Petroleum Refinery Processes II

(RP 374)

By Cornelius

June 2024
OBJECTIVES

This course aims to help students to acquire knowledge in how to improve or add
more value to the refining of petroleum products beyond the conventional process.
The following objectives are set out, that the student will among other things:

• Understand Thermal Conversion Processes: Viscosity breaking (Visbreaking),

delayed coking, fluid coking, flexi-coking, etc.
• Understand Catalytic Conversion Processes: Fluid Catalytic Cracking (FCC), RFCC,
Deep Catalytic Cracking (DCC), Thermal Catalytic Cracking (TCC). Hydrocracking,
hydrotreating processes, etc.
• Understand catalytic reforming, isomerisation, hydrodealkylation, gas purification,
hydrogen production, sulphur conversion processes, amine treating, sour water
treatment, etc.
• Understand Evaluation of crude for Production of lubes and waxes. Product
blending and finished products.
COURSE ASSESSMENTS

Assessment of students
The student’s assessment will be in three forms:

Continuous
Assessment [40%]
• Laboratory practical
• Attendants
End of semester
(COMPULSORY) examination [60%]
• Quizzes, Test, Group
and project works,
assignments
COURSE ASSESSMENTS

Assessment of Lecturer
At the end of the course each student will be required to evaluate the course and
the lecturer’s performance by answering a questionnaire specifically prepared to
obtain the views and opinions of the student about the course and lecturer. Please
be sincere and frank.
REFERENCES

▪Gary, J. H. and Handwerk, G. E. (2007), Petroleum Refining Technology and

Economics, CRC Press, Florida, United States, 5th Edition, 488 pp.

▪Mark, J. K., Arno de K., James, H. G. and Glenn, E. H. (2019), Petroleum Refining
Technology, Economics and Market, CRC Press, Florida, United States, 6th
Edition, 722 pp

▪Meyers, R. A. (2016), Handbook of Petroleum Refining Processes, McGraw-

Hill Education, New York, United States, 4th Edition, 832 pp.

▪Mohammed, A. F., Al-Sahhaf, T. A. and Amal, E. (2009), Fundamentals of

Petroleum Refining, Elsevier Science, United States, 1st Edition, 516 pp.
CRUDE DISTILLATION (RECAP)
Petroleum Refinery Processes II
(RP 381)
June 2024

By Cornelius
CRUDE DISTILLATION (RECAP)

The crude distillation unit produces raw products which have to be processed in
downstream unit to produce products of certain specifications.

This involves the removal of undesirable components like sulphur, nitrogen and metal
compounds, and limiting the aromatic contents.
CRUDE DISTILLATION (RECAP)
Typical products from the unit are:

• Gases

• Light straight run naphtha (also called light gasoline or light naphtha)

• Heavy gasoline (also called military jet fuel)

• Kerosene (also called light distillate or jet fuel)

• Middle distillates (called diesel or light gas oil (LGO))

• Heavy distillates (called atmospheric gas oil (AGO) or heavy gas oil (HGO))

• Crude column bottoms (called atmospheric residue or topped crude).

CRUDE DISTILLATION
Process Description

• Crude oil is pumped from storage tanks where it is

freed from sediments and free water by gravity.

• It goes through a series of heat exchangers where it is

heated with hot products coming out from the
distillation column and by the exchange with heat from
the pumparound liquid streams.
Figure 1 Process flow diagram of an
atmospheric distillation unit
• The temperature of the crude feed can reach 120 to
150℃.
 CRUDE DISTILLATION
Process Description

• The crude oil contains salt in the form of dissolved

salt in the tiny droplet of water which forms a
water-in oil emulsion.

• This water cannot be separated by gravity or

through mechanical means.

• It is separated through electrostatic water Figure 1 Process flow diagram of an

separation. This process is called desalting. atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• The crude is further heated in product heat

exchangers.

• The preheating of the crude using the hot

products cools down the products to the desired
temperature for pumping to the storage tanks.

