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EVALUATION OF PROGRESSIVE DISTILLATION
Dan Dobesh – Jesse SandlinDr. Miguel Bagajewicz
04.29.2008
This presentation is not about this Insurance Company
Not about this one either…
Our Mission“Analyze progressive crude fractionation, a technology
patented in 1987 that claims to be more energy efficient than conventional fractionaltion.”
Punchline“Progressive Distillation can reduce the heat duty
requirement of the distillation process by 17% for a heavy crude, and use 16% less furnace heat utility while
producing more valuable products for a light crude.”
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Petroleum Value Chain
http://en.wikipedia.org/wiki/Image:Oil_well.jpg
Petroleum Production http://en.wikipedia.org/wiki/Oil_refinery
Petroleum Refining
www.ehow.com/how_2041839_siphon-gas-car.html
www.freddiesasphaltoval.com/
FuelsSolventsLubricantsPlasticsDetergentsNylonPolyesters
http://www.lakewoodconferences.com/direct/dbimage/50241031/Plastic_Toy.jpg
Petroleum Products
Oil Refinery Schematic
Over 2% of the energy content in a crude stream is used in distillation.*
Distillation accounts for about 40% of energy use in a refinery.**
* Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626
Diagram Source: http://en.wikipedia.org/wiki/Oil_refinery
**Haynes, V.O. “Energy Use in Petroleum Refineries.” ORNL/TM-5433, Oak Ridge NationalLaboratory, Tennessee, September (1976).
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Light Crude Feed
Petroleum crude component boiling points range from -161 C (CH3) to over 827 C (C40H82+)
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Normal Boiling Point (NBP) of Component (°C)
Barr
els/
day
Heavy Crude Feed
Petroleum crude component boiling points range from -161 C (CH3) to over 827 C (C40H82+)
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Conventional Distillation Products Heavy Crude
NBP of Component (°C)
Barr
els/
Day
ASTM D86-07b, “D86 Point”• American Society for
Testing and Materials (ASTM): international organization that is a source for technical standards
• Rigorously developed method for quantitatively testing the boiling range of a petroleum product
(1) Oil sample heated in glass flask using electric heater
(2) Vapor is condensed and collected
(3) Temperature versus amount collected is recorded
• Not applicable to products containing large amounts of residual
Product SpecificationsGenerated from Pro/II Computer Model
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
Naphtha
Kerosene
Diesel
Gasoil
Resid
Crude FeedNBP of Component (°C)
Barr
els/
day
This graph compares the boiling point range of the five
products
D86 5% point heavy component
-263.2-43.6
31.1 121163
212262
312362
412462
512562
612662
713761
823924
10211107
12251438
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
NBP of Component
Com
positi
onProduct Gaps Explanation
- D86 95% point light component390⁰ C - 360⁰ C = 30⁰ C
D86 5% point heavy component
D86 95% point light component
Positive gaps indicate more distinct separation.
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Conventional Distillation
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Crude Composition
NBP of Component
Com
positi
onConventional Distillation
Simulation0
0.020.040.060.08
0.10.12 Naphtha
NBP of Component
Com
posi
tion
-16413.2 73
128183
239294
350405
495597
781
00.05
0.10.15
0.2 Kerosene
NBP of Component
Com
posi
tion
00.05
0.10.15
0.20.25 Diesel
NBP of Component
Com
positi
on
00.05
0.10.15
0.2 Gasoil
NBP of Component
Com
posi
tion
-0.04
0.01
0.06
0.11
0.16 Resid
NBP of Component
Com
positi
on
Gaps – Conventional Distillation
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0.00E+00
1.00E+03
2.00E+03
3.00E+03
4.00E+03
5.00E+03
6.00E+03
Conventional Distillation Products Light Crude
Naphtha
Kerosene
Diesel
Gasoil
Resid
Crude Feed
NBP of Component (°C)
Barr
els/
Day
D86 95% point anchors products on the right side, gaps change the left side
Conventional = Indirect
Takes the heaviest component as the bottom product in each column. Lighter components are sent to the next column.
