suited for harsh conditions
existing in wash sections of refinery fractionators
 Raschig ring
Berl saddle

2nd generation random 3rd generation random

Grid Packing

EF 25A Glitsch
Mellagrid Sulzer
Snap Grid Nutter
Flexigrid Koch
 Structured packing
Sheet metal ~ 0.1 - 0.2 mm thick parallel to one
another having enhanced surface grooved and
perforated .
Each unit an element and ~ 200 to 300 mm high .
Each layer as installed in a column to promote
uniform distribution .
Surface finishing in manufacturing to enhance
liquid wetting characteristics .
High capacity, high efficiency, reduced entrainment
from top layer, low pressure drop compared to trays
in particular, relatively unaffected by foaminess of
the system
 HETP- Height of packing equivalent to Theoretical
Plate or Equilibrium stage . Reciprocal of #
theoretical stages per meter NTSM
HTUov - Overall height of transfer unit for vapor
phase
Turndown Ratio- Maximum design load divided by
minimum design load
Vapor Load - V Load product of volumetric vapor
rate and square root of ratio of vapor density to
difference of liquid and vapor densities
Capacity Factor Cs defined as V Load divided by
tower cross-sectional areaL
 Critical criteria for liquid distribution :
1. Pour Point Density or Distribution Density
(number/m2)
2. Uniform flow of liquid from various pour points
points
3. Geometric uniformity of distribution points
across tower cross-section with particular
attention to irrigation near the column wall
4. Open area for vapor flow
For HETP in 250 to 750 mm, pour point density of
100 points per square meter adequate
 Turndown : Liquid distributor often bottleneck
in operation at high turndown ratio Normal
turndown ratio ~ 2.5 : 1
Liquid Redistribution : Separation efficiency
deteriorates with increase in packed bed depth
Redistribute liquid after maximum of 20
theoretical stages or about 8-10 meter
Redistributors required to introduce feed or take
a side-draw . Installed carefully on top of bed
Vapor Distribution not as critical as liquid Vapor
distributor required if vapor velocity very high
Mixed phase feeds require very careful design
 Liquid Collector for partial liquid draw, feeding liquid
redistributors or in transition from packed bed to trays in
a column .
Provide good mixing redistribution .
For drawoff it can use an integral sump .
Packing Support should not induce vapor
maldistribution, should have high open area not to
restrict tower performance .
Hold Down Grid confines packing and prevents packed
bed movement .
Solids and fouling troublesome Though cleaning liquid
distributor feasible , packing is difficult . Special trays
handle solids and fouling much better
than Packing .External strainers are recommended for
external feeds
 Capacity or Flood Point of a random packing
defined as point beyond which column operation
cannot be controlled and column inoperable
The point at which the mass transfer start to
decrease considered as packing useful capacity .
Mass Transfer Efficiency or HETP of random
packing relatively insensitive to loading and
constant for different systems under various
pressures . Very sensitive to liquid distributor
Liquid Holdup the liquid held on the surface of
packing and in voids expressed as volume percent .
Rises with liquid rate and unaffected by vapor rate
upto flood point
 Channeling :Tendency of vapor, liquid to flow
preferred paths in packed bed ;
Affected by initial distribution of vapor and liquid,
packing size, type .
Given sufficient packed depth a bed tends toward a
natural number of channels a function of packing
type and size
When pressure drop to be minimised as in vacuum
applications structured packing has no comparison
. Trays have highest pressure drop unsuited for
vacuum service .
Foaming best handled by packings rather than tray
Solids easily foul packing whereas trays relatively
unaffected and chosen
 High liquid rates reduce structured packing performance
whereas multi-pass trays easily handle high liquid loads
Feed point and product draw options incorporated easily and
at multiple locations in a tray column. Such flexibility limited
in packed bed columns
Vortex Breakers as grating or flat plates that introduce shear
and prevent entrainment of vapor as liquid converges
towards an outlet nozzle Draw off rate limitations, pump
cavitation, tower instability avoided
Non-circular geometry of most intermediate liquid drawoffs
tend to make them less prone to vortex formation . Vortex
breakers therefore not mandatory for side outlets, designers
tend to specify them as added safeguards
Liquid Collector used for partial liquid draw , total liquid
draw , feeding liquid re-distributor, in transition from packed
bed to trays in a column It should be provide good mixing
redistribution . For drawoff it can use an integral sump
 Feed Inlet Device

With trays little concern for distribution of incoming feed

For structured packing P only a couple of mmHg /m, any
incoming mal-distribution persists up to a few meters of bed .
Uneconomical to have large feed nozzles, distribution
arrangement is required for efficient column operation .
Tangential Vapor Horn very effective having complicated nozzle-
welding contour
Shell Schoepentoeter type shown above is increasingly being
used due to simplicity and effectiveness
THANKS