广东石油化工学院

Student number: 14014430113

Design Project Description

7.3 Mt/a CDU Process design

College Guangdong University of Petrochemical Technology

Specialty Chemical Engineering

Class 化工国际 14-1

Student number 14014430113

Name Azeez Mubarak (穆永福）

Supervisor Xie ying, Chen hong, Deng yiqiang, Shan shufeng

Email: barryazeez12345@gmail.com

2017 . 05 . 15 to 2017 . 05 . 28
 广东石油化工学院

This page intentionally left blank

 广东石油化工学院

Guangdong University of Petrochemical and Technology

Chemical engineering and technology

Design Project Description

Design topic: 7.3 Mt/a CDU Process design

Deadline: 2017.05.28
Fundamental data for the design: See Tables 1-2
Contents
0. Fundamental data

1. Introduction

Literature review

2. Process design

2.1. Technological process; 2.2. Product scheme;

2.3. Process flow diagram

3. Process simulation of atmospheric distillation tower

3.1. Draw flowsheet; 3.2 Input components; 3.3 Select properties method;

3.4 Set streams parameters; 3.5 Set column parameters; 3.6 Optimizing column

parameters; 3.7 Get hydraulics data; 3.8 Optimization results; 3.9 Simulation

results (Material balance and energy balance);

4. Size calculation of tower

4.1. Tower diameter; 4.2. Tower height

 广东石油化工学院

5. Tray Hydraulics calculation

6. Reference

Appendix
I. Atmospheric tower sketch.

II. Process flow diagram of crude distillation unit (all process parameters)

(6) Date of issue: 2017.05.12

Supervisor: XieYing, ChenHong, DengYiQiang, ShanShufeng
Due date: 2017 . 05 . 28

Student signature: 穆永福

 广东石油化工学院

0. Fundamental data

Saudi Arabia medium crude oil

1. Properties of the crude oil

Saudi Arabia medium crude oil, =0.8664 d 20
4
2. TBP data of Saudi Arabia medium crude oil
Table 1 TBP data of the Saudi Arabia medium crude oil

Every cut/wt Characterization factor

No. Boiling point range/oC Total yield/wt% Density(20 oC)/g/cm3
% K
1 <15 0.8 0.8 0.5930
2 15～65 3.8 4.6 0.6246 13.1
3 65～80 1.5 6.1 0.6523 13.0
4 80～100 2.5 8.6 0.6974 12.4
5 100～130 3.9 12.5 0.7230 12.2
6 130～145 2.3 14.8 0.7449 12.1
7 145～160 2.4 17.2 0.7574 11.9
8 160～180 3.3 20.5 0.7695 12.0
9 180～200 3.1 23.6 0.7805 12.0
10 200～230 4.7 28.3 0.7956 12.0
11 230～250 2.8 31.1 0.8086 11.9
12 250～275 4.1 35.2 0.8256 11.9
13 275～300 4.0 39.2 0.8402 11.9
14 300～320 3.2 42.4 0.8502 11.8
15 320～350 4.8 47.2 0.8677 11.7
16 350～365 2.5 49.7 0.8863 11.8
17 365～395 4.2 53.9 0.8905 11.8
18 395～425 5.0 58.9 0.9032 11.7
19 425～460 4.2 63.1 0.9241 11.8
20 460～475 2.5 65.6 0.9308 11.8
21 475～500 3.4 69 0.9380 11.8
22 500～530 3.4 72.4 0.9478 11.9
23 530～560 3.6 76 0.9560
24 >560 23.8 99.8 1.0370

1
 广东石油化工学院

3. Product scheme and its properties

Table 2 Yield and properties of products

Relative ASTM D86 distillation data/oC
density
Boiling point Yield
Product d 20
4
range/oC /wt% IBP 10% 30% 50% 70% 90% EP

