CRUDE DISTILLATION UNIT

INTRODUCTION
2

Crude distillation unit involves complex stream interactions

with various sections of the main column that is supplemented with secondary columns. A simple block diagram is as shown :

Designations (Help file)

3

Box with a green background designates the derived data

Box with a blue background designates the calculated data

Box with a red background designates the final data

Problem 1 :
4

For the Ecudaor crude stream whose TBP, sulfur and API assay are presented below, determine the TBP of the products emanating from the CDU unit using the concept of ASTM gaps.

Cumulative volume % 0 1 1.5 2 3 4 6.5 9 11.5 14 17.5

TBP oF -30 30 60 90 120 150 180 210 240 270 310

oAPI

Sulfur content (wt %)

100 85 80 72 64 60 55 50

0.035 0.035 0.04 0.04 0.045 0.045 0.05 0.055

19 21 22.5 24.5 26 28 30 32 34 36 38.5 39.5 42.5 44.5

330 350 370 390 410 430 450 470 490 520 540 560 580 600

48 46 45 43 42 41 40 38 37 36 34 33 32 31

0.06 0.07 0.08 0.10 0.12 0.16 0.19 0.25 0.3 0.36 0.43 0.48 0.57 0.63

47 49 52 55 57

620 640 660 680 700

30 29.5 29 28 27

0.71 0.77 0.80 0.85 0.87

59
61 62.5 63.8 64.5 66 68

720
740 760 780

26.5
26 25.5 25 24.5 24 23.5

0.89
0.91 0.93 0.96 0.98 1.02 1.06

70

23

1.14

Assume the following cut range of the products on the crude TBP
Naphtha: -30 to 310 oF
Kerosene: 310 to 475 oF LGO: 475 to 585 oF

HGO: 585 to 680 oF

Solution 1
9

Naphtha product ASTM & TBP Data

Firstly, we evaluate the TBP data of Naphtha cut. For

this we use end point correlation and TBP 50 % of the Naphtha cut to obtain ASTM 50 % and ASTM 100 % data. Using these two data points and using end point correlation, the ASTM data of naphtha cut is obtained. Once again using Edmister correlation we obtain the ASTM of the naphtha product. The hierarchy of these steps along with obtained data are presented as follows.

10

TBP data of naphtha cut

Cumulative volume % 0 1 1.5 2 3 4 6.5 9 11.5 14 17.5 Differential volume % 0 5.714 8.571 11.428 17.143 22.857 37.142 51.428 65.714 80 100 TBP oF -30 30 60 90 120 150 180 210 240 270 310

11

TBP 50 % of the Naphtha cut on the crude assay = 208 oF. From Edmister correlation, ASTM 50 % = 215 oF
Naphtha cut end point = 310 oF. From end point correlation, ASTM end point = 310 1 = 309 oF From Probability chart and Edmister correlation, the naphtha product ASTM and TBP are obtained as follows:

12

ASTM data of Naphtha

Cumulative volume % 0 10 30 50 70 90 100 TBP oF 152 178 198 215 230 255 309

13

Product TBP (from Edmister correlation)

Vol % 0 10 30 50 70 90 100 DTASTM (0F) 26 20 17 NR 15 25 54 DTTBP (0F) 49 37 30 NR 24 34 60 TTBP (0F) 92 141 178 208 239 273 333

14

Kerosene product TBP & ASTM data

ASTM gap of naphtha kerosene = 25 oF From ASTM data of Naphtha product, ASTM 95 % of

naphtha = 295 oF Therefore, ASTM 5 % of kerosene = 295 + 25 = 320 oF Kerosene product end point on the crude = 385 oF. For this value from end point correlation, ASTM end point of kerosene cut = 456 oF

15

From Probability chart and Edmister correlation, the kerosene product ASTM and TBP are obtained as follows:

ASTM data of kerosene product

Vol % 0 10 30 50 70 90 100 TASTM (0F) 305 330 350 367 380 405 456

16

Kerosene product TBP

Vol % 0 10 30 50 70 90 100 DTASTM (0F) DTTBP (0F) 25 20 17 13 13 25 51.5 48 38 30 NR 22 34 57 TTBP (0F) 249 297 335 365 387 421 478

17

LGO product TBP & ASTM data

ASTM gap of kerosene LGO = -10 oF

From ASTM data of Kerosene product, ASTM 95 % of

Kerosene = 445 oF Therefore, ASTM 5 % of LGO = 445 10 = 435 oF LGO product end point on the crude = 585 oF. For this value from end point correlation, ASTM end point of LGO product = 585 10 = 575 oF.

18

ASTM data of LGO (from Probability chart)

Vol % 0 10 30 50 70 90 100 TASTM (0F) 458 480 492 505 520 545 575

19

TBP data of LGO product (from Edmister correlation)

Vol % 0 10 30 50 70 90 100 DTASTM (0F) 22 12 13 NR 15 25 30 DTTBP (0F) 44 25 24 NR 24 34 34 TTBP (0F) 407 451 476 500 524 558 592

20

HGO product TBP & ASTM data

ASTM gap between LGO and HGO products = -35 oF From LGO ASTM data, ASTM 95 % of LGO product = 573 oF Therefore, ASTM 5 % of the HGO product = 573 35 = 538 oF. TBP end point of HGO on crude assay = 680 oF. 90% TBP point of HGO on

the crude assay = 670 oF

Using the 90% correlation available in the end point correlation data, 90%

ASTM point = 627 oF.

21

From probability chart, HGO product ASTM data is

Vol % 0 10 30 50 70 90 100 TASTM (0F) 522 552 571 575 600 627 675

22

From Edmister correlation, the HGO product TBP is

Vol % 0 10 30 50 70 90 100 DTASTM (0F) 29 19 4 25 27 48 DTTBP (0F) 55 37 8 38 37 53 TTBP (0F) 466 521 558 566 604 642 695

Problem 2
23

Using the product TBPs estimated in Q1, determine the average product properties (including residue product) such as API, molecular weight, characterization factor. Appropriate pseudo-component selection could be made on the TBP and API assay of the crude.

Solution 2
24

For the crude, the following pseudo-component range along with mid vol, average API for each pseudocomponent are summarized based on the TBP and API assay of the crude oil. Sulfur calculations are ignored in this section, as sulfur balance is not going to affect design calculations associated to the CDU.

25

Psuedocomponent No. 1 2 3 4 5 6 7

TBP range on crude (oF) 60 100 100 140 140 180 180 220 220 250 250 280 280 310

Mid Boiling point on crude oF 75 125 160 195 235 265 295

Mid vol % on crude

Mid oAPI

2.25
3.25 5.25 8.25 11 13.5 16.25

90
81 71 64 58 53 52

8
9 10

310 330
330 350 350 370

320
340 360

18.5
20.5 22.5

52
46 45

26

11 12 13 14 15 16 17 18 19 20 21 22 23 24

370 390 390 410 410 430 430 450 450 480 480 -500 500 520 520 540 540 560 560 610 610 630 630 650 650 670 670 700

380 400 420 440 470 490 510 530 550 595 620 640 660 685

24.5 26.5 28.5 30.5 32.5 34.5 36.5 38.5 40.5 44 47.5 49.5 51.5 54

42 41 40 39 37 37 36 34 33 32 31 30 29 27.5

27

Based on product TBPs evaluated previously, the corresponding volume % of various pseudo-components in product TBPs is obtained graphically. The same is summarized in the next table.

28

Psuedocomponent No.

Naphtha product differential vol %

Kerosene LGO product product differential differential vol% vol %

HGO product differential vol %

1 2 3 4 5 6 7 8 9 10

1.8 7.2 20 28 19 15 3 3 5.5 10 11 13 14.5

29

11 12 13 14 15 16 17 18 19 20 21 22 23 24 Total

18 13 7 4 4

3 5 24 17 17 13 10 10

97*

100

100

5 4.8 8.3 14.4 40.5 12 7.1 3.9 4 100

30

*For the very first component API gravity is not available and hence volume% is not reported.
For these pseudo-components, their molecular weight as a

function of their API and mid boiling point is determined from Maxwells correlations presented in Refinery Property Estimation chapter. The same is presented in the next table.

31

Psuedocomponent No. 1 2 3 4 5 6 7 8 9 10

Mid Boiling point on crude oF 75 125 160 195 235 265 295 320 340 360

Mid oAPI

Molecular weight 70 80 87 94 108 110 115 118 141 144

90 81 71 64 58 53 52 52 46 45

Table contd .
32

11 12 13 14 15 16 17 18 19 20 21 22 23 24

380 400 420 440 470 490 510 530 550 595 620 640 660 685

42 41 40 39 37 37 36 34 33 32 31 30 29 27.5

151 159 165 175 191 197 203 218 230 254 270 283 291 300

33

Since molecular weight needs to be accommodated on a mass

basis and since product TBPs do not match with the crude TBPS due to anamolies associated in the volumetric balance pointed earlier, all molecular weight calculations are carried out using crude data only. With the background information ready for calculations, we next present the calculations involved for the estimation of average properties of the products namely API, characterization factor and molecular weight, as only these are required for the design calculations of the CDU.

Average Naphtha product properties

34

1. API and specific gravity

Psuedocomponen t No. 1 2 3 4 5 6 7 8 Vol % distilled [A] 1.8 7.2 20 28 19 15 3 3 Mid pt API S.G. [B] 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117

90 81 71 64 58 53 52 52

Average specific gravity of the naphtha product =

35

2. Characterization factor (K)

Slope of the Naphtha product TBP = (T70 T10)/60 = (239-141)/60 = 1.63333 The volume average boiling point TVABP = (T0 + 4T50 + T100)/6 = (92 +

4x298+333)/6 = 269.5 oF
From Maxwells correlation, MEABP = 269.5 3.2 = 266.3 oF Naphtha product characterization factor which is a function of the MEABP and

API is obtained from Maxwells correlation as 12.5.

36

3. Molecular weight
Psuedocomp onent No. 1 2 3 4 5 6 7 8 Total Vol % on crude 0.5 1.5 2.5 3.5 2 3 2.5 2 S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117 Weight Factor 0.319413 0.998824 1.746914 2.533248 1.493404 2.300813 1.927793 1.542234 12.86264 Molecular Weight 70 80 87 94 108 110 115 118 Mole Factor 0.004563 0.012485 0.020079 0.026949 0.013828 0.020916 0.016763 0.01307 0.128655

Average molecular weight = 12.86264/0.128655 = 99.97799 = 100 (approximately).

Average Kerosene product properties

37

1. API and specific gravity

Psuedo-component No. 6 7 8 9 10 11 12 13 14 15 Vol % distilled [A] 5.5 10 11 13 14.5 18 13 7 4 4 Mid pt API 53 52 52 46 45 42 41 40 39 37 S.G. [B] 0.766938 0.771117 0.788301 0.797183 0.8017 0.815562 0.82029 0.825073 0.829912 0.839763

Average specific gravity of the kerosene product =

38

2. Characterization factor (K)

Slope of the kerosene product TBP = (T70 T10)/60 = (387-297)/60 = 1.5 The volume average boiling point TVABP = (T0 + 4T50 + T100)/6 = (249+4x365+478)/6 = 364.5 oF From Maxwells correlation, MEABP = 364.5 0 = 364.5 oF Kerosene product characterization factor which is a function of the MEABP and API is obtained from Maxwells correlation as 11.85.

39

3. Molecular weight
Psuedocom ponent No. 6 7 8 9 10 11 12 13 14 15 Vol % on crude 3 2.5 2 2 2 2 2 2 2 2 100 S.G 0.82029 0.825073 0.825073 0.797183 0.8017 0.815562 0.82029 0.825073 0.829912 0.839763 Weight Factor 2.46087 2.062682 1.650146 1.594366 1.603399 1.631124 1.64058 1.650146 1.659824 1.679525 17.63266 Molecular Weight 110 115 118 141 144 151 159 165 175 191 Mole Factor 0.022372 0.017936 0.013984 0.011308 0.011135 0.010802 0.010318 0.010001 0.009485 0.008793 0.126134

Total

Average molecular weight = 17.632/0.126134 = 139.79

Average LGO product properties

40

1. Average specific gravity

Psuedocomponent No. 13 14 15 16 17 18 19 20 Vol % distilled [A]
3 5 24 17 17 13 10 10

Mid pt API
40 39 37 37 36 34 33 32

S.G. [B]
0.825073 0.829912 0.839763 0.839763 0.844776 0.854985 0.860182 0.865443

Average specific gravity = 0.846336.

41

2. Characterization factor
Slope of the LGO product TBP = (T70 T10)/60 = (524 451)/60 = 1.2167 The volume average boiling point TVABP = (T0 + 4T50 + T100)/6 =

(407+4x500+592)/6 = 499.83 oF
From Maxwells correlation, MEABP = 499.83 + 7 = 506.83 oF LGO product characterization factor which is a function of the MEABP and

API is obtained from Maxwells correlation as 11.6.