• This is essential for the economics of the unit in Figure 1 Process flow diagram of an
terms of energy conservation and utilization. atmospheric distillation unit
CRUDE DISTILLATION
Process Description

• Preheating is not enough, as the crude has to be

partially vaporized to the extent that all
products, except for the atmospheric residue
have to be in the vapour phase when the crude
enters the atmospheric distillation column.

• Thus a furnace is required to boost the

temperature to between 330 and 385℃
depending on the crude composition. Figure 1 Process flow diagram of an
atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• The partially vaporized crude is transferred to the

flash zone of the column located at a point lower
down the column and above what is called the
stripping section.

• The main column is typically 50m high and is

equipped with about 30–50 valve trays.

Figure 1 Process flow diagram of an

atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• The vapour goes up in tremendous amounts and

at a high flow rate, necessitating a large diameter
column above the flash zone.

• At the bottom of the stripping section, steam is

injected into the column to strip the atmospheric
residue of any light hydrocarbon and to lower the
partial pressure of the hydrocarbon vapours in the
flash zone. Figure 1 Process flow diagram of an
atmospheric distillation unit
CRUDE DISTILLATION
Process Description

• 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.

• As the hot vapours from the flash zone rise

through the trays up the column, they are
contacted by the colder reflux down the column. Figure 1 Process flow diagram of an
atmospheric distillation unit
CRUDE DISTILLATION
Process Description

• In the overhead condenser, the vapours are

condensed and part of the light naphtha is
returned to the column as reflux.

• Further reflux is provided by several

pumparound streams along the column.

Figure 1 Process flow diagram of an

atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• In the distillation tower, heat required for

separation is provided by the enthalpy of the feed.

• For effective separation heat has to be removed

from the tower, in this case, by the overhead
condenser and several pumparound streams along
the tower length.
Figure 1 Process flow diagram of an
atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• The pumparound stream is a liquid 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.
• This pumparound cooling accomplishes a number
of tasks.
Figure 1 Process flow diagram of an
atmospheric distillation unit
 CRUDE DISTILLATION
Process Description
• First, the cold liquid condenses more of the rising
vapours thus providing more reflux to compensate
for the withdrawal of products from the column.
• Second, heat is removed from the column at
higher temperatures.
• 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. Figure 1 Process flow diagram of an
atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• Third, pumparound streams reduce the vapour

flow rate throughout the column.

• The drawback to using more pumparound streams

is that they tend to reduce the fractionation
because a more fractionated liquid is mixed after
cooling with a less fractionated liquid a few trays
above. Figure 1 Process flow diagram of an
atmospheric distillation unit
 CRUDE DISTILLATION
Process Description

• The side draw products are usually stripped to

control their initial boiling point.

• The strippers contain several trays and the

stripping is done using steam at the bottom of the
stripper or reboiler type side stream strippers.

• The end boiling point of the side stream is Figure 1 Process flow diagram of an
controlled by the flow rate of the side stream atmospheric distillation unit
product.
CRUDE DISTILLATION
Process Description
The overhead vapour is condensed at the top of the
tower by heat exchange with the cool crude coming
into the unit and by air and cooling water.
The liquid product is called light straight run
naphtha. Part of this product is returned to the
column as an external reflux.
Down the column, other products are withdrawn,
such as heavy straight run naphtha, kerosene or jet
fuel, LGO and HGO.
Figure 1 Process flow diagram of an
atmospheric distillation unit
CRUDE DISTILLATION
Process Description

• All of these products are withdrawn above the

feed tray.

• The atmospheric residue is withdrawn from the

bottom of the column.

• The main column is equipped with between 30

Figure 1 Process flow diagram of an
and 50 valve trays. atmospheric distillation unit
CRUDE DISTILLATION

Tray distribution in a crude distillation unit

OPERATION OF CRUDE DISTILLATION UNITS
Fractionation
• The degree of fractionation in a crude unit is
determined by the gap or overlap between two
adjacent side stream products.