(1)Naphtha HK~145 14.8 0.7025 49 73 87 102 117 135 163

(2)Kerosene 145~230 13.5 0.7810 153 170 178 186 197 213 229
(3)Light Diesel 230~320 14.1 0.8444 236 249 259 272 285 302 318
(4)Heavy Diesel 320~365 7.3 0.8465 253 267 278 292 310 332 343
(5)Residual Oil >365 50.3 0.9788

4. Processing capacity: (0.10×Student number+6) Mt/a, on-stream time: 8000 h/a.

(0.10×Student number+6) Mt/a

= (0.10 ×13＋6) Mt/a
= 7.3 Mt/a

Operating time foe CDU= 8000h/yr

What is mass flow rate?

Mass flow rate = = 0.0009125Mt/h 7.3Mt / a

Convert Mt/h into Kg/h 8000h / yr
Mt = 106 t, 1t = 1000Kg

= 912500Kg/h 0.0009125Mt 106 1000Kg

 
h Mt 1t
1. Introduction
A crude oil refinery is a group of industrial facilities that turns crude oil and other
inputs into finished petroleum products. A refinery's capacity refers to the maximum
amount of crude oil designed to flow into the distillation unit of a refinery, also
known as the crude unit.
Crude oil is made up of a mixture of hydrocarbons, and the distillation process
aims to separate this crude oil into broad categories of its component hydrocarbons,
or "fractions." Crude oil is first preheated before putting into a distillation column,
also known as a still, where different products boil off and are recovered at different
temperatures.
Lighter products, such as butane and other liquid petroleum gases (LPG), gasoline
blending components, and naphtha, are recovered at the lowest temperatures. Mid-
range products include jet fuel, kerosene, and distillates (such as home heating oil and
diesel fuel). The heaviest products such as residual fuel oil are recovered at
2
 广东石油化工学院

temperatures sometimes over 1,000oF.

Most refineries in the United States, China, Saudi Arabia, and other developed
countries reprocess the heavier fractions into lighter products to maximize the output
of the most desirable products using more sophisticated refining equipment such as
catalytic crackers, reformers, and cokers.

Literature review of 10 refineries in the Middle East and their production capacity

1 Ras Tanura
Capacity: 550 000bpd
Location: Saudi Arabia

Operator: Saudi Aramco

Ras Tanura is the oldest refinery in Saudi Arabia, located on the eastern coast of the
Kingdom. It came on stream in 1945 with a processing capacity of 50 000 b/d.
Several units were added in the following decades. Currently, it is considered as the
most complex Saudi Aramco refinery with a crude distillation capacity of 550 000
barrels per day (bpd). Ras Tanura Refinery also has a 305 000 bpd NGL processing
facility, a 960 000 bpd crude stabilisation facility, and 75 crude oil and products
storage tanks with a combined capacity of 5.8 million barrels.

Ras Tanura Refinery’s major refining facilities include a 325 000 bpd crude
distillation Unit, a 225 000 bpd gas condensate distillation unit, 50 000 bpd
hydrocracker and a total of 107 000 bpd capacity of catalytic reforming.

Ras Tanura Refinery is the only Saudi Aramco refinery that contains a visbreaker.
This refinery also produces 17 000 bpd of asphalt, more than any other refinery in the
Kingdom. Crude is normally transferred to Ras Tanura through a pipeline and can
also be supplied by ship. Most of Ras Tanura’s production is for domestic use and
transferred to the Dhahran bulk plant, while some products are exported.

02
Mina al Ahmadi
Capacity: 442 000 bpd
Location: Kuwait
Operator: Kuwait National Petroleum Company

The Mina al Ahmadi Refinery (MAA) was built in 1949 as a simple refinery with a
processing capacity not exceeding 25 000 bpd to supply the local market with its
needs of gasoline, kerosene and diesel. The refinery is located 45 km to the South of
Kuwait City on the Arabian Gulf.