42

3. Molecular weight
Psuedo component No. 13 14 15 16 17 18 19 20 Vol % on crude 2 2 2 2 2 2 2 5

S.G 1.076046 1.076046 0.825073 0.839763 0.844776 0.854985 0.860182 0.865443

Weight Factor 2.152091 2.152091 1.650146 1.679525 1.689552 1.70997 1.720365 4.327217

Molecular Weight 165 175 191 197 203 218 230 254

Mole Factor 0.013043 0.012298 0.00864 0.008526 0.008323 0.007844 0.00748 0.017036

Average molecular weight = 17.08/0.08319 = 205.328

Average HGO product properties

43

1. Average Specific gravity

Psuedocomponent No. 16 17 18 19 20 21 22 23 24 Vol % distilled [A] 5 4.8 8.3 14.4 40.5 12 7.1 3.9 4 Mid pt API 37 36 34 33 32 31 30 29 27.5 S.G. [B] 0.839763 0.844776 0.854985 0.860182 0.865443 0.870769 0.876161 0.88162 0.88994

Average specific gravity = 0.864055

44

2. Characterization factor
Slope of the HGO product TBP = (T70 T10)/60 = 1.38 The volume average boiling point TVABP = (T0 + 4T50 + T100)/6 = 570.83 oF From Maxwells correlation, MEABP = 574.83 oF HGO product characterization factor which is a function of the MEABP and

API is obtained from Maxwells correlation as 11.55.

45

3. Molecular weight
Psuedo component No. 16 17 18 19 20 21 22 23 24 Vol % on crude 2 2 2 2 5 2 2 2 1 S.G 1.076046 0.611231 1.076046 1.076046 1.076046 0.870769 0.876161 0.88162 0.887147 Weight Factor 2.152091 1.222462 2.152091 2.152091 5.380228 1.741538 1.752322 1.76324 0.887147 Molecular Weight 197 203 218 230 254 270 283 291 300 Mole Factor 0.010924 0.006022 0.009872 0.009357 0.021182 0.00645 0.006192 0.006059 0.002957

Average molecular weight = 20.985/0.084841 = 247.3545

Average residue properties

46

1. The residue specific gravity is determined from mass balance. Crude SG is 0.873996 or 0.874. Vol % [A] 17.5 16 13 7 46.5 S.G [B] 0.703 0.8039 0.8463 0.8641 x [A] X [B] 12.3025 12.8624 11.0019 6.0487 46.5x

From volumetric balance, (46.5x+42.2155)/100 = 0.874. From this expression, specific gravity of the residue x = 0.97171 or 0.972 approx.

47

2. Residue characterization factor

Assume MEABP of the residue as 910 oF. From residue API of 0.972 and Maxwells correlation, residue characterization factor K = 14.1.

48

3. Residue molecular weight

First determine molecular weight of the crude and from mass balance determine the

molecular weight of the residue. This is also due to the reason that residue TBP is not known. The characterization factor of the crude is determined as follows Slope of TBP =-(T70 - T10)/60-=(870-220)/60 = 10.833 VABP = (T20 + T50+ T80)/3 = 686.6667 oF From Maxwells correlation, MEABP of the crude = 686.6 68 = 618.6 oF Crude SG = 0.874 From Maxwells characterization factor correlation, crude characterization factor = 11.7. From Maxwells molecular weight correlation, crude molecular weight = 252.

49

Product
Naphtha Kerosene Light Gas Oil Heavy Gas Oil Residue

Vol % (A) 17.5 16 13 7 46.5

S.G (B)
0.703 0.8039 0.8463 0.86455 0.972

Weight Factor 12.3025 12.8624 11.0019 6.051867 45.198

Molecular Weight 99.978 139.794 205.328 247.35 z

Mole Factor
0.123052 0.09201 0.053582 0.024466 45.198/z

50

In summary, the evaluated properties of the crude and products are as follows:
Molecular weight

Stream

SG

Crude Naphtha Kerosene Light Gas Oil Heavy Gas Oil Residue

0.874 0.703 0.8039 0.8463 0.86455 0.972

11.4 12.5 11.85 11.6 11.55 14.1

252 99.978 139.794 205.328 247.35 843.5

Problem : 3
51

For the Ecudaor crude stream whose average product properties are estimated, conduct the mass balances across the CDU and the overflash zone. Consider a basis of 50,000 barrels/day of crude oil processing in the CDU.

52

Column 1 and 2 are calculated earlier Column 3 Flow (BPSD) is obtained by multiplying basis with vol % i.e ( Basis * vol%/100)
Range (oF) CDU Products IBP 310 310 475 475 585 585 680 680 +

Stream Crude Naphtha Kero LGO HGO Residue

Vol % 100 17.5 16 13 7 46.5

BPSD 50000 8750 8000 6500 3500 23250

53

Column 4 is obtained by :GPH = 1.75*BPSD Column 5 i.e. Specipic gravity is obtained earlier in problem 2.

Stream Crude

Range (oF) IBP 310

Vol % BPSD 100 50000 CDU Products 17.5 8750 8000 6500

GPH 87500

S.G 0.874

Naphtha Kero LGO 310 475 475 585 585 680 680 +

15312.5 14000 11375

0.703 0.804 0.8463

16 13

HGO Residue

7 46.5

3500 23250

6125 40687.5

0.8645 0.9716

54
Column 6 is obtained by : Density = 8.34* Sp. Gravity Column 7 i.e flow rate (lb/hr) is obtained by : lb/hr = density * GPH

Stream Crude

Range (oF) -

Vol % 100

BPSD GPH 50000 87500 CDU Products 8750 8000 6500 3500 23250 15312.5 14000 11375 6125 40687.5

S.G 0.874

Density (lbs/gal) 7.2891

lbs/hr 637798.6

Naphtha Kero

IBP 310 310 475 475 585

17.5 16 13

0.703 0.804 0.8463 0.8645 0.9716

5.8629 6.70426 7.05845 7.21034 8.10345

89776.86 93859.74 80289.88 44163.4 329710.9

LGO 585 680 HGO Residue 680 +

7 46.5

55
Column 8 i.e. wt % is obtained by :

Wt% of naptha = (lb/hr of naptha /lb /hr of crude)*100 Column 9 i.e molecular wt is obtained earlier in problem 2
Stream Crude Range (oF) Vol % 100 BPSD 50000 GPH S.G 87500 0.874 CDU Products 15312.5 14000 11375 6125 40687.5 0.703 0.804 0.8463 0.8645 0.9716 Density (lbs/gal) 7.2891 lbs/hr 637798.6 Wt % 100 Mol. Wt 252

Naphtha Kero LGO HGO Residue

IBP 310 310 475 475 585 585 680

17.5 16 13 7 46.5

8750 8000 6500 3500 23250

5.8629 6.70426 7.05845 7.21034 8.10345

89776.86 93859.74 80289.88 44163.4 329710.9

14.07 14.71 12.58 6.92 51.69

99.97 139.9 205.3 247.35 843.577

680 +

56
Column 10 i.e. Mol/hr = (lb/hr) /(Mol wt )

Stream
Crude Naphtha Kero

Range (oF)
IBP 310 310 475

Vol % BPSD
100 17.5 16 50000 8750 8000 6500 3500 23250

GPH
87500 15312.5 14000 11375 6125 40687.5

S.G

Density (lbs/gal)

lbs/hr
637798.6 89776.86 93859.74 80289.88 44163.4 329710.9

Wt %
100 14.07 14.71 12.58 6.92

Mol. Wt
252 99.97 139.9 205.3 247.35

Mol/hr
2530.947 898.038 670.906 391.0856 178.55 390.85

0.874 7.2891 CDU Products 0.703 0.804 0.8463 0.8645 0.9716 5.8629 6.70426 7.05845 7.21034 8.10345

475 585 LGO 585 680 HGO Residue 680 + 7 46.5 51.69 843.577 13

CDU mass balance

57 From average product properties, the CDU mass balances are summarized in the following table.

Stream
Crude Naphtha Kero

Range (oF)
IBP 310 310 475

Vol % BPSD
100 17.5 16 50000 8750 8000 6500 3500 23250

GPH
87500 15312.5 14000 11375 6125 40687.5

S.G

Density (lbs/gal)

lbs/hr
637798.6 89776.86 93859.74 80289.88 44163.4 329710.9

Wt %
100 14.07 14.71 12.58 6.92

Mol. Wt
252 99.97 139.9 205.3 247.35

Mol/hr
2530.947 898.038 670.906 391.0856 178.55 390.85

0.874 7.2891 CDU Products 0.703 0.804 0.8463 0.8645 0.9716 5.8629 6.70426 7.05845 7.21034 8.10345

475 585 LGO 585 680 HGO Residue 680 + 7 46.5 51.69 843.577 13

58

For the overflash stream,

% Overflash = 3% This means that the cumulative volume% = 53.5 to 56.5 TBP range on the crude: 680 700 oF Mid volume % = 55 Mid boiling point = 695 oF API = 26. SG = 0.898413 Molecular weight = 316

Flash zone mass balance

59

The crude stream fed to the flash zone in a partially vaporized state (3 -5 % of overflashing is usually done). The purpose of the over flashing is to enable the arrangement of the internal reflux for the control of the product quality. The following procedure is adopted for the flash zone mass balance.

Crude
60

Row 1 is the data set for crude which is obtained from CDU mass balance.

Range (oF) Stream Crude

Density Vol % BPSD GPH S.G (lbs/gal) 100 50000 87500 0.874 7.2891

lbs/hr 637798.6

Wt % 100

Mol. Wt Mol/hr 252 2530.947

Overflash
61
Row 2 is the data set for overflash.We assume 3% overflash. For the 3 % overflash

stream, estimate cumulative volume %, barrels/day, molecular weight, specific gravity etc. from crude assay and first principles of refinery property estimation. Vol%,BPSD ,GPH are simply calculated to be 3% of the crude. S.G. is calculated from the curve and then the rest of overflash calculations are done as stated before.
Range Vol (oF) % BPSD 100 50000 680 700 Density S.G (lbs/gal) lbs/hr 0.874 7.2891 637798.6 Flash zone products 0.898413 7.492764 19668.51

Stream Crude

GPH 87500

Wt % 100

Mol. Wt 252

Mol/hr 2530.947

Overflash

1500

2625

3.083812

316

62.24

Products
62
Row 3 is the data set for products which includes naptha ,kero,LGO & HGO. For products Vol%,BPSD,GPH are simply the sum of

data obtained

for naptha

,kero,LGO & HGO. S.G. is calculated by (AB)/A Where A is vol% and B is S.G.(for N,K,L,H) Rest of product calculations are done as stated before.
Range Vol (oF) % 100
680 700 IBP 680 Density S.G (lbs/gal) lbs/hr 0.874 7.2891 637798.6 Flash zone products 0.898413 7.492764 19668.51 308064.6

Stream Crude

BPSD 50000

GPH 87500

Wt % 100

Mol. Wt 252

Mol/hr 2530.947

Overflash Products

3 53.5

1500 26750

2625

3.083812 48.30123

316 143.84

62.24 2141.66

46812.5 0.789067 6.580818

Total vapour
63
Row 4 is the data set for total vapours which includes overflash and products.

For total vapor Vol%,BPSD,GPH are simply the sum of data obtained for overflash and products . S.G. is calculated by (AB)/A Where A is vol% and B is S.G.(for overflash and products) Rest of product calculations are done as stated before.
Stream Crude Range (oF) 680 700 IBP 680 IBP 700 Vol % 100 BPSD 50000 GPH 87500 Density S.G (lbs/gal) lbs/hr 0.874 7.2891 637798.6 Flash zone products 0.898413 7.492764 19668.51 Wt % 100 Mol. Wt 252 Mol/hr 2530.947

Overflash

1500

2625

3.083812

316

62.24

Products Total Vapour

53.5
56.5

26750
28250

46812.5 0.789067 6.580818

49437.5 0.794873 6.62924

308064.6
327733.1

48.30123
51.38504

143.84
148.71

2141.66
2203.90

Residue
64

Row 5 is the data set for residue.We estimate the residue variables such as flow

rates, specific gravity without the overflash variables from total mass balance. These variables refer to the residue liquid stream that is bereft of condensable part (of the overflash). For residue Vol%,BPSD,GPH are simply obtained by subtracting the total data from the total vapor. Then we will first calculate flow rate(lb/hr) by subtracting the total data from the total vapor data Once the flow rate is calculated we can calculate the wt% and density .And finally the S.G. can be evaluated. Similarly once we have the Wt % ,mol wt and Mol/hr can be evaluated.