• Lets consider the gap or overlap in the boiling

point range between kerosene and LGO

• For example.
• In the ideal case there would be no overlap
between these products and the end boiling point
of kerosene would be the initial boiling point of
the LGO.
 OPERATION OF CRUDE DISTILLATION UNITS
Fractionation

• However, comparing the ASTM distillation

boiling points, and since ASTM distillation does
not give perfect fractionation, the ASTM end point
of kerosene is higher than the initial ASTM
boiling point of LGO.

• This is called fractionation overlap.

OPERATION OF CRUDE DISTILLATION UNITS
Fractionation
• The fractionation gap is defined as the difference between the ASTM 5% boiling
point of the product and the 95% point of the lighter product.

• When this difference is positive, we have a gap indicating good fractionation.

• A negative difference is called an overlap indicating that some of the light product is
still in the heavier product and vice versa.

• The degree of fractionation can be affected by controlling the cut point of any two
consecutive products.
FRACTIONATION
Cut Points

• The cut points in the CDU are controlled by the overhead vapour temperature and by the
flow rate of the various products straight from the column or the side stream strippers.
• The atmospheric residue level control inside the column determines its flow rate and thus
its initial cut point.
• 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.
• Changing the drawoff rate of any product affects the cut points of the heavier product
below it.
• The residue flow rate, the internal reflux rate, the drawoff temperatures and the
pumparounds are also affected.
 FRACTIONATION
Cut Points
• 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.

• For example, if the end point of kerosene is lowered by decreasing the kerosene flow rate
by a certain amount, the flow rate of LGO has to be increased by the same amount.

• If this action is taken, only the cut point of kerosene is affected and the cut points of the
other products remain unchanged.
 FRACTIONATION
Cut Points
• The side stream rate also affects the temperature at the withdrawal tray and lowers the
internal reflux coming out of that tray.

• The internal reflux rate affects the degree of fractionation.

• It can be increased by increasing the heater outlet temperature, and by lowering the
pumparound duty in the lower section of the column.

• When less heat is removed by the lower pumparound, more vapours will be available up
the column and more internal reflux is produced as the vapours are condensed.
 FRACTIONATION
Degree of Fractionation
• The fractionation quality between two consecutive streams 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 pumparound.

• Fractionation quality is formulated in terms of gap or overlap of the products.

• For perfect fractionation, zero gap and overlap are required.

• This means that the EBP of the light cut would be the IBP of the heavier cut and so on.
OPERATION OF CRUDE DISTILLATION UNITS
Overflash
• In order to fractionate the crude oil into the various products, it has to be heated to a
temperature between 330 and 385℃, 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 3–5 vol% of the bottom product.
• This overflash has the function of 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.
OPERATION OF CRUDE DISTILLATION UNITS
Overflash
• This necessitates that there must be few trays in the region between the flash zone
and the HGO drawoff.
• The overflash 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.
• 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 crude.
 OPERATION OF CRUDE DISTILLATION UNITS
Column Pressure
• The pressure inside the CDU column is controlled by the back pressure of the overhead
reflux drum at about 0.2–0.34 bar gauge (3–5 psig).

• The top tray pressure is 0.4–0.7 bar gauge (6–10 psig) higher than the reflux drum.

• The flash zone pressure is usually 0.34–0.54 bar (5–8 psi) higher than the top tray.
OPERATION OF CRUDE DISTILLATION UNITS
Overhead Temperature

• The overhead temperature must be controlled to be 14–17 ℃ higher than the dew point
temperature for the water at the column overhead pressure so that no liquid water is
condensed in the column.

• This is to prevent corrosion due to the hydrogen chloride dissolved in liquid water
(hydrochloric acid).
 OPERATION OF CRUDE DISTILLATION UNITS
Pre-flash Columns and Crude Column Capacity

• The crude flow rate to the CDU determines the capacity of the whole refinery.
• A crude column is typically designed for 80% loading, which means that the unit can be
operated at 20% throughput more than the design value.
• 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, 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.
OPERATION OF CRUDE DISTILLATION UNITS
Pre-flash Columns 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 pumparound heat exchangers is
flashed into a column where the lightest products are 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.
OPERATION OF CRUDE DISTILLATION UNITS
Pre-flash Columns and Crude Column Capacity

• 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.
THANK YOU

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