Following the establishment of KPC and the restructuring of the oil sector, ownership

3
 广东石油化工学院

of the refinery was passed from Kuwait Oil Company (KOC) to Kuwait National
Petroleum Company (KNPC) which became responsible for the oil refining and gas
liquefaction operations in Kuwait.

In the early 1980s, as part of an overall plan to upgrade the refining industry and
expand the refineries, work started on two ambitious projects to modernise Mina Al-
Ahmadi Refinery, namely the MAA-Refinery Modernisation Project (MAA-RMP)
(which was completed in 1984) and the Further Upgrading Project MAA-FUP (which
was commissioned in 1986). Within the framework of these two projects, 29 new
units were built.

The refinery has become one of the world’s modern refineries in terms of both
refining capacity, which exceeds 460 000 bpd and the advanced technology it
employs.

Mina al-Ahmadi Refinery Modernisation Project (RMP) was intended to provide the
local and world markets with low sulphur content petroleum products, and to reduce
dependence on gas as fuel, providing cheaper and more stable fuel to the country’s
power generation plants.

The Further Upgrading Project (FUP) was based on more comprehensive view of the
future of petroleum product markets in order to maximise profits and ensure a stable
market for the three refineries output.

The project further sought to increase the share of light and medium products of the
distillation process and minimise the share of fuel oil in the end output, resulting in a
higher return from the crude oil refining processes.

The refinery now contains 29 new units, in addition to the old units, including the
crude distillation units, the fluid catalytic cracking unit, the atmospheric residue
desulphurisation units, the vacuum rerun unit and the sulphur recovery unit.

03
Ruwais
Capacity: 417 000 bpd
Location: Ruwais, United Arab Emirates
Operator: Abu Dhabi Refining Company (Takreer)

The Ruwais Refinery was commissioned in June, 1981, and was officially
inaugurated in March 1982, located some 240 kilometers west of Abu Dhabi City.
Soon after commissioning the original 120 000 bpd hydro skimming refinery in June
1981, plans were drawn up to add a 27 000 bpd hydro cracker complex that was
started in 1985.

4
 广东石油化工学院

To consolidate operations, a general utilities plant, set up in 1982 to provide

electricity and water for the area, was merged with the refinery in 1986.

In March 2010, Takreer signed contracts valued at $9.6bn for work to expand its
Ruwais plant. The refiner signed two accords with SK Engineering & Construction
and contracts with Samsung Engineering and Daewoo Engineering & Construction.

Takreer said that the project will serve 3 main objectives including satisfying the
growing demand of high quality petroleum products in the local market as well as
increasing ADNOC’s presence in the international market for finished products while
meeting future stringent specifications.

He also added that integration with the petrochemical industry through exporting 1.1
million tonne per year of propylene to the Borouge Olefins Complex in Ruwais.

This will result in saving investment cost and reduce operating cost to the benefit of
both operating companies. The process configuration consists of 21 major process
units with supporting offsite and utilities units. Currently, Takreer produces liquified
petroleum product, premium unleaded gasoline, naphtha grades, and many other
products.

In June 2010 CB&I have been awarded a contract valued in excess of US$70 million
by Daewoo for the propylene storage tanks for the Ruwais Refinery expansion project
in Abu Dhabi. CB&I is expected to complete its remit in 2013.

04
Rabigh
Capacity: 400 000 bpd
Location: Rabigh, Saudi Arabia
Operator: Petro Rabigh

The Rabigh Refinery, located 165 km north of Jeddah and 185km south of Yanbu on
the Red Sea coast of Saudi Arabia, was commissioned in 1989. Rabigh refinery has a
400 000bpd crude topping facility.

Saudi Aramco assumed full control of the refinery and associated facilities in June
1995. The refinery was constructed by the Italian company Snamprogetti based on
licensed and non-licensed “open-art” technologies.

The refinery was a basic topping refinery (a refinery that only fractionates the crude
oil into constituent products and does not include any conversion processes for
upgrading low value, heavy oil products).

The refinery was originally designed to process 325 000 bpd and a de-bottlenecking
exercise in 1998 resulted in an increase of crude processing capacity to 400 000bpd,
5
 广东石油化工学院

making the refinery the largest single train crude distillation unit refinery in the
world.

The main products are fuel oil, naphtha, and jet fuel. LPG and oil are used as fuel for
the refinery while recovered sulphur is bagged and shipped. In 2003, Saudi Aramco
decided to upgrade the refinery into a fully integrated petrochemical and refining
complex.

It joined hands with Sumitomo Chemical from Japan, and established Rabigh
Refining and Petrochemical Company “Petro Rabigh” to operate the project which
was inaugurated officially in November 2009.

This was Saudi Aramco’s first entry into the petrochemicals business. Petro Rabigh
currently produces 2.4m t/y of petrochemicals products and 18m t/y of refined
products.

05
Yanbu
Capacity: 400 000 bpd
Location: Yanbu, Saudi Arabia
Operator: Saudi Aramco

Like Rabigh, the Yanbu Export Refinery, is located on the Kingdom’s Red Sea coast.
Saudi Aramco and China Petrochemical Corporation (Sinopec) signed an MoU
related to the development of the $10bn project to upgrade the refinery which is set to
process 400 000 bpd of Arabian heavy crude and produces 90 000 b/d of gasoline,
263 000 b/d of ultra-low-sulfur diesel, 6 300 metric tonnes per day (mtd) of coke, and
1 200 mtd of sulfur.

It will use existing Saudi Aramco facilities to receive crude oil and export refined
products. The project’s projected completion date is 2014.

06
Jubail
Capacity: 400 000 bpd
Location: Jubail, Saudi Arabia
Operator: Saudi Aramco

Located in Jubail’s industrial district Jubail refinery is currently undergoing a huge

makeover. The existing refinery will be incoprporated into a mixed use integrated
project by 2013.

Feedstock will come by pipeline from two giant offshore fields, Manifa and Safaniya.
Saudi Aramco Total Refining and Petrochemical Co (SATORP) is developing the

6
 广东石油化工学院

integrated project, which will have a processing capacity of 400 000 bpd, or roughly
20 million metric tonnes a year when completed by 2013.

The product mix of the full-conversion refinery will primarily consist of diesel and jet
fuels. In addition, it will produce 700 000 t/y of paraxylene, 140 000 t/y of benzene,
and 200 000 t/y of polymer-grade propylene. Aramco and Total will share the
marketing of the refinery’s products.

07
Baiji
Capacity: 310 000 bpd
Location: Salahuddine, Iraq
Operator: North Refineries Company

Baiji is Iraq’s largest oil refinery with a nameplate capacity of 310 000 bpd and has
two sections. The refinery, which operates is located 180 km north of Baghdad, but
currently operates at around 70% capacity due to the lack of crude oil feedstock,
frequent power cuts and the general infrastructure problems that Iraq is dealing with
after eight years of war and conflict.

Baiji produces 11 million litres of gasoline per day, 7 million litres of benzene and 4.5
million litres of kerosene.

The refinery was subject to a terrorist attack in early February 2011. The blast
damaged unit six, the hydrogen unit that feeds the refinery’s hydrocracker, and unit
one, the north refinery’s distillation unit.

The refinery resumed normal operations in March 2011.

08
SASREF
Capacity: 305 000 bpd
Location: Jubail, Saudi Arabia
Operator: Saudi Aramco Shell Refining Company (SASREF)

SASREF is a joint venture between Saudi Aramco and Royal Dutch Shell, and is
located in Jubail, in the eastern part of Saudi Arabia.

The refinery has a processing capacity of 305 000 bpd and processes Saudi Aramco’s
crude. “Crude is purchased from Saudi Aramco at the prevailing export price as per
the time of delivery,” says Abdulhakim Abdullah al-Gouhi, SASREF president and
managing director.

SASREF is a full-conversion refinery at maximum crude intake as it includes a

hydrocracker unit, a visbreaker unit, and a thermal gas-oil unit (TGU).
7
 广东石油化工学院

“This leading edge technology further boosts SASREF’s international

competitiveness as a firmly established pacesetter refinery,” he says.

The refinery produces a wide range of products with different specifications, meeting
the requirements of the different markets it targets.

“We produce many products that meet the specifications and the requirements of our
clients, for instance, we produce naphtha, gas oil 0.5% and 500ppm along with
bunker fuel oil that meets Asian specifications,” says Al-Gouhi.

“We are working on producing gas oil 10ppm target to meet the Euro5 summer
specification, as well as the Asia specification,” he adds.

09
Skikda
Capacity: 300 000 bpd
Location: Algeria
Operator: Sonatrach

The 300 000 b/d Skikda refinery, the largest in Africa, came on stream in March
1980. Its first naphtha exports were shipped in April 1980 and full capacity was
reached later that year.

The plant can process 15m t/y of Saharan Blend, pumped through a 34-inch Haoud El
Hamra to Skikda pipeline, and 300 000 t/y of sour crudes imported through the
Skikda oil terminal which is linked to the plant by pipeline.

The plant, often running at more than 350 000 b/d, was built by Snamprogetti and
Saipem under a contract signed in 1974. Its naphtha output consists of naphthenic
grades suitable for re-formulation into gasoline.

A reforming unit and an additional storage tank, built by JGC/Itochu, under a $200m
contract, to turn naphtha into 1.6m t/y of gasoline, were completed in 1993. Algerian
Gasoline imports were then stopped. Exports of naphtha from Skikda have had 75%
paraffins, compared to about 70% before the reformer was built.

The refinery has: two 7.5m t/y crude distillation units; a 9 000 b/d vacuum unit; a 30
000 b/d catalytic reformer; a 1 900 b/d isomerisation unit; a 380 000 t/y aromatics
unit producing benzene, toluene and xylenes; and a 145 000 t/y bitumen unit
producing road and oxidised asphalts. Naftec wants a hydrocracker at Skikda.

Sonatrach is currently renovating the refinery. In 2009, the Algerian NOC awarded
Samsung Engineering a $2.6bn contract to upgrade the facility.

The upgrade operation is expected to increase the refinery’s annual production

8
 广东石油化工学院

capacity from 15 million tonnes to 16.6 million tonnes.

10
Mina Abdullah
Capacity: 270 000 bpd
Location: Kuwait
Operator: KNPC

The refinery was first built in 1958 during the rule of the late Sheikh Abdullah Al-
Salem Al-Sabah, by the American Independent Oil Company “AMINOIL”. It was at
that time a simple refinery that contained one crude oil distillation unit with a
capacity of approximately 30 000 bpd. Mina Abdullah was transferred to KNPC in
1978.

The Refinery Modernisation Project, (MAB-RMP) was launched in mid 1980s, which
was completed in late 1988 and officially inaugurated in February 1989. When it was
completed, the refining capacity had been increased to more than 230 000 bpd.

Besides the crude throughput capacity augmentation, RMP-MAB also envisaged new
dedicated product dispatch facilities and took into account integration with the
existing MAB refinery and also with Mina Ahmadi and Shuaiba refineries.

Following Iraq’s invasion in 1990, the refinery approved a revamp project to remove
the bottle-necks in the refinery utility system. This effort led to a significant increase
in the plant’s refining capacity which is currently running at around 270 000 bpd.

Other sources are:

1. Refiners' Total Operable Atmospheric Crude Oil Distillation Capacity as of January 1, 2016. Energy
Information Administration (EIA), Form EIA-820, "Annual Refinery Report. "
www.eia.gov/petroleum/refinerycapacity/table5.pdf 2016; Table 5, page 38-42
2. Bagajewicz, M. 1998. The Design Flexibility of Crude Atmospheric Fractionation Units. Chemical
Engineering Communications, 166, 111-136. http://dx.doi.org/10.1080/00986449808912383
3. Bagajewicz, M. and Ji, S. 2001. Rigorous Procedure for the Design of Conventional Atmospheric Crude
Fractionation Units. Part1: America Chemical Society Journal, 40 (2): 617–626.
http://dx.doi.org/10.1021/ie000302+
4. Robert Brelsford (Downstream Technology Editor), Nigeria advances programs to rehabilitate, expand
refining capacity. Oil and Gas Journal, 01/02/2017; Table 1-3
5. Husain Al-Muslim; Ibrahim Dincer; Syed M. Zubair. Energy analysis of single and two stage crude
distillation units, J. Energy Resour. Technol. 2003; 125(3):199-207; by ASME.
6. Refinery Capacity Report June 2016 With Data as of January 1, 2016, Energy Information Administration
(EIA) www.eia.gov/petroleum/refinerycapacity/refcap16.pdf.

9
 广东石油化工学院

7. V. V. Fedorov, G. P. Pikalov, Yu. M. Sverdlov, P. I. Korotkov, and V. V. Ektov, Khim. i Tekhnol. Topliv i Masel,
No. 4 (1970).
8. Adoyi, O.B. 2014. Design and Fabrication of Crude Distillation Unit Components for a Mini Petroleum
Refinery. MS thesis, Ahmadu Bello University, Zaira (November 2014)
9. Shuncheng, J.I. 2001. Optimal Design of Crude Oil Distillation Plants. PhD dissertations, University of
Oklahoma College, Norman (2001)
10. Brown, K.B., Maxwell, B.L., Rick, R.V., and Shumway, M.D. 2003. Modular Oil Refinery. United State Patent
No. WO2003031012A1

2. Process design
The typical oil/petroleum refinery is an industrial process plant with many different
structures designed to receive crude oil , processes and refine it into petroleum
products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and
liquefied petroleum gas. Oil refineries are typically very large complexes with
extensive piping running throughout, connecting the various chemical processing
units. To design/model a complete refinery would take up a lot of space on a layout.
So design/model Structures has designed various stand alone structures that can be
purchased separately. This way you can choose and fit the structures you like for your
layout.

10
 广东石油化工学院

2.1. Technological process

11
 广东石油化工学院

2.3. Process flow diagram

12
 广东石油化工学院

3. Process simulation of atmospheric distillation tower

The distillation system consists of a main column coupled with 3 side strippers and 3
pump-around. This main column is a strippers with a sub-cooled condenser. The input
data of this process design is shown below in section 3.2.

13
 广东石油化工学院

3.1. Draw flowsheet

14
 广东石油化工学院

15
 广东石油化工学院

3.2 Input components

The determination of various stream properties in a refinery process needs to first obtain the crude
assay. Crude assay consists of a summary of various refinery properties. For refinery design
purposes, the most critical charts that are to be known from a given crude assay are TBP curve, o
API curve and Sulfur content curve. An illustrative example is presented below for a typical crude
assay for Saudi Arabia Medium crude oil.
Properties of Saudi Arabia Medium crude oil

TBP data of Saudi crude oil

Total yield /wt Middle yield /wt
No. IBP /℃ EP /℃ % %
API Gravity

whole crude 31
1 15 0.8
2 15 65 4.6 2.7 93.3
3 65 80 6.1 5.35 83.8
4 80 100 8.6 7.35 70
5 100 130 12.5 10.55 63
6 130 145 14.8 13.65 57.4
7 145 160 17.2 16 54.3
8 160 180 20.5 18.85 51.4
9 180 200 23.6 22.05 48.8
10 200 230 28.3 25.95 45.4
11 230 250 31.1 29.7 42.6
12 250 275 35.2 33.15 39.1
13 275 300 39.2 37.2 36.2
14 300 320 42.4 40.8 34.2
15 320 350 47.2 44.8 30.9
16 350 365 49.7 48.45 27.5
17 365 395 53.9 51.8 26.8
18 395 425 58.9 56.4 24.5
19 425 460 63.1 61 21.1
20 460 475 65.6 64.35 20
21 475 500 69 67.3 18.8
22 500 530 72.4 70.7 17.3
23 530 560 76 74.2 15
24 560 99.8

16
 广东石油化工学院

Properties of straight-run distillation products

Products Yields /wt% IBP /℃ EP /℃
(1)Naphtha 12.6 65 145
(2)Kerosene 11.1 145 230
(3)Light Diesel 14.1 230 320

(4)Heavy Diesel 7.3 320 365

(5)Residual Oil 50.3 365

3.3 Select properties method

The design property set for crude tower is BK10 or Peng-Rob, we chose BK10 for the
property method in this design. Simulation diagram using ASPEN PLUS illustrate

3.4
Set

streams parameters

Required input incomplete

Streams  Which streams should we input the parameters?

1CRUOIL

17
InputSpecification

1CRUOIL
04KERSTM
07BTMSTM
06HDISTM
05LDISTM Feed
Stripping steam
 广东石油化工学院

 Temperature : set as 200℃

 Pressure: set as 2 bar
 Composition: Mass-frac of SAUDI = 1

Mass flow of 1CruOil

 Processing
Temperature capacity: (0.10×Student number+6) Mt/a, on-stream time: 8000 h/a.
: set as 200℃
 Pressure: set as 2 bar
 Composition: Mass-frac of SAUDI = 1
(0.10×Student number+6) Mt/a
= (0.10 ×13＋6) Mt/a
= 7.3 Mt/a

Operating time for CDU= 8000h/yr

What is mass flow rate?

Mass flow rate = = 7.3Mt / a

0.0009125Mt/h 8000h / yr
Convert Mt/h into Kg/h
Mt = 106 t, 1t = 1000Kg

= 912500Kg/h 0.0009125Mt 106 1000Kg

 
The stream parameters are h Mt 1t
display below using ASPEN PLUS

18
 广东石油化工学院

19
 广东石油化工学院

20
 广东石油化工学院

3.5 Set column parameters

The column parameter for Saudi Arabia Medium crude oil is set according to the
known parameters. The diagram below shows details for the given parameters,
however, the result that will be display later using ASPEN PLUS shows the
optimization results after we have run the result of the previous by setting condenser
temperature to 40oC and using partial vapor-liquid condenser. We discovered the
result does not attained our requirement, so we changed the temperature to 50 oC and
sub-cooled condenser to re-run the result before we attained the requirement.

21
 广东石油化工学院

22
 广东石油化工学院

3.6 Optimizing column

Requirements of streams
(1)What is the requirement?

Properties of straight-run distillation pro STREAMS D86-0 D86-

ducts 100

Yields /wt IBP / 3NAPHTH ≤147℃

Products EP /℃ A
% ℃
4KERO ≥145 ≤232
(1)Naphtha 12.6 145 ℃ ℃

(2)Kerosene 11.1 145 230 5LDIESEL ≥230 ≤322

℃ ℃
(3)Light Diese
14.1 230 320
l 6HDIESEL ≤365
℃
(4)Heavy Dies
7.3 320 365 7RESOIL
el

(5)Residual O
50.3 365 　
il

Blocks 

T1CRUDE

SetupConfiguration

Note: The distillate rate is different for each student, knowing the ratio to feed (0.1507) from the table below, the distillate rate can be obtain by

23
 广东石油化工学院

multiplying ratio feed by F1CRUOIL.

Optimization ratio to feed
Distillate rate kg/h 137514 0.1507
4KEROSEN kg/h 122138 0.13385
5LDIESEL kg/h 127759 0.14001
6HDIESEL kg/h 35032 0.038391
P1-Top Gcal/h -35.66 -3.908E-05
Heat duty P2-MID1 Gcal/h -25.73 -2.820E-05
P3-MID2 Gcal/h -12.92 -1.416E-05
05LDISTM kg/barrel 4
Stripping Steam
07BTMSTM kg/barrel 4

Mathematical expression:
Distillate rate = Ratio feed × F1CRUOIL

0.1507 × 912500 = 137514 kg/hr

Blocks 

T1CRUDE

SetupStreams

24
 广东石油化工学院

Blocks 

T1CRUDE

SetupSteam

Blocks 

T1CRUDE

SetupPressure

Blocks 

T1CRUDE

SetupCondenser

25
 广东石油化工学院

Blocks 

T1CRUDE

SetupFurnace

The flow specification for the mass bottom product for S1KERO is Mathematically
calculated using the ratio to feed of the Stripper in the table above multiply by the
F1CRUOIL i.e
Mass = ratio feed × 912500

= 0.13385 × 912500
= 122138
(same calculation procedure apply to S2LDIES and S3HDIES, using the ratio to feed
of 5LDIESEL and 6HDIESEL, we can get the parameter for bottom product mass of S2LDIES and
S3HDIES respectively).

Blocks 

T1CRUDE

Strippers

S1KERO

26
 广东石油化工学院

Blocks 

T1CRUDE

Strippers

S2LDIES

Blocks 

T1CRUDE

Strippers

S3HDIES

27
 广东石油化工学院

Blocks 

T1CRUDE

Pumparounds

P1-TOP

Blocks 

T1CRUDE

Pumparounds

P2-MID1

28
 广东石油化工学院

Blocks 

T1CRUDE

Pumparounds

P3-MID2

(Below show the result for Pumparound P1- TOP, P2-MID1, P3-MID2)

3.7
Get

hydraulics data

29
 广东石油化工学院

BlocksT1CRUDE

Tray Sizing1 |

Specifications

30
 广东石油化工学院

3.8 Optimization results

Optimization column result Saudi Arabia Medium crude oil for Student ID 13:
Blocks  T1CRUDE Stream Results Saudi Oil, Student
NO. =13
Vol.% Curves

| ASTM D86 curve

31
 广东石油化工学院

3.9 Simulation results (Material balance and energy balance)

Table 1 Mass balance of the CDU
Input Output
Item wt% Mass flow rate/kg/h Item Yield/wt% Mass flow rate/kg/h

Naphtha
14.76 137514.0

Kerosene
13.11 122138.0

Light diesel
13.72 127859.0

Crude oil 100

912500 Heavy diesel
3.75 34932.0

Atomospheric residue
52.63 490355.1

32
 广东石油化工学院

Total 100 19170.1　 Total

100 931670.2　
Stripping Steam ---
12.8
Side stream 1
2445.3
20.0
Side stream 2
3836.3 Condensed water
2.03 18872.1
1.3
Side stream 3
251.3
65.9
Bottom steam
12637.2

4. Size calculation of tower

Using Souders-Brown method:

wc v  l v  
1
2

w680 0.3681 39.460.3681 

1
2

 2579.4lbs / hr  2579
 ft  1548 .84
12.946.4ftlb / sec 3
hr ( .ftft ) 22

Tower 3600 sec 0.3681

 795.lb / ft
9 ft 2
3

cross-section area 1.946

4.1. Tower diameter

Diameter 4  2
1

   152 ft 2   13.9 ft  4.24m

 
Diameter 4
1
 2
   795.9  31.83 ft  9.7 m
4.2. Tower height  

H  Ns  trayseparation
 0.7  52  36.4m  119 .4 ft

5. Tray Hydraulics calculation

Top Bottom

Vapor rate, ft3/sec 1548.40 186.04

Liquid rate, gpm 4561.48 2821.20

Vapor density, lb/ft3 0.3681 0.0416

33
 广东石油化工学院

Liquid density 39.46 47.77

Surface tension, 11.27 13.71

dynes/cm
From fig. 8-82