65

Stream Crude

Range (oF) 680 700 IBP 680 IBP 700 700 +

Vol % 100

BPSD 50000

GPH 87500

Density S.G (lbs/gal) lbs/hr 0.874 7.2891 637798.6 Flash zone products 0.898413 7.492764 19668.51 308064.6 327733.1 310065.5 637798.6

Wt % 100

Mol. Wt 252

Mol/hr 2530.947

Overflash Products Total Vapour Residue Total

3 53.5 56.5 43.5 100

1500 26750 28250 21750 50000

2625

3.083812 48.30123 51.38504 48.61496 100

316 143.84 148.71 948.08 252

62.24 2141.66 2203.90 327.04 2530.947

46812.5 0.789067 6.580818 49437.5 0.794873 38062.5 0.976765 87500 6.62924 8.14622

0.873996 7.289127

Flash zone mass balance

66

Mass balances across the flash zone are presented as follows

Stream Crude

Range (oF) 680 700 IBP 680 IBP 700 700 +

Vol % 100

BPSD 50000

GPH 87500

Density S.G (lbs/gal) lbs/hr 0.874 7.2891 637798.6 Flash zone products 0.898413 7.492764 19668.51 308064.6 327733.1 310065.5 637798.6

Wt % 100

Mol. Wt 252

Mol/hr 2530.947

Overflash Products Total Vapour Residue Total

3 53.5 56.5 43.5 100

1500 26750 28250 21750 50000

2625

3.083812 48.30123 51.38504 48.61496 100

316 143.84 148.71 948.08 252

62.24 2141.66 2203.90 327.04 2530.947

46812.5 0.789067 6.580818 49437.5 0.794873 38062.5 0.976765 87500 6.62924 8.14622

0.873996 7.289127

Flash zone temperature

67

Flash zone temperature estimation is an important task in the design procedure

of the CDU.
This is due to the fact that flash zone temperature will enable heat balance

across the flash zone to yield the residue product temperature.

The Crude EFV (Equilibrium flash vaporizer) curve is the starting point for the

flash zone temperature.

Since live steam is present in the main column (along with hydrocarbon

vapors), the hydrocarbon partial pressure needs to be estimated .

And using the same, the flash zone temperature shall be estimated at the

desired hydrocarbon partial pressure.

68

The procedure is elaborated as follows: Draw the equilibrium flash vaporization curve of the crude oil at 1 atm using

Maxwells correlations summarized in refinery property estimation chapter.

Assume 1.2 lbs of steam used to produce one gallon of residue. With this

assumption, estimate the steam flow rate in lbmol/hr.

Assume flash zone pressure = 40 psia. Estimate the partial pressure (PPHC) of the hydrocarbon using the expression

PPHC= moles HC vapor/(moles HC vapor + moles steam) x flash zone pressure

69

Adjust the EFV curve to the desired partial pressure. In other words, we need to draw a new EFV curve. The new EFV curve FRL will be the same as that exists at 1 atm. Therefore, all we require is a point (as the slope is known) to draw the new

EFV line.
The point is estimated using vapor pressure curve data presented in Table 2.18

(follow solved example 2.9 for further delibeations on calculations).

70

The existing EFV data point is taken at 50 % and 14.7 psia. The new vapor pressure is determined from Table 2.18 at the hydrocarbon

partial pressure for 50 % point.

For the new EFV curve draw the line with known co-ordinates and slope of the

FRL
On the new EFV curve, find the flash zone temperature as that temperature

that corresponds to the overflash cumulative volume %.

An example is presented next to elaborate the above steps.

Vapor pressure of hydrocarbons

71

Problem 4
72

Q. For the Ecuador crude stream, determine the flash zone temperature in the main column.

Solution 4
73

Solution: We first determine the slope of the EFV curve

Slope of TBP = STBP = (TTBP,70 - TTBP,10) / 60 = (890 - 220) / 60 = 11.167

Equation of DRL

y - y(at x=10) = STBP(x - x(at x=10) y - 220 = 11.167(x - 10), y = 11.167x + 108.33
The slope of the FRL, SFRL is found from the Maxwells correlation as

SFRL = 8.1

Maxwells correlation
74

75

From another Maxwells correlation, we obtain the difference between the

DRL and at 50 % volume distilled, and this is, Dt50(DRL - FRL) = 40 0F

TDRL,50 = 666.7 0F
Then, TFRL,50 = 666.7 - 40 = 626.7 0F Equation of FRL :

y - y(at x=50) = SFRL(x - x(at x=50)) y - 627 = 8.1(x - 50) y = 8.1x + 222

Maxwells correlation
76

77

The table for Crude TBP, DRL and FRL Temperature Data is presented as follows :
Vol % 0 10 30 50 70 90 TTBP (0F) -30 220 450 650 890 1250 TDRL (0F) 108 220 443 667 890 1113 TFRL (0F) 222 303 465 627 789 951

100

1430

1225

1032

78

From Maxwells third correlation for the EFV, data is summarized as follows

Calculation of EFV:

At Vol % = 30 ,TDRL = 443 0F & TFRL = 465 oF

tTBP - DRL = TTBP,30 - TDRL,30

= 450 - 443 = 7 0F
tEFV - FRL/tTBP-DRL = 0.34 from which, TEFV,30 = 467 0F

79

The EFV data is summarized as follows :

Vol % 0 TEFV (0F) 185

10
30 50

303
467 629

70
90 100

789
998 1102

80

Calculation of flash zone temperature

Assume 1.2 lbs of steam/gal residue

Steam flow rate (lbs/hr) =( 1.2*40687.5) = 48825 Steam flow rate (lbmol/hr) = 2712.5
Flash zone pressure = 40 psia Partial pressure of hydrocarbon = 17.93 psia

81

EFV 50 % of the crude = 629 oF

From vapor pressure correlation, first locate the first point corresponding to 50

% EFV on 14.7 psia line and then extend this line parallel to the existing graph till 17.93 psia to obtain the new EFV value.
From graph, EFV 50 % at 17.93 psia = 665 oF Slope of the FRL = 8.1 (same as before)

82

EFV at 17.93 psia is defined using the line y = 665 + 8.1 (x-50)

where x refers to the cumulative volume %. For a value of 56.5 % of x (which is the overflash value), y = 717.65 oF which is the flash zone temperature.

Draw off stream temperatures

83

Estimation of draw off stream temperatures :

The following procedure is adopted for the estimation of draw off temperatures which are useful for the energy balance calculations to yield the side stripper products (kerosene, LGO and HGO) temperatures:
Estimate the steam requirements for different products. Use the following assumptions on a mass ratio basis:

Steam to HGO ratio = 0.5; Steam to LGO ratio = 0.5; Steam to kerosene ratio = 0.65.

84

Estimate the FRL of the draw off TBP cut. This is done using the TBP cuts of

the crude.
Establish its IBP at atmospheric pressure. This is regarded as 0% vol

temperature on the FRL. This value is required for using packies correlation to estimate the actual draw off temperature.
Predict overflow from the draw-off tray as a liquid reflux to the tray below

using the following rules of thumb

Molar ratio of overflow liquid to HGO product = 2.9 Molar ratio of overflow liquid to LGO product = 1.2 Molar ratio of overflow liquid to kero product = 0.9 to 1.0

85

Calculate hydrocarbon partial pressure using the expression:

Partial pressure = (Product vapor moles + Moles overflow)/(product vapor moles + moles steam) x tray pressure
Here product vapor corresponds to total products that are vaporized and

leaving the tray.

These include HGO + LGO + Kerosene + naphtha for the HGO draw off tray,

LGO + Kerosene + naphtha for the LGO draw off tray, Kerosene + naphtha for the kerosene draw off tray.

86

Also in the above expression, steam moles corresponds to :

steam entering at tray 1 for HGO draw off tray steam entering at residue and HGO for LGO draw off tray, steam entering at residue, HGO and LGO for kerosene draw off tray.
Estimate the tray pressure from assumed pressure drops. Using vapor pressure curves, determine the IBP of the cut at the evaluated

partial pressure.

87

Use Table 4.1 (Packies correlation data) to determine the differential

temperature.
For this curve, the x-axis data is to be taken with respect to atmospheric

TBP cut point and not the partial pressure based cut point.
Use differential temperature and 0 % point on the FRL (adjusted to the partial

pressure) to estimate the draw off temperature.

Packies correlation
88

Table 4.1: Packies correlation data to estimate the draw off temperature
0% point of cut on atmospheric TBP curve of product oF 197.75 301.27 300.12 500.32 599.31 686.79 743.21 798.48 851.45 897.52 Theoretical side draw temperature Actual side draw temperature 9.29 24.43 24.43 66.37 95.31 122.62 142.95 162.21 183.06 201.23

Problem 5
89

Q . For the Ecudaor CDU design problem, determine the draw off streams temperatures associated to HGO, LGO and Kerosene.

90

Solution:
For all three draw-off stream trays, the tray pressure is evaluated first.
HGO draw off tray = 10 Flash zone pressure = 40 psia HGO draw off tray is located 6 trays above the flash zone. Average pressure drop per tray = 0.32 psia per tray

HGO draw off tray pressure = 40 6 x 0.32 = 39.1 psia. LGO draw off tray pressure = 40 (6 + 10) x 0.32 = 34.88 psia Kerosene draw off tray pressure = 40 (6 + 10 + 12) x 0.32 = 31.04 psia

91

Next, we evaluate the steam requirements in the side stream strippers.

Residue zone fresh steam flow rate (from flash zone calculations) = 2712.5 lbmol/hr HGO zone fresh steam flow rate = 6125 x 0.5/18 = 170.13 lbmol/hr LGO zone fresh steam flow rate = 11375 x 0.5/18 = 5687.5 lbmol/hr Kerosene zone fresh steam flow rate = 14000 x 0.65/18 = 505.55 lbmol/hr

92

From mass balance table summarized previously:

Naphtha vapor flow rate = 898.03 lbmol/hr Kerosene vapor flow rate = 670.9 lbmol/hr LGO vapor flow rate = 391.1 lbmol/hr HGO vapor flow rate = 181.63 lbmol/hr

93

1.

HGO draw off tray temperature calculation

Moles overflow = 2.9 x 181.63 = 526.72 lbmol/hr Hydrocarbon vapor flow rate = 898.03 + 670.9 + 391.1 + 181.63 = 2140 lbmol/hr

Steam flow rate = 2712.5 lbmol/hr (Only that steam that is reaching the HGO

draw off tray is the steam that enters at the bottom of the main column).
Therefore, partial pressure of hydrocarbons at HGO draw off tray

= (2140 + 526.72)/(2140 + 526.72 + 2712.5) x 38.1 = 18.89 psia.

94

Now, the EFV of the Heavy gas oil is determined using Maxwells correlation.

The procedure is not shown here. The obtained IBP from EFV curve is 561 oF.
From vapor pressure curves, estimated theoretical HGO draw off temperature

at a partial pressure of 18.89 psia (instead of 14.7 psia) is 620 oF.

From Packies correlation, for an x-axis data point of 561 oF, the y-axis point

(Table 4.1) is 83 oF.

Therefore, actual HGO draw off temperature = 620 83 = 537 oF.

95

2. LGO draw off tray temperature calculation :

Moles overflow = 1.2 x 391.08 = 469.3 lbmol/hr Hydrocarbon vapor flow rate = 898.03 + 670.9 + 391.1 = 1960.03 lbmol/hr

(All HC vapors other than the HGO and residue products).

Steam flow rate = 2712.5 + 170.13 = 2882.64 lbmol/hr (This is the steam that

enters at the residue zone and also in the HGO side stripper).
Therefore, partial pressure of hydrocarbons at HGO draw off tray = (1960.03 +

469.3)/(1960.03+469.3+ 288.26) x 34.2 = 15.96 psia.

96

Now, the EFV of the LGO is determined using Maxwells correlation. The

procedure is not shown here. The obtained IBP from EFV curve is 485 oF.
From vapor pressure curves, estimated theoretical LGO draw off temperature

at a partial pressure of 15.66 psia (instead of 14.7 psia) is 510 oF.

From Packies correlation, for an x-axis data point of 510 oF, the y-axis point

(Table 4.1) is 60 oF.

Therefore, actual LGO draw off temperature = 510 60 = 450 oF.

97

3. Kerosene draw off tray temperature calculation :

Moles overflow = 0.9 x 670.9 = 603.81 lbmol/hr. Hydrocarbon vapor flow rate = 898.03 + 670.9 = 1568.03 lbmol/hr (All HC

vapors other than the LGO, HGO and residue products).

Steam flow rate = 3198.611 lbmol/hr

98

Therefore, partial pressure of hydrocarbons at HGO draw off tray = (1568 +

603.81)/(1568 + 603.81 + 3198.6) x 30.2 = 12.5 psia.