Source: Smith, Robin, Chemical Process Design
Conventional = Indirect
Stacking these columns on top of each other is essentially conventional distillation.
Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626
Conventional = Indirect
Stacking these columns on top of each other is essentially conventional distillation.
Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626
Stacked columns from the indirect sequence.
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Patent: Process for Distillation of Petroleum by Progressive
Separations• This is an expired patent for crude fractionation that is now being commercialized by Technip.
• Main idea is to heat components only as much as necessary.
• Several companies are excited by this concept that promises large energy savings.
• A new refinery is being built in central Germany using this concept.
Progressive Crude Distillation Patent
Progressive Crude Distillation Patent
Technip’s Progressive Brochure
Technip’s Progressive Brochure
Technip’s Progressive Brochure
Progressive Crude Distillation - Gaps
-164 -42 50 86128
169211
253294
336378
419495
573663
8270
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Crude Composition
NBP of Component
Com
positi
on
-164 -42 50 86128
169211
253294
336378
419495
573663
8270
5001000150020002500300035004000
Top of Column 1
NaphthaKerosene
NBP of Component (°C)
Barr
els/
Day
-16413.2 100
169239
308378
467597
8270
200400600800
10001200140016001800
Top of Column 2
KeroseneDiesel
NBP of Component (°C)
Barr
els/
Day
-164 -42 50 86128
169211
253294
336378
419495
573663
8270.00E+002.00E+024.00E+026.00E+028.00E+021.00E+031.20E+031.40E+031.60E+031.80E+03
Top of Column 3
DieselGasoil
NBP of Component (°C)
Barr
els/
Day
-164 -42 50 86128
169211
253294
336378
419495
573663
8270
0.02
0.04
0.06
0.08
0.1
0.12
Naphtha
NBP of Component
Com
positi
on
-164 -42 50 86128
169211
253294
336378
419495
573663
8270
0.020.040.060.08
0.10.120.140.160.18
Kerosene
NBP of Component
Com
positi
on-164 -42 50 86
128169
211253
294336
378419
495573
663827
0
0.05
0.1
0.15
0.2
0.25
Diesel
NBP of Component
Com
positi
on-164 -42
13.2 50 73100
128155
183211
239266
294322
350378
405439
495549
597663
7810
0.02
0.04
0.06
0.08
0.1
0.12
Gasoil
NBP of Component
Com
positi
on
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
Resid
NBP of Component
Com
positi
on
Gaps – Progressive DistillationLight Crude
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
NaphthaKeroseneDieselGasoilResidCrude Feed
NBP of Component (°C)
Barr
els/
Day
Progressive = Direct
Takes the lightest component as the top product in each column. Heavier components are sent to the next column.
Source: Smith, Robin, Chemical Process Design
Indirect Direct
Conventional vs. Progressive
Summary
Recover heavy components first Recover light components first
One main column Many columns
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Simulation Development Method
1) Build PRO/II progressive crude simulation2) Obtain correct D86 95% points3) Synchronize product gaps 4) Mimimize heat duty5) Compare to conventional heat duty6) Determine areas for improvement
Simulation Assumptions
• SRK is a valid thermodynamic model for hydrocarbon systems
• Pseudocomponents represent crude composition
• PRO/II provides a close representation of reality
Basis of ComparisonPRO/II Conventional Simulation, 260 ⁰C steam
PRO/II Computer Model(s)Progressive Model – 4 column direct
Furnace heat duty = 89 MW This is higher than 58.7 MW for conventional distillation
Previous work suggested that this setup provided no furnace heat utility benefit over conventional distillation. Our results verify this.
Initial Complex Simulation
• Unnecessarily complicated
Too many products for conventional comparison
PRO/II Computer ModelPatent
Vacuum distillation for residual product is not important for comparison
Second Type Simulation
• Too much furnace heat utility: 200+ MW
Each column has a reboiler
Third Type Simulation
• Furnace utility is lower, but steam utility his very high
All seven columns have steam input
Heating Supply-Demand
Temperature ⁰C
F*C
p M
W
Demand Curve – dark line showing heat needed by systemSupply boxes – heat utility able to be recovered from system• Heat can be transferred down and left by second law• Heat can only move right across pinch via a pumparound
Final Type Simulation
Replaced steam with reboilers in the first series of columns
Heating Supply-Demand
Temperature ⁰C
F*C
p M
W
Specifications
Variables
Controller-Variable Systems
1) Naphtha-kerosene gap varies with steam flowrate in Column 12) Kerosene-diesel gap varies with steam flowrate in Column 23) Diesel-gas oil gap varies withsteam flowrate in Column 34) D86 95% points are obtained by varying the condenser duty
Column 1
Column 2
Column 3
After hours of red simulations and Red Bulls…days… weeks MONTHS
After hours of red simulations and Red Bulls…After hours of red simulations and Red Bulls…After hours of red simulations and Red Bulls…
Happy hour
Final Simulations
• Conventional: four simulations– 260 ⁰C steam, 135 ⁰C steam– Heavy feed, light feed
• Progressive: eight simulations– Reboilers, steam– 260 ⁰C steam, 135 ⁰C steam– Heavy feed, light feed– High heat exchanger temperatures, low heat
exchanger temperatures
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Conventional vs. ProgressiveLight Crude
15% Decrease
9% Decrease
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
Conventional Distillation Products
NaphthaKeroseneDieselGasoilResidCrude Feed
NBP of Component (°C)
Barr
els/
day
Light Crude
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
1000
2000
3000
4000
5000
6000
Progressive Distillation Products Light Crude
NaphthaKeroseneDieselGasoilResidCrude Feed
NBP of Component (°C)
Barr
els/
Day
Progressive Heat usageLight crude heat utility diagram
-50 0 50 100 150 200 250 300 3500
50
100
150
200
250
300
350
400
Progressive DistillationLight Crude
H
T
The intersection that is unaccounted for is the cold and hot utility
Hot Utility
Cold Utility
Progressive Heat usageLight Crude
Temperature ⁰C
F*C
p M
W
Conventional vs. ProgressiveHeavy Crude 9% Decrease
14% Decrease
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
2000
4000
6000
8000
10000
12000
14000
16000
Conventional Distillation Products Heavy Crude
NaphthaKeroseneDieselGasoilResidCrude Feed
NBP of Component (°C)
Barr
els/
Day
-164 -4213.2 50 73
100128
155183
211239
266294
322350
378405
439495
549597
663781
0
2000
4000
6000
8000
10000
12000
14000
16000
Progressive Distillation Products Heavy Crude
NaphthaKeroseneDieselGasoilResidCrude Feed
NBP of Component (°C)
Barr
els/
Day
Progressive Heat usageHeavy crude heat utility diagram
-50 0 50 100 150 200 250 300 3500
50
100
150
200
250
300
350
400Progressive Distillation
Heavy Crude
H
T
Progressive Heat usageHeavy Crude
Temperature ⁰C
F*C
p M
W
Our Conclusion
“Progressive Distillation can reduce the heat duty requirement of the distillation process by at least 17%
for a light crude, and at least 16% for a heavy crude, while producing similar amounts of products.”
Economic Analysis
• 120,000 BPD plant• Gross profit = Product sales – Utility costs• Progressive provides gross profit increase of
$10.2 million each year using light crude feed and $27.3 million each year using a heavy crude feed
Vacuum Economic Analysis
• Gas oil and residue profits are recovered in equal amounts in both cases
• Progressive provides gross profit increase of $25.7 million each year using light crude feed and $57.2 million each year using a heavy crude feed
Overview1) Background:
– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation
2) Methodology3) Results4) Accuracy & Limitations
Limitations
• Different column sequences and setups may offer lower heat utility
• Optimum setup is based on composition of crude feed
• Simulations are a simplification of reality• Heat exchanger network in the simulation is
not optimized
Accuracy
• D86 95% point comparisons between conventional and progressive are within 0.1 degrees Celcius
• Product gap comparisons between conventional and progressive are within 1.0 degrees Celcius
• Flowrate comparisons between conventional and progressive are within 10 cubic meters per hour
Questions
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