From EFV, vapor pressure curves and packies correlation, actual kero

draw off-temperature = 320 oF.

Tower top temperature

99

The tower top temperature is very important to determine, as the know-how of

the temperature will lead to further delineating the condenser duty.

The tower top temperature is determined from a dew point calculation. The procedure for the same is similar to that provided in the gasoline blending

problem illustrated in the refinery mass balances chapter.

100

The procedure for the same is outlined below:

Set the reflux drum temperature and pressure as 100 oF and 10 psig. Assume 5

psia pressure drop and hence, tower top pressure = 15 psig or 29.7 psia.
Assume external reflux as 0.8 times the total moles overhead product.

Determine external reflux flow rate

Determine partial pressure of hydrocarbons in the tower top section.
Assume a tower top temperature of 250 oF. This value is required to determine

the equilibrium constants (K) for different pseudo-components.

101

As reflux will have a composition similar to the gas + naphtha fraction whose

pseudo-component distribution is previously known, determine the vapor pressures of each pseudo-component as a function of its mid boiling point and API.
Determine mole fraction of each pseudo-component. Calculate equilibrium constant for each pseudo-component as the ratio between its

vapor pressure (determined from Maxwells vapor pressure correlations) and the partial pressure of the hydrocarbons .
Assume the determined mole fractions to correspond to the vapor stream.

Eventually, determine liquid stream mole fraction using the expression x = y/K where K is the equilibrium constant.

102

Eventually, evaluate summation of all x values For the last pseudo-component, determine its new equilibrium constant using

the expression K2 = K1 (sum of all x values).

From the K2 values, determine the new tower top temperature.
If significant differences exist between the new tower top temperature and

assumed value (250 oF), then iterate the procedure until a converging tower top temperature is determined.

Problem 5
103

Q For the Ecudaor CDU design problem, determine the tower top temperature.

Solution 5
104

Solution :
Tower top pressure = 29.7 psia

Vapor flow rate = (1+0.8) x 898.03 = 1616.46 lbmol/hr

Steam flow rate in the tower top section = 3704.1 lbmol/hr

Partial pressure of hydrocarbons in the tower top section

= 1616.4/(1616.4 + 3704.1) x 29.7 = 9.02 psia.

105

For determining the tower top temperature, we first assume a tower top

temperature of 250 oF. At this temperature, using Maxwells vapor pressure correlation, we determine the corresponding vapor pressures. All evaluations are presented in the proceeding table.

106

Column 1,2,3,4 are obtained from directly from the given curve.
Vol % on crude 1.85567 7.42268 20.61856 28.86598 19.58763 15.46392 3.092784 3.092784

Component 1 2 3 4 5 6 7 8

Mid BP 75 125 160 195 235 265 295 320

S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117

107

Column 5 (wt factor ) is obtained by multiplying column 3 and

column 4
Component 1 2 3 4 5 6 7 8 Total Mid BP 75 125 160 195 235 265 295 320 Vol % on crude 1.85567 7.42268 20.61856 28.86598 19.58763 15.46392 3.092784 3.092784 S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117 Wt Factor 1.185451 4.942632 14.40753 20.89277 14.62612 11.85986 2.384898 2.384898 72.68416

108

Column 6 (mole fraction) is evaluated after we calculate the

molecular wt which is a function of mid B.P. and Specific gravity.

Once molecular wt is known mole fraction can directly be

obtained by dividing wt factor by molecular wt.

Hence the obtained molecular wt starting from component 1 are

70,80,87,94,108,265,295 and 320 resp for the 8th component.

109

Column 6 is then calculated to be :

Component 1 2 3 4 5 6 7 8 Total Mid BP 75 125 160 195 235 265 295 320 Vol % on crude 1.85567 7.42268 20.61856 28.86598 19.58763 15.46392 3.092784 3.092784 S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117 Wt Factor 1.185451 4.942632 14.40753 20.89277 14.62612 11.85986 2.384898 2.384898 72.68416 Mole Fraction(y) 0.01631 0.068001 0.198221 0.287446 0.201228 0.16317 0.032812 0.032812 1

110

Column 7(PS from Maxwell)is a function of mid B.P. and the

assumed temperature(2500C).
Vol % on Component Mid BP crude 1 75 1.85567 2 125 7.42268 3 160 20.61856 4 195 28.86598 5 235 19.58763 6 265 15.46392 7 295 3.092784 8 320 3.092784 Total
S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117 Wt Factor 1.185451 4.942632 14.40753 20.89277 14.62612 11.85986 2.384898 2.384898 72.68416

Mole Fraction(y) 0.01631 0.068001 0.198221 0.287446 0.201228 0.16317 0.032812 0.032812 1

PS from Maxwell 12.4 6 3.8 2.1 1.36 0.7 0.56 0.35

111

Column 8( equilibrium constant K) is evaluated as the ratio between its vapor

pressure (determined from Maxwells vapor pressure correlations) and the partial pressure of the hydrocarbons
Component 1 2 3 4 5 Mid BP 75 125 160 195 235 Vol % on crude 1.85567 7.42268 20.61856 28.86598 19.58763 S.G 0.638826 0.665882 0.698765 0.723785 0.746702 Wt Factor 1.185451 4.942632 14.40753 20.89277 14.62612 Mole Fraction (y) 0.01631 0.068001 0.198221 0.287446 0.201228 PS from Maxwell 12.4 6 3.8 2.1 1.36 K 20.20128 9.774811 6.190714 3.421184 2.215624

6
7 8 Total

265
295 320

15.46392
3.092784 3.092784

0.766938
0.771117 0.771117

11.85986
2.384898 2.384898 72.68416

0.16317
0.032812 0.032812 1

0.7
0.56 0.35

1.140395
0.912316 0.570197

112

Column 9 (liquid stream mole fraction , X = y/K) is obtained to be :

Component 1 2 3 4 5 6 7 8 Total

Mid BP 75 125 160 195 235 265 295 320

Vol % on crude 1.85567 7.42268 20.61856 28.86598 19.58763 15.46392 3.092784 3.092784

S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117

Wt Factor 1.185451 4.942632 14.40753 20.89277 14.62612 11.85986 2.384898 2.384898 72.68416

Mole Fraction (y) 0.01631 0.068001 0.198221 0.287446 0.201228 0.16317 0.032812 0.032812 1

PS from Maxwell 12.4 6 3.8 2.1 1.36 0.7 0.56 0.35

K 20.20128 9.774811 6.190714 3.421184 2.215624 1.140395 0.912316 0.570197

X=y/K 0.000807 0.006957 0.032019 0.084019 0.090822 0.143082 0.035965 0.057545 0.451217

113

The entire table is summarised as :

Component 1 2

Mid BP 75 125

Vol % on crude 1.85567 7.42268

S.G 0.638826 0.665882

Wt Factor 1.185451 4.942632

Mole Fraction (y) 0.01631 0.068001

PS from Maxwell 12.4 6

K 20.20128 9.774811

X=y/K 0.000807 0.006957

3
4 5 6

160
195 235 265

20.61856
28.86598 19.58763 15.46392

0.698765
0.723785 0.746702 0.766938

14.40753
20.89277 14.62612 11.85986

0.198221
0.287446 0.201228 0.16317

3.8
2.1 1.36 0.7

6.190714
3.421184 2.215624 1.140395

0.032019
0.084019 0.090822 0.143082

7
8 Total

295
320

3.092784
3.092784

0.771117
0.771117

2.384898
2.384898 72.68416

0.032812
0.032812 1

0.56
0.35

0.912316
0.570197

0.035965
0.057545 0.451217

114

K2 = X *K8 = 0.451217 x 0.35 = 0.257283. From Maxwells vapor pressure curves, for pseudo-component 8,

this vapor pressure corresponds to 220 + 0.8 x 20 = 236 oF.

We take this as the tower temperature for future calculations.

Residue product stream temperature

115

Estimation of residue product stream temperature

The residue product stream temperature is determined by consider the

envelope shown in figure 1 for the flash zone.

Figure 1: Envelope for the enthalpy balance to yield residue product temperature.

116

For the chosen envelope, the incoming streams are :

residue liquid (at flash zone temperature), strip out liquid (at flash zone temperature) fresh steam (entering tray 1)
The fresh steam is usually taken as superheated steam at 450 oF and 50 psig. The outgoing streams are:

residue liquid at unknown temperature t strip out vapor at flash zone temperature steam at flash zone temperature

117

For stripout vapor + hydrocarbon vapor leaving the flash zone, assume that

their temperature is 5 oF lower than the flash zone temperature.

For steam at flash zone temperature, its enthalpy is determined at its partial

pressure that exists in the flash zone and using steam tables.
Relevant data from steam tables is summarized in the proceeding table :

118
Psia (psi) Saturation Temp. (oF) 350 oF 400 oF 500 oF 600 oF 700 oF 800 oF 900 oF 1000 oF 1100 oF 1200 oF 1300 oF Enthalpy (Btu/lb) at temperature

15 20 30 40 50 60 70 80 90 100

213.03 227.96 250.34 267.25 281.02 292.71 302.93 312.04 320.28 327.82

1216.2 1215.4 1213.6 1211.7 1209.9 1208.0 1206.0 1204 1202 1199.9

1239.9 1239.2 1237.8 1236.4 1234.9 1233.5 1232.0 1230.5 1228.9 1227.4

1287.3 1286.9 1286.0 1285.0 1284.1 1283.2 1282.2 1281.3 1280.3 1279.3

1335.2 1334.9 1334.2 1333.6 1332.9 1332.3 1331.6 1330.9 1330.2 1329.6

1383.8 1383.5 1383.0 1382.5 1382.0 1381.5 1381.0 1380.5 1380 1379.5

1433.2 1432.9 1432.5 1432.1 1431.7 1431.3 1430.9 1430.5 1430.1 1429.7

1483.4 1483.2 1482.8 1482.5 1482.2 1481.8 1481.5 1481.1 1480.8 1480.4

1534.5 1534.3 1534 1533.7 1533.4 1533.2 1532.9 1532.6 1532.3 1532

1586.5 1586.3 1586.1 1585.8 1585.6 1585.3 1585.1 1584.9 1584.6 1584.4

1693.2 1693.1 1692.9 1692.7 1692.5 1692.4 1692.2 1692 1691.8 1691.6

1803.4 1803.3 1803.2 1803.0 1802.9 1802.8 1802.6 1802.5 1802.4 1802

119

For all calculations, the following important information needs to be remembered always:
Hydrocarbon streams liquid or vapor enthalpy is determined from Maxwells

correlation.
The Maxwells correlations need to be interpolated for both average MEABP

of the stream as well as its K value.

Therefore, for any stream, it is mandatory to determine first the MEABP and K

value. To determine K value, we have to know its API.

120

For all product streams, their MEABP is assumed to be known. If not known,

it is approximated to be same as the its VABP.

For stripout streams, their MEABP is determined as an average of the MEABP

values corresponding to the adjacent cuts. Same is the case for the K value as well as API.
For fresh steam, superheated steam data at 450 oF is taken from steam tables.

For steam at any other location in the column, its saturated vapor enthalpy at the prevalent partial pressure of the steam is determined.

Problem 6
121

Q For the Ecudaor stream determine the residue product stream temperature.

Solution 6
122

The enthalpy balance for the envelope shown in figure 1 provides the following

information for the incoming streams to the flash zone.

Stream
Residue Stripout Fresh Steam Total

V/L
L L V

API
14.1 23.1 -

MEABP
910 oF 780

K
11.45 11.75

oF

Lb/hr
329710.8 18309.4 48825 396845.3

Btu/lb
389 401 1262.6

mmBtu/hr
128.25 7.34 61.64 197.2

717.65 717.65 450

123

For the outgoing streams, the consolidated stream enthalpy data is presented as

follows in the flash zone:

Stream Residue Stripout Steam Total V/L L V V (PP = 22.07 psia) API 14.1 23.1 MEABP 910 oF 780 K 11.45 11.75
oF

Lb/hr 329710.8 18309.4 48825 396845.3

Btu/lb x 487 1389.7

mmBtu/hr 0.329710x 8.92 67.85 76.77 + 0.329710x

t 712 712

124

Equating the incoming and outgoing heat balance total, we get the enthalpy of

the residue liquid product as x = 365.4 Btu/lb.

From Maxwells correlation upon interpolation, we get T = 686.5 oF

which is the residue product temperature.

Side stripper products temperature

125

Estimation of side stripper products temperature

Consider the side stripper itself as an envelope for the heat balance. For the

side stripper the incoming streams are:

1. Product draw off stream at draw off temperature that was evaluated using packies correlation. The product draw off stream (liquid) consists of two portions : a. Hydrocarbon vapor equivalent to the final product flow rate b. Strip out stream that enters the side stripper as liquid and leaves the side stripper as vapor. 2.Fresh steam at 450 oF and 50 psig.

126

Similarly, the outgoing streams are:

1.Side stripper product stream at unknown temperature. 2. Stripped hydrocarbon vapor whose temperature is assumed to be 5 oF lower than the draw off temperature.

3. Steam at its partial pressure and vapor temperature.

127

In these enthalpy balances, the stripout vapor/liquid flowrate is estimated to

be 5 % for HGO side stripper unit and 8 % for LGO and Kerosene side stripper units.

Subsequently, API is determined to be the average of the corresponding API values of the adjacent cuts.

Since in the above consolidated enthalpy balance stream only side striper

product stream enthalpy is unknown it can be determined.

From the enthalpy values using Maxwells correlation, one can determine the side stripper products temperature.

The same procedure is applicable for Kerosene, LGO and HGO side strippers.

Problem 7
128

For the Ecudaor CDU, determine the side stripper product

temperatures.

Solution 7
129

We present the enthalpy balance table for the HGO side stripper first. Incoming streams

Stream V/L Feed ex L strip out Stripout L Fresh V Steam Total

API 32.2

MEABP K 575 11.7

oF

537

Lb/hr 44163.4

Btu/lb 290

mmBtu/hr 12.81

33.9

545

11.7

537 450

2205 3062.5
49430.9

292 0.64 1262.6 3.86

17.31

130

Outgoing streams
Stream
HGO Stripout Steam Total

V/L
L V V (PP = 19.21 psia)

API
32.2 33.9

MEAB P 575
545

K
11.7 11.7

oF

Lb/hr
44163.8 2205 3062.5

Btu/lb
x 393 1302.5

t 532

mmBtu/h r 0.44163x
0.8665 3.9889 4.8554 + 0.44163x

Solving for x we get x = 282.09 Btu/lb From Maxwells correlations and interpolation, we get HGO product stream temperature = 526.8 oF

131

Next, we present the LGO stripper enthalpy balance Incoming streams

Stream Feed ex strip out V/L L API 35.7 MEAB P 500 K 11.65
oF

Lb/hr 80289.8

Btu/lb 234

450

mmBtu/h r 18.78

Stripout
Fresh Steam

L
V

40.1

421

11.6

450
450

6215.3
5687.5

241
1262.6

1.497
7.181

Total

27.466

132

Outgoing streams
Stream LGO Stripout Steam Total V/L L V V (PP = 17.43 psia) API 35.7 40.1 MEABP 500 421 K 11.65 11.6
oF

Lb/hr 80289.8 6215.3 5687.5

Btu/lb x 353 1260.6

mmBtu/hr 0.0802x 2.194 7.169 0.0802x + 9.36363

t 445 445

From heat balance, x = 225.5 Btu/lb. From Maxwells correlation and interpolation, LGO product stream temperature = 435.4 oF.

Incoming streams

133

Finally, we present Kerosene stripper heat balance Incoming streams

Stream V/L API MEABP K
oF

Lb/hr

Btu/lb

mmBtu/hr

Feed ex strip out

Stripout Fresh Steam

44.5

364

11.65

320

93859.7

163

15.299

L V

57.1

285

12.1

320 450

7000 9100

178 1262.6

1.246 11.489

Total

28.034

134

Outgoing streams
Stream
LGO Stripout Steam Total

V/L
L V V (PP = 15.01 psia)

API
44.5 57.1

MEABP
364 285

K
11.65 12.1

oF

Lb/hr
93859.7 7000 9100

Btu/lb
x 297 1199.6

mmBtu/hr
0.09386x 2.079 10.91 12.995

t 315 315

From heat balance, x = 160.3 Btu/lb. From Maxwells correlation and interpolation, Kerosene product stream temperature = 315 oF.

Total Tower energy balance and total condenser duty estimation

135

The total tower energy balance is carried out to consolidate the following

streams :
Incoming streams:

1. Crude (Vapor + Liquid): Its flow rate is determined from mass balance for both liquid and vapor streams separately. Eventually, using first principles, total enthalpy (mmBtu/hr) is evaluated. 2.Steam: Fresh steam with its total flow rate is estimated and its total enthalpy (mmBTu/hr) entering the CDU is estimated.

136

Outgoing streams:

1.All products at their respective stream temperatures that were determined previously.
The balance energy of the incoming and outgoing streams is determined as the

energy removed from condenser, bottom and top pump around (Qc + QBPA + QTPA).
An illustrative example is presented next for the Ecuador crude CDU.

Problem 8
137

For the Ecuador crude stream, determine the total condenser and pump around duties with the help of the total tower balance.

138

Crude enthalpy data evaluated from first principles is presented as follows:

Stream Crude Vapour Crude Liquid

V/L V L

API 46.5 13.4

MEABP 360 910

oF

lb/hr 327733.1 310065.5

Btu/lb 526 390

mmBtu/hr 172.3876 120.9255

11.7 717.65 11.4 390

Total

637798.6

293.3132

139

Overall enthalpy balance is summarized in the following table from where the

total condenser and pump around duties can be estimated:

Stream IN Crude Steam Total OUT Residue HGO LGO Kero Naphtha Refluxes Total V/L V+L V K 11.7 T (oF) 717.65 lb/hr 637798.6 66675 704473.6 329710.9 44163.38 80289.88 93859.74 89776.86 Btu/lb mmBtu/hr 293.3132 84.1897 377.5028 120.4773 12.4582 18.1059 15.0467 4.7582 206.6565 377.5028

1263

L L L L L

11.5 11.55 11.6 11.9 12.75

686.6 526.9 435.4 315.1 100

365.4 282.1 225.5 160.3 53

From the above table, QC + QBPA + QTPA = 206.65 mmBtu/hr

Condenser duty
140

Estimation of condenser duty The condenser duty is estimated using the heat balance envelope presented in

Figure 2

Figure 2: Heat balance Envelope for condenser duty estimation.

141

The condenser duty is estimated using the heat balance envelope presented in

Figure 2.

For the chosen envelope, the incoming streams are: 1. Naphtha vapor (from tray 45) 2. Reflux vapor (from tray 45) 3. Steam (at its partial pressure)

The temperature of these streams is the tower top temperature that was

estimated as a dew point earlier.

142

The outgoing streams for the envelope are :

1. Naphtha liquid product 2.Water liquid product 3. Cold naphtha reflux.

All these streams are assumed to be at 100 oF.

143

The only term that is missing in the outgoing enthalpy balance is the

condenser heat duty.

This is therefore estimated from the enthalpy balance. We next present an illustrative example for the determination of condenser

duty.

Eventually, total pump around duties is determined from the previously known total heat removed minus the condenser duty (TPAD =Total heat removed Condenser duty)

Problem 9
144

Q : Determine the condenser duty for the Ecuador crude oil CDU problem.

Solution 9
145

The enthalpy balance table for the evaluation of condenser duty is summarized

as follows:
Stream IN Naphtha Reflux Steam Total OUT Naphtha Refluxes Water Cond duty Total V/L V V V K 12.75 12.75 T 236 236 236 lb/hr 89776.86 71821.49 66675 228273.3 89776.86 71821.49 66675 228273.3 Btu/lb 258.33 258.33 1161.8 mmBtu/hr 23.1921 18.5536 77.4630 119.2087 4.4888 3.5911 6.6675 104.4613 119.2087

L L L

12.75 12.75

100 100 100

53 53 67.3 100

From the enthalpy balance table, Condenser duty = 104.46 mmBtu/hr. Therefore, bottom + top pump around duties = 206.65 104.46 = 102.19 mmBtu/hr.

Overflow from Top tray

146

The tower top most tray overflow is determined also from the enthalpy

balance by considering an envelope shown in Figure 3 .

Figure 3: Envelope for the determination of tower top tray overflow.

147

The top most tray overflow is important to determine, as later it will be

checked to meet the fractionation efficiency.

For the chosen envelope, the incoming streams are :

1. Nnaphtha vapor (from tray 44) 2. Overflow vapor (from tray 44) 3. Steam (from tray 44) Eventually heat is lost in the condenser duty and overflow liquid, naphtha liquid product (at 100 oF), water (at 100 oF).

148

In these terms, the overflow enthalpy is estimated from where the overflow rate

(lbs/hr) is evaluated.
However, for these calculations, it is important to assume the overflow liquid and

vapor temperatures.
It is fair to assume that the overflow liquid is 5 oF higher than the tower top

temperature and the overflow vapor is 5 6 oF higher than the over-flow liquid.

This rule of thumb will be applicable in future calculations as well that the approaching vapor and liquid are at a temperature difference of 5oF.

We next present an illustrative example for the estimation of overflow from the

top tray.

Problem 10
149

For the Ecuador crude CDU, determine the top tray

overflow rate in lbs/hr.

Solution 10
150

The energy balance table for the envelope presented in Figure 3 is presented below:
Stream IN Naphtha O/Flow Steam Total OUT Naphtha O/Flow Water Cond duty Total V/L V V V API 69.8 57.1 MEABP K 266 315 12.75 12.25 T (oF) lb/hr Btu/lb mmBtu/hr

252 89776.86 252 x 252 66675 156451.9+x 156451.9 100 89776.86 246 x 100 66675

268.03 24.06289 264.675 274.5x 1169.6 77.98308 103.43+274.5x 102.046 53 4.758174 129.975 141.8x 67.3 4.487228 104.4613 116.011+141.8x

L L L

69.8 57.1

266 315

12.75 12.25

156451.9+x

151

From the enthalpy balance, we get x = 86568.14 lbs/hr. API of the overflow = 57.1 which corresponds to 6.2497 lbs/gal. Therefore, the top tray overflow in gallons per hour = 13851.55 GPH. This is regarded as cold GPH. In fractionation efficiency calculations, we need to determine the hot GPH.

Therefore, it is important to note this concept in the design calculations.

Fractionation criteria
152

Verification of fractionation criteria

In a distillation column, the generation of adequate amount of vapor requires

adequate amount of liquid.

Therefore, fractionation criteria is usually defined as the ratio of vapor and

liquid (reflux) flow rates.

However, in the case of CDU, the fractionation criteria is defined using the

product vapor flow rates and corresponding reflux rates.

153

Fractionation criteria is defined using the following terms for the performance

of the CDU :
A.

Factor F: Defined as the ratio of the hot gallons per hour (GPH) of the lighest product from draw off tray to the total vapor product (cold GPH) leaving the lightest product draw off tray.For different combinations of product streams, the factor F is defined as

i) Naphtha-Kerosene

154

ii) Kerosene-LGO

iii) LGO-HGO

iv) HGO-LGO

155

A convenient correlation between the cold stream specific gravity (at 60 oF)

and the hot stream specific gravity (at desired temperature) is presented in proceeding table.
Using these two specific gravities, the following expression is used to convert

the cold GPH values (which are usually known from CDU mass balances):

Since usually hot stream SG is lower than the cold stream SG, the hot GPH is

usually higher than the cold GPH.

156

After applying the fractionation criteria, one would be able to carry out mass and energy balances as follows:
a)

Top tray: Provides appropriate liquid flow rate (reflux) for sections below the top tray. Kerosene draw off tray: Provides appropriate liquid flow rate (reflux) to sections below the kerosene draw off tray LGO draw off tray: Provides appropriate liquid flow rate (reflux) to sections below the LGO draw off tray. HGO draw off tray: Provides appropriate liquid flow rate (reflux) to sections below the HGO draw off tray.

b)

c)

d)

Table 4.1 : Variation of specific gravity with temperature (a) Data range: SG = 0.5 to 0.7 at 60 oF
157
SG = 0.5 T (oF) SG 0.48 0.46 0.44 0.42 0.39 0.36 0.35 T SG = 0.52 (oF) SG 0.50 0.48 0.47 0.45 0.43 0.40 0.38 0.35 T SG = 0.54 (oF) SG 0.52 0.51 0.49 0.48 0.46 0.44 0.39 0.37 0.35 T SG = 0.58 (oF) SG 0.56 0.55 0.53 0.52 0.50 0.49 0.47 0.46 0.43 0.40 0.37 0.35 T SG = 0.6 (oF) SG 0.58 0.56 0.54 0.52 0.50 0.48 0.45 0.42 0.39 0.37 T SG = 0.62 (oF) SG 0.60 0.58 0.56 0.54 0.52 0.51 0.48 0.45 0.42 0.38 0.35 T SG = 0.64 (oF) SG 0.62 0.60 0.58 0.56 0.54 0.52 0.49 0.47 0.44 0.41 0.38 0.35 T SG = 0.66 (oF) SG 0.64 0.63 0.62 0.60 0.58 0.56 0.55 0.53 0.51 0.49 0.47 0.45 0.43 0.41 0.38 0.35 T SG = 0.68 (oF) SG 0.65 0.64 0.62 0.60 0.58 0.57 0.55 0.53 0.51 0.49 0.47 0.44 0.42 0.39 0.36 T SG = 0.7 (oF) SG 0.68 0.66 0.63 0.61 0.59 0.58 0.55 0.53 0.51 0.49 0.46 0.44 0.42 0.39 0.37 0.35

80.07 100.84 119.16 139.92 160.66 178.94 182.58

81.38 102.17 121.73 141.28 160.82 184.00 198.64 212.02

79.02 101.03 120.59 140.15 160.93 180.47 213.42 232.93 239.00

80.39 99.96 121.98 141.55 163.55 183.12 200.23 216.12 249.10 267.40 289.37 301.54

87.81 115.94 137.96 164.86 197.88 227.23 262.66 289.53 309.05 323.68

86.67 117.26 146.61 177.18 204.10 228.56 267.70 301.92 331.24 367.87 386.16

90.42 122.24 151.60 182.18 217.67 251.93 293.50 330.20 368.10 397.43 427.95 446.23

85.62 110.09 138.24 168.82 200.63 230.00 259.37 285.06 322.99 351.12 373.13 403.72 428.16 453.82 483.13 501.44

101.59 139.54 171.36 201.95 233.77 260.68 288.83 335.32 367.14 395.26 430.74 463.76 491.89 523.66 557.85

98.01 139.62 181.23 217.94 257.10 287.69 339.09 377.03 411.29 445.55 487.14 520.17 549.52 580.08 604.51 616.69

Table 4.2 : Variation of specific gravity with temperature (b) Data range: SG = 0.72 to 0.98 at 60 oF.
158
SG = 0.72 T (oF) 100.53 140.91 181.30 221.69 263.30 293.90 336.73 383.24 424.83 477.45 520.27 565.53 610.77 SG 0.70 0.67 0.65 0.63 0.61 0.60 0.57 0.55 0.52 0.50 0.47 0.44 0.40 SG = 0.74 T (oF) 114.07 165.48 225.45 285.43 341.73 401.70 462.88 522.83 569.31 612.12 659.79 SG 0.71 0.68 0.66 0.63 0.60 0.57 0.53 0.50 0.47 0.44 0.40 SG = 0.76 T (oF) 101.91 139.85 182.70 224.33 263.49 299.00 336.94 381.00 422.62 465.46 503.38 549.88 593.90 639.17 673.41 702.73 SG 0.74 0.72 0.70 0.68 0.66 0.65 0.63 0.61 0.59 0.56 0.54 0.51 0.48 0.46 0.43 0.40 SG = 0.78 T (oF) 100.78 142.41 188.92 237.88 286.87 323.58 361.54 404.38 434.97 475.36 524.32 564.69 603.84 644.21 678.45 712.68 756.68 SG 0.76 0.74 0.72 0.70 0.68 0.66 0.65 0.63 0.61 0.59 0.56 0.54 0.52 0.49 0.47 0.44 0.40 SG = 0.8 T (oF) 102.08 160.85 223.29 283.28 344.51 404.50 458.35 504.86 550.15 588.09 635.80 671.28 710.43 744.66 776.44 811.86 SG 0.78 0.76 0.73 0.71 0.68 0.66 0.63 0.61 0.58 0.57 0.54 0.52 0.49 0.46 0.44 0.40 SG = 0.82 T (oF) 118.07 175.62 230.73 291.96 343.38 398.48 462.13 541.70 593.09 635.92 675.08 721.55 772.92 814.50 842.62 SG 0.79 0.77 0.75 0.73 0.71 0.69 0.66 0.62 0.59 0.57 0.55 0.51 0.48 0.45 0.43 SG = 0.84 T (oF) 101.01 157.35 208.78 263.89 311.63 353.27 404.69 447.54 491.60 530.78 566.26 604.22 645.83 686.20 722.89 754.71 785.30 819.54 850.10 SG 0.82 0.80 0.78 0.77 0.74 0.73 0.71 0.69 0.67 0.65 0.63 0.61 0.59 0.57 0.54 0.52 0.51 0.48 0.46 SG = 0.88 T (oF) 119.54 185.67 248.12 311.80 375.46 451.38 515.04 581.14 655.81 721.89 773.28 816.10 879.71 SG 0.86 0.83 0.81 0.79 0.76 0.73 0.70 0.67 0.64 0.60 0.57 0.54 0.51 SG = 0.94 T (oF) 111.21 178.55 254.48 310.81 385.51 440.62 485.92 544.70 588.77 634.06 690.39 752.83 810.37 865.44 903.38 SG 0.92 0.90 0.87 0.85 0.82 0.80 0.79 0.76 0.74 0.72 0.70 0.68 0.65 0.62 0.60 SG = 0.98 T (oF) 104.01 154.23 195.86 244.85 302.41 357.52 413.85 477.53 524.07 576.72 624.47 668.54 717.53 766.51 815.47 863.23 904.86 SG 0.96 0.95 0.93 0.92 0.90 0.88 0.86 0.84 0.82 0.80 0.78 0.76 0.74 0.72 0.70 0.68 0.67

159

B.

No of trays in various sections (N): The number of trays in various sections is taken as follows for various combinations: i) Naphtha-Kerosene: N = 12 (No pump arounds, therefore, all trays included in the evaluation)

ii) Kerosene-LGO: N = 11 (2 Pump around trays get a credit of only 1 tray).

iii) LGO-HGO: N = 11 (2 pump around trays get a credit of only 1 tray).

160

iv) HGO-residue: Criteria not required.

This is due to the fact that usually ASTM gaps are defined for Naphtha-

kerosene, Kerosene-LGO, LGO-HGO combinations and the final TBP temperature of the residue is usually specified.

161

C. ASTM Gaps (G):

ASTM Gaps are usually defined as per the following product specifications for the CDU i) Naphtha-Kerosene: G = 25 oF ii) Kerosene-LGO: G = -10 oF iii) LGO-HGO: G = -35 oF

162

The fractionation criteria is defined as a correlation between Reflux Ratio, N,

G and DT50% TBP between the adjacent cuts.

Typically, fractionation criteria is correlated between (Reflux ratio x N) and

G for various values of DT50% TBP.

The fractionation criteria correlation data are presented in proceeding table for

steam stripping conductions in the CDU.

Table 4.3 : Fractionation criteria correlation data for naphthakerosene products

163
DTBP50% = 100 oF ASTM Gap (oF) 23.30 22.13 19.81 15.54 12.83 9.72 6.62 4.29 -0.36 F = RR x N 100.63 69.63 50.12 34.69 29.24 24.65 21.62 19.46 16.41 DTBP50% = 150 oF ASTM Gap (oF) 45.40 43.85 41.52 38.03 33.38 29.50 22.13 14.76 9.72 F = RR x N 101.75 70.40 50.02 34.62 24.60 19.93 14.93 11.64 10.08 DTBP50% = 200 oF ASTM Gap (oF) 65.18 64.79 63.63 62.85 61.30 59.75 56.26 53.16 46.95 F = RR x N 101.56 81.21 60.80 49.92 39.92 34.54 24.54 19.37 14.90 DTBP50% = 250 oF ASTM Gap (oF) 81.08 79.92 77.59 76.81 75.26 73.32 69.83 64.79 59.75 F = RR x N 102.75 49.84 40.39 34.04 29.85 24.50 19.60 14.68 12.06

-3.85
-7.73 -11.22 -15.87 -19.36 -24.79 -28.67

14.78
13.48 12.46 10.93 9.84 8.98 8.19

5.46
0.80 -3.85

8.84
7.96 7.07

39.97
36.09 29.50

11.02
9.92 8.04

54.32
50.83 46.95 45.01

9.90
8.80 7.92 7.32

Table 4.4 : Fractionation criteria correlation data for side stream-side stream products
164
DTBP50% = 100 oF ASTM Gap (oF) -24.82 -22.69 -19.36 -16.02 -11.77 -7.22 -3.58 0.36 4.31 7.35 F = RR x N 5.72 6.73 7.68 9.14 10.76 12.79 15.06 18.10 21.52 26.94 DTBP50% = 150 oF ASTM Gap (oF) -16.37 -9.70 -2.11 4.86 10.33 17.61 21.26 24.61 F = RR x N 4.75 6.13 8.41 11.42 14.44 21.28 27.47 38.08 DTBP50% = 200 oF ASTM Gap (oF) -2.75 1.19 6.65 12.41 16.96 24.23 28.18 32.43 36.69 37.91 F = RR x N 5.26 6.38 8.07 9.60 11.18 14.43 18.06 22.84 29.47 36.89 DTBP50% = 250 oF ASTM Gap (oF) 1.47 8.44 16.02 24.51 30.27 37.85 46.34 51.21 51.82 F = RR x N 4.51 5.88 7.82 9.99 12.00 15.64 22.81 32.27 36.48 DTBP50% = 300 oF ASTM Gap (oF) 12.65 16.29 20.54 26.60 33.27 38.43 43.89 51.16 54.50 59.36 F = RR x N 4.33 5.15 6.31 7.58 9.20 11.17 13.69 18.21 21.44 28.24

10.09
12.21

32.37
37.72

62.11

37.97

165

The fractionation criteria can be applied in two ways which are summarized as follows:
Assume ASTM Gap as desired for the combination of products and determine the

hot GPH liquid reflux flow rates.

Eventually, conduct energy balance to determine unknown parameters such as pump around duties etc.

166

Assume the value of the unknown parameter such as pump around duty and

determine the hot GPH as an unknown parameter from energy balances of respective sections of the CDU.
Eventually, with the known values of the hot GPH, verify whether desired

ASTM gap has been met or not. If desired ASTM gap values are not met, then unknown parameters need to be adjusted.

167

A careful dissection of the CDU design calculations conducted so far indicates the following information:
Reflux ratio of 0.8 (on a molar basis) has been assumed previously. The reflux ratio enabled the determination of the tower top temperature. The tower top temperature enabled the evaluation of liquid and vapor

enthalpies at the top section for the energy balance.

From energy balance of the tower top section, we have been able to determine

the condenser duty. From this the total pump around duties can be estimated.

168

Since the design calculations of the CDU follow in a sequential manner, it is

inevitable that the selection of the reflux ratio (on a molar basis) at the tower top section is very important. This unique variable has the key for all design calculations and satisfaction of the fractionation criterion.
a)

A wrong choice of reflux ratio may provide negative flow rates. This is unacceptable. Even if one chooses an appropriately high value of reflux ratio, positive reflux flow rate values may be obtained. However, fractionation criteria needs to be satisfied. Very high values of reflux ratio enhances the column diameters and contributes to the cost.

b)

c)

169

Therefore, through these slides we uniquely wish to provide elabotations

towards this important variable. We consider different values of naphtha reflux ratio in the tower top section and we wish to elaborate upon this .
Coming back to the fractionation criteria, the immediate issue that we can

consider in the CDU calculations is to execute the following calculations:

a)

Apply fractionation criteria for the naphtha-kerosene section and verify whether fractionation crtieria is satisfied or not. Conduct energy balances for the section below the kero draw-off tray whose envelope is shown in Figure 4.

b)

Figure 4
170

Figure 4: Energy balance envelope for the estimation of reflux flow rate below the LGO draw off tray

171

The heat balance envelope consists of the following consolidated stream data
Heat in Heat out

Crude Vapor + Liquid (Obtain data from flash zone Overflow vapor (Mass will be same as unknown mass and energy balance calculations) reflux rate. Temperature is known from tower temperature profile).

Total fresh superheated steam at 450 oF

Vapor products to draw off tray (known from mass balance tables).

LGO draw off tray liquid reflux rate (Flow rate is Steam to tray 34 (all steam other than kerosene fresh unknown but temperature is known from assumed steam) tower temperature profile)

LGO product
HGO product Total Pump around duties

172

From the above table, for the heat balance envelope, one requires the

knowledge of the total pump around duties, which is obtained from the total refluxes and condenser duties.
With this knowledge, determine the liquid reflux flow rates (GPH) and apply

fractionation criteria.

If we get negative flow rates then we enhance the reflux ratio systematically until we get both applicable criteria satisfied i.e., positive reflux flow rates (hot GPH) and fractionation criteria.

Problem 11
173

Q : Verify the fractionation criteria for the Ecudaor crude oil case and determine the optimal reflux ratio that provides all criteria (positive flow rates and ASTM gap based fractionation criteria) satisfied.

Solution 11
174

From previous solutions, we obtain the following information:

1. 2.

Condenser duty = 104.46 mmBtu/hr (from previous solution). Condenser duty + TPA duty + BPA duty = 206.65 mmBtu/hr (from previous solution). Therefore, pump around duty = 102.19 mmBtu/hr.

3.

175

First, we apply the fractionation criteria for naphtha-kerosene combination:

From the solution of Q10 : 1. We obtain the cold GPH of the liquid reflux as 13851.5 GPH.
2. 3. 4. 5.

Specific gravity of the stream at tower top temperature (246 oF) = 0.587393 From mass balance table, SG of Naphtha = 0.705736 (at 60 oF) Hot GPH = 13851.55*0.705736/0.587393. = 17692.29 GPH Cold Naphtha product GPH (from mass balance table) = 15271.35 GPH

176

Factor F = Hot GPH/Naphtha product rate = 17692.29/15271.35 = 1.16 N = 12 Ordinate on fractionation criteria correlation = 1.16 x 12 = 13.9 From product TBP curves, DT50% = 157. From fractionation criteria correlation data (Table 4.4), ASTM gap = 27 oF Desired minimum ASTM gap = 25 oF

Since obtained ASTM gap is greater than desired ASTM gap, the fractionation criteria is concluded to be satisfied

177

We next carry out the energy balances for the energy balance envelope presented in Figure 4. A summary of the energy balance table is presented below:
Stream IN Crude Steam Tray 34 overflow Total OUT O/F to tray 34 Vapor to tray 34 Steam to tray 34 LGO HGO Residue PA Total API V+L V L MeABP K T (oF) lb/hr 637798.6 75425.0 X 713223.6 X 183636.6 75425.0 80289.9 44163.4 329710.9 Btu/lb mmBtu/hr 293.3132 95.2316 388.5448+162.3X 293.0 302.4 1203.4 225.5 282.1 365.4 293X 55.5317 90.7694 18.1059 12.4582 120.4773 102.1952 399.5378+293X

45.5

408

11.9

450 321.83

1262.6 162.3

V V V L L L

45.5 57.2 35.7 32.2 14.1

408 315 PP=

11.9 12.25 22.1 11.6 11.55 11.5

325.8 325.8 325.8 435.4 526.9 686.6

713225.8

178

Solving for X, we get X = -84.106.2 Since we obtained a negative flow rate, we conclude that the naphtha

reflux ratio is not enough to meet even the column mass balance requirements.
We next increase column reflux ratio to a value of 1.5 on a molar basis and

repeat all relevant calculations.

For First we determine the tower top temperature. From dew point calculations, tower top temperature = 248 oF

179

Eventually, condenser duty and total pump around duty are evaluated as follows:
Stream IN Naphtha Reflux Steam Total OUT Naphtha Refluxes Water Cond duty Total Total pump around duty= 84.9965 291117.2 mmBtu/hr L L L 12.75 12.75 100 100 100 89776.86 134665.3 66675 53 53 67.3 165 100 4.7582 7.1373 4.4872 121.6600 138.0427 V V V 12.75 12.75 248 248 248 89776.86 134665.3 66675 291117.2 268.1 268.1 1167.9 24.0692 36.1038 77.8697 138.0427 K T (oF) lb/hr Btu/lb mmBtu/hr

180

Next we carry out the energy balance for the envelope presented in Figure 4

to determine the tower top tray reflux stream flow rate. Relevant energy balances are summarized in the following table.
Stream IN Naphtha O/Flow Steam Total OUT Naphtha O/Flow Water Cond duty Total x= K V V V 12.75 12.25 T 264 264 264 lb/hr Btu/lb mmBtu/hr 24.65273 274.5x 78.3898 103.43+274.5x 4.758174 141.8x 4.487228 121.6600 116.011+141.8x

89776.86 274.6 x 274.1 66675 1175.7 156451.9+x 89776.86 x 66675 53 143.9 67.3

L L L

12.75 12.25

100 258 100

214000.7

lb/hr

34241.71

156451.9+x GPH

181

Using information from the above table, we next apply the fractionation criteria for naphtha-kerosene combination.
Cold GPH = 34241.7

SG at 258 oF = 0.5455
SG at 60 oF = 0.7057 Hot GPH = 47090 Naphtha GPH = 15721.3

F = 3.08
N = 12 Factor = 37

From fractionation criteria correlation ASTM gap = 42 oF. Desired ASTM gap = 25 oF. Therefore, criteria is satisfied.

182

Next we present the summary of the energy balances carried out for the heat

balance envelope presented in Figure 4

Stream IN Crude Steam Tray 34 overflow Total OUT O/F to tray 34 Vapor to tray 34 Steam to tray 34 LGO HGO Residue PA Total API V+L V L MeABP K T lb/hr 637798.6 75425.0 X 713223.6 X 183636.6 75425.0 80289.9 44163.4 329710.9 713225.8 Btu/lb mmBtu/hr 293.3132 95.2316 162.3X 388.5448+162.3X 293X 55.5317 90.7694 18.1059 12.4582 120.4773 84.9965 382.3391+293X

45.5

408

11.9

450 321.83

1262.6 162.3

V V V L L L

45.5 57.2 35.7 32.2 14.1

408 315 PP=

11.9 12.25 22.1 11.6 11.55 11.5

325.8 325.8 325.8 435.4 526.9 686.6

293.0 302.4 1203.4 225.5 282.1 365.4

183

Solving for X we get X = 47479.03 lb/hr which corresponds to 7129.74 cold

GPH.
Since we got positive flow rates, we proceed towards applying

fractionation criteria based on correlation data presented in Table 4.4.

184

SG at 326 = 0.64 Hot GPH = 8905.8 Kero + Naphtha product flow rate = 29312.5 F = 0.3

N = 11
Ordinate = 3.3 From product TBP data obtained earlier, DT50% TBP = 135 oF. ASTM gap from Table 4.5 = -28 oF Desired ASTM gap = -10 oF

This time we failed only in obtaining the desired ASTM gap.

185

We next consider a reflux ratio of 2 and repeat all calculations.

Hopefully, this time we should satisfy all criteria desired. attempt to be more careful to all calculations desired.

Therefore, we

Tower top temperature calculations: a) Moles of overhead product =898.038moles/hr b) Total moles HC in the overhead vapour = 2694.114 c) Total moles of steam in the overhead vapour =3704.167 d) PPHC in overhead vapour =12.50573 psia = 0.85073atm To find the tower top temperature, assume initially a value of 250oF, and then conduct dew point calculations as given under.

186

Table: Calculation of Tower Top Temperature

Component 1 2 3 4 5 6 7 8 Total Mid BP 75 125 160 195 235 265 295 320 Vol % on crude 0.5 1.5 2.5 3.5 2 3 2.5 2 S.G 0.638826 0.665882 0.698765 0.723785 0.746702 0.766938 0.771117 0.771117 Wt Factor 0.319413 0.998824 1.746914 2.533248 1.493404 2.300813 1.927793 1.542234 12.86264 Mole Fraction 0.024833 0.077653 0.135813 0.196946 0.116104 0.178876 0.149875 0.1199 1 PS 12.4 6 3.8 2.1 1.36 0.7 0.56 0.35 K 14.57572 7.052766 4.466752 2.468468 1.598627 0.822823 0.658258 0.411411 X=y/K 0.001704 0.01101 0.030405 0.079785 0.072627 0.217393 0.227685 0.291436 0.932045

K2 = K1 * SX =

0.383454

Vapour Pressure corresponding to K2 = 0.326216 Atm

187

From Maxwells correlation, we get tower top temperature = 250 oF. Next, we

proceed towards condenser duty calculations and total pump around duties. A summary of the calculations is presented below:
Stream K IN Naphtha V 12.75 Reflux V 12.75 Steam V Total OUT Naphtha L 12.75 Refluxes L 12.75 Water L Cond duty Total Total pump around duty= T 250 250 250 lb/hr 89776.86 179553.7 66675 336005.6 89776.86 179553.7 66675 336005.6 mmBtu/hr Btu/lb 269 269 1167.9 mmBtu/hr 24.1500 48.3000 77.8697 150.3197 4.7582 9.5163 4.4872 131.5579 150.3197

100 100 100

53 53 67.3 165 100

75.0986

188

Next, we determine the reflux overflow rate from the tower top tray. Calculations are summarized below
Stream IN Naphtha O/Flow Steam Total OUT Naphtha O/Flow Water Cond duty Total x= K T lb/hr Btu/lb mmBtu/hr

V V V

12.75 12.25

266 266 266

89776.86 275.5 x 275 66675 1175.7 156451.9+x 156451.9 89776.86 x 66675 53 145 67.3

24.73352 274.5x 78.3898 103.43+274.5x 103.1233 4.758174 141.8x 4.487228 131.5579 116.011+141.8x 140.8033

L L L

12.75 12.25

100 260 100

156451.9+x 289846.1 46377.53 lb/hr GPH

189

We next apply the fractionation criteria for naphtha-kerosene products

a) b)

c)
d) e) f)

Cold GPH = 46377.53 Hot GPH = 64606.02 Naphtha product GPH = 15721.35 F = 4.23 Ordinate = 50.8 DT50% TBP = 157 oF\

From fractionation correlation, ASTM gap = 45 oF. ASTM gap desired =

25 oF. Therefore, the criteria is satisfied.

190

Next we carry out the energy balances for the envelope shown in Figure 4. The

following table summarizes the energy balances and evaluated liquid reflux flow rate from the LGO draw off tray.
Stream API IN Crude Steam Tray 34 overflow Total OUT O/F to tray 34 Vapor to tray 34 Steam to tray 34 LGO HGO Residue PA Total V+L V L MeABP K T lb/hr 637798.6 75425.0 X 713223.6 X 183636.6 75425.0 80289.9 44163.4 329710.9 713225.8 Btu/lb mmBtu/hr 293.3132 95.2316 162.3X 388.5448+162.3X 293X 55.5317 90.7694 18.1059 12.4582 120.4773 75.0986 372.4412+293X

45.5

408

11.9

450 321.83

1262.6 162.3

V V V L L L

45.5 57.2 35.7 32.2 14.1

408 315 PP=

11.9 12.25 22.1 11.6 11.55 11.5

325.8 325.8 325.8 435.4 526.9 686.6

293.0 302.4 1203.4 225.5 282.1 365.4

191

From energy balance calculations X = 123206.6 lbs/hr which corresponds to

18501.4 GPH. We next apply the fractionation criteria

LGO cold GPH = 18501.4 GPH SG at 326 oF = 0.64 Hot GPH = 23110.49

Kero + Naphtha product GPH = 29312.5

Factor F = 0.79 Ordinate = 8.7. DT50% TBP = 135 oF

192

ASTM gap from fractionation criteria correlation = -7.5 oF ASTM gap desired = -10 oF Since the obtained ASTM gap is higher than the desired ASTM gap, we accept

this value. Since both flow rates and fractionation criteria are satisfied, we conclude with this value.

193

The procedure outlined will provide an outlook for the design engineer to

explore and understand the intricacies involved in pump around duties.

Also, it can be observed that we may have slightly approximated the reflux ratio to be on the higher side.

A very accurate evaluation of the reflux ratio will provide a value of

about 1.9. For all future calculations, we use the values generated for a reflux ratio of 2 only.
We next present the discussion for the evaluation of top pump around duties.

This calculation is carried out only after the desired criteria are satisfied.

Top and Bottom Pump Around Duty

194

The estimation of TPA duty is tricky. The top pump around duty is estimated using the heat balance envelope

presented in Figure 5 .
The envelope considered is from tower top section to the LGO draw off tray

along with the Kerosene and LGO side strippers.

Figure 5
195

Figure 5 : Heat balance envelope for the estimation of top pump around duty

196

For the chosen heat balance envelope, the incoming streams enthalpy terms are itemized as: Hydrocarbon product vapors (Naphtha + Kerosene + LGO) entering tray 22 (LGO draw off tray). By assuming the temperature of these vapors, their enthalpy can be estimated. Steam in vapors entering tray 22 (LGO draw off tray). Once again by assuming the partial pressure of the steam (from Draw off temperature calculations), and assumed temperature of the consolidated vapor stream entering the tray 22, using steam tables, the enthalpy contributed by the steam in vapors entering tray 22.

1.

2.

197

3. Cold naphtha liquid reflux entering tray 1. The enthalpy of this stream is known from previous calculations.

4. Reflux vapor stream entering tray 22. Since consolidated vapor stream temperature is known (assumed), the enthalpy of the reflux vapor entering tray 22 is known. However, its flow rate is not known. The vapor reflux flow rate is determined from the fractionation criteria for LGO HGO product combination which will give hot GPH reflux and then this is eventually converted to lbs/hr. Therefore, vapor reflux stream
enthalpy is known.

198

The outgoing streams for the chosen heat balance envelope are itemized as: 1.

Reflux liquid leaving tray 34. This is at LGO draw off tray temperature. With the temperature known, enthalpy can be estimated and heat lost through this stream can be estimated. Consolidated vapor stream leaving tray 1 at its temperature. The consolidated vapor stream consists of naphtha reflux vapor + naphtha product + steam. The consolidated vapor stream enthalpy data need not be calculated as it is available as a total enthalpy leaving the heat balance envelope chosen to estimate the condenser duty. Therefore, the stream data is known.

2.

199

3. Kerosene product. Its flow rate and enthalpy are known from total tower energy balance table. 4. LGO product. Its flow rate and enthalpy are known from total tower energy balance table. 5. Top pump around duty. This is unknown and should be estimated from the energy balance.

200

By equating total energy out and total energy coming in, we can estimate the

top pump around duty.

The most tricky issues in these calculations is the vapor and liquid

enthalpy values estimation. Since enthalpy estimation is a function of MEABP and K value, it needs to be assumed.

For instance, since hydrocarbon vapors consist of naphtha + kerosene + LGO products, a rough estimation of MEABP and K would be based on their cut ranges and average values.

Problem 12
201

Q : For the Ecuador crude oil CDU problem assuming data from solutions generated in Q 1 10, estimate the top pump around exchanger duty.

Solution 12
202

Solution:
First we apply fractionation criteria for LGO-HGO combination to estimate the liquid and vapor reflux flow rates (lbs/hr).
From TBP data evaluated for LGO and HGO, DT50% = 575 505 = 70 oF ASTM gap desired = -35 oF From Graph, Ordinate 5 No. of plates = 11

203

Hot GPH = 5/11 x (15312.5+14000+11375) = 18494.31 GPH. Draw off temperature = 537 oF

Vapor stream temperature = 547 oF

Liquid stream temperature = 542 oF Liquid API = (6500*0.8463+3500*0.8645)/(6500+3500) = 0.85267 Vapor API = (8750*0.702995+6500*0.8463+8000*0.80387)/(8750+6500+8000)

= 0.7777684

204

Steam entering vapor = 48825+3062.5 = 51887.5 lbs/hr Fresh steam entering the envelope = (315.97+505.55)*18 = 14787.36 lbs/hr

Hydrocarbon vapor flow rate = 89776.85+93859.7+80289.87 = 263926.42 lbs/hr

LGO SG = 0.846337 Hot LGO SG = 0.71 Cold GPH = 18494.31 x 0.71/0.846337 = 15515.056 GPH = 109380.96 lbs/hr

205

Hydrocarbon vapor enthalpy at T = 547 oF, MEABP = 340 oF and K = 11.5

(Assumed values) = 411.3 Btu/lb.

Hydrocarbon liquid enthalpy at T = 542 oF, MEABP = 300 oF and K = 12

(Assumed values) = 340 Btu/lb.

206

We next apply the energy balances for the envelope presented in Figure 5. For the

envelope, entering streams enthalpies are:

a) b) c)

Hydrocarbon vapors = 263926.2 x 411.3/1000000 = 108.55 mmBtu/hr Steam fresh enthalpy = 14787.36 x 1262.6/1000000 = 18.67 mmBtu/hr Steam enthalpy in vapor at a partial pressure of 1.2 bar and vapor temperature = 1304.2 Btu/lb. Thereby, steam enthalpy = 51887.5 x 1304.2/100000 = 67.7 mmBtu/hr

207

d) Enthalpy of told cold naphtha reflux stream at 100 oF from previous heat balance tables = 4.7582 mmBtu/hr
e) Hydrocarbon vapor reflux = 109380.96 x 411.3/100000 = 44.98 mmBtu/hr
Total energy in = 244.648 mmBtu/hr

208

For the envelope, leaving stream enthalpies are : a) b) c)

Hydrocarbon liquid reflux = 109380.5 x 340/1000000 = 37.18 mmBtu/hr Vapor enthalpy at tower top temperature (250 oF) = 150.32 mmBtu/hr LGO product enthalpy from overall tower energy balance table = 18.11 mmBtu/hr Kerosene product enthalpy from overall tower energy balance table = 15.0467 mmBtu/hr

d)

209

Total energy going out = 220.66 mmBtu/hr. Therefore, Top pump around duty = 244.648 200.66 = 23.98 mmBtu/hr.

Bottom pump around duty = 75.0986 23.98 = 51.11 mmBtu/hr.

Flash zone liquid reflux rate

210

The flash zone liquid reflux rate is determined by conducting the energy balance

across the heat balance envelope taken from below the HGO draw off tray and for the flash zone (Figure 6).
For this heat balance envelope, the incoming streams are :
1. 2.

3.

Crude (V +L), Fresh steam entering at the bottom most tray Liquid reflux stream.

211

The outgoing streams in the envelope are : 1. 2. 3.

4.

Product vapor stream consisting of Naphtha + Kerosene + LGO + HGO, Steam in vapor at its partial pressure of the draw off tray pressure, Reflux vapor stream Residue product stream.

212

The liquid reflux stream temperature is taken as the HGO draw off tray

temperature.
The vapor stream temperature is taken as 5 oF plus the liquid reflux

temperature.
At these temperatures, from Maxwells correlation, approximate enthalpy

values can be obtained.

Eventually, one can determine the unknown reflux liquid/vapor mass flow rate.

213

Figure 6: Heat balance envelope for the estimation of flash zone liquid reflux rate

Problem 13
214

Q : For the Ecuador crude oil CDU design problem, determine the reflux liquid stream flow rate at the flash zone.

215
The heat balance taken for the heat balance envelope taken as Figure 6 is presented below:
Stream IN Crude Steam Liquid Reflux Total OUT Product vapor Steam in vapor Reflux vapor Residue Total API V+L V L MeABP K T lb/hr 637798.6 48825.0 X 686623.6 V V V L 47.8 32.2 14.1 426 PP=19.1 575 12.15 11.55 11.5 542 542 542 686.6 308089.9 48825.0 X 329710.9 686625.8 415.0 1304.0 404.0 365.4 Btu/lb mmBtu/hr 293.3132 61.6464 282.1X 354.9596 +282.1X 127.8573 63.6678 404X 120.4773 312.0024 +404X

32.2

11.55

450 537

1262.6 282.1

216

From energy balance table, X = 353277.9 lbs/hr which

corresponds to a GPH of 48939 for an assumed HGO SG of 0.8643 for the liquid reflux stream.

Column diameters
217

A critical observation of vapor and liquid flow rates estimated at various sections of the CDU indicate that column diameters will different for:
1) 2) 3) 4)

Tower top section LGO draw off tray HGO draw off tray Section below the Flash zone

218

Since HGO draw off tray provides maximum vapor flow rates, HGO draw off

tray diameter will be maximum.

Therefore, for operational convenience, the CDU is usually designed as a

column with three different diameters.

These refer to diameters of the tower top section, HGO draw off tray, section

below the flash zone.

219

For these sections, the column diameter calculations involve the following steps: A.

Calculate the consolidated liquid flow rate on the tray.

a)
b)

c)

d)

This will be equal to tray 45 liquid reflux rate for the tower top section. This will be equal to liquid reflux + pump around stream flow rate + LGO product stream flow rate for the LGO draw off tray This will be equal to liquid reflux + pump around stream flow rate + HGO product stream flow rate for the HGO draw off tray This will be equal to the liquid reflux for the section below the flash zone.

220

In these calculations, the pump around flow rate is estimated using TPA and

BPA cooling duties that were estimated from energy balance.

The pump around cooling fluid outlet is assumed as 300 oF to evaluate the

pump around flow rate for BPA.

For LGO, if desired these calculations can be done by assuming the cooling

fluid outlet to be about 150 - 200 oF.

Actually, these values are important design variables as the crude oil is heat

integrated with these pump around exchangers.

221

B . Calculate the consolidated vapor flow rate to the tray :

a)

For the tower top section, this will be equal to the tray 45 consolidated vapor including naphtha product vapor + steam vapor + reflux vapor For the HGO draw off tray, this will be equal to the sum of (Naphtha + Kerosene + LGO + HGO product vapor), residue steam, and reflux vapor.

b)

c)

For the section below the flash zone, this will be equal to the sum of residue steam + reflux vapor.

222

C.

Determine the liquid and vapor densities using suitable approximations. For liquid, SG of various products can be assumed. For the vapor, SG can be estimated using ideal gas law.

D. Use flooding correlation data as those presented in Table 5 to determine the Kf value. Ideally, it is assumed that Kf = 1100 for a tray spacing of 24 inches.
E.

From known value of Kf determine the maximum allowed vapor mass flux using the expression

Table 5
223
Sieve & Valve tray flood line Tray spacing (inches) Kf 10.1 309.1 10.6 372.4 11.2 441.5 12.0 507.8 13.2 605.9 14.7 712.7 16.2 828.1 17.4 909.0 18.9 964.3 19.9 1010.7 21.7 1063.3 23.7 1116.0 25.0 1156.8 27.1 1212.4 28.7 1256.3 30.1 1294.4 30.9 1317.7 Sieve and valve tray design Tray spacing (inches) Kf 13.4 505.7 14.2 580.7 15.0 635.5 16.1 713.5 17.2 774.3 18.7 835.3 20.1 902.0 22.1 980.4 23.3 1032.7 25.0 1082.3 26.4 1117.5 28.5 1155.9 30.1 1185.5 32.2 1203.9 35.0 1225.5 Bubble cap trays (flood) Tray spacing (inches) Kf 9.9 151.5 11.3 226.8 12.4 304.7 13.2 359.6 14.7 480.7 15.6 538.5 17.2 596.7 18.4 643.3 20.0 712.9 23.4 786.4 25.1 816.1 28.8 884.0 30.3 904.9 32.2 917.5 33.6 926.9

Table 5: Variation of Kf (Flooding factor) for various tray and sieve specifications.

224

F. From the known value of Gf, determine the maximum permissible value of Gf during operation at 80 % flooding value. G. Determine the diameter of the tray from the 80% flood mass flux and total vapor mass flux on the tray. This is termed as Av H. For downcomer sizing, determine first the volumetric flow rate of liquid on the tray using total liquid mass flow rate and liquid density. Eventually, the down comer area is determined by assuming that the permissible value is 0.6 cft/s using the expression:

225

I. Assume an additional 20 % area as waste area J. The total area of the tray is evaluated using the expression

K. Calculate the diameter of the tray using the expression :

Problem 14
226

Q : Determine the diameter of the CDU processing Ecuador crude oil at three different sections namely, tower top section, HGO draw off tray and section below the flash zone.

Solution 14
227

1. Tower top section

Reflux Liquid = Total, G = So, G/x = So, x = rv = SG of liquid = Gf = A= Downcomer liquid velocity=0.6 ft/s cfs of liquid flow Aw = Adc = At = D= 289846.1 lb/hr 446297.9 lb/hr 7501.156 59.49722 Mol. Wt. 0.193156 5.855948 43.80249 3192.544 174.7423 1.838087 34.94845 3.063478 6.126957 215.8177 16.57673 5.052586 lb/ft3 lb/gal lb/cft ft2 ft3/s

2 down comers ft m

228

2. HGO Draw off tray

Liquid reflux HGO K = 11.75 MEABP = 575 Enthalpy at 300 oF Enthalpy at 560 oF BPA duty PA flow rate Liquid reflux HGO product Total liquid flow Liquid SG GPH of liquid Reflux vapor Steam flow rate Product vapor Total vapor 375354.8 lbs/hr 142.9 306.5 51.11 312423.3841 375354.8 44163.38 731941.5641 0.864386072 101653.807 375354.8 48825 308089.84 732269.64

Btu/lb mmBtu/hr lbs/hr lbs/hr lbs/hr lbs/hr

lbs/hr lbs/hr lbs/hr lbs/hr

229

2. HGO Draw off tray (Contd.)

Total, G= So, G/x = So, x= rv= SG of liquid= Gf= A= Downcomer liquid velocity=0.6 ft/s cfs of liquid flow= Aw= Adc= At= D= 732269.64 lb/hr 6368.462308 114.983744 Mol. Wt. 0.387837589 7.20033598 53.85851313 5009.28187 182.7281981 3.775022542 36.54563962 6.291704236 12.58340847 231.8572462 17.18167815 5.236975499 lb/ft3 lb/gal lb/cft ft2 ft3/s

2 down comers ft m

230

3. Section below the flash zone

Steam flow rate= Reflux vapor Total, G= So, G/x = So, x= SG of liquid= Gf= A= Downcomer liquid velocity=0.6 ft/s cfs of liquid flow= Aw= Adc= At= 48825 352377.9 401202.9 6368.49 62.99812 7.201702 53.86873 3714.269 135.0208 lb/hr lb/hr lb/hr Mol. Wt. lb/gal lb/cft ft2

1.817061 ft3/s 27.00416 3.028434 6.056869 2 downcomers 168.0819

D=

14.62903 ft 4.45893 m

231

In summary, we observe that the diameters of the CDU are : 1. 2. 3.

4.45 m at the flash zone, 5.23 m at the HGO draw off tray 5.05 m at the tower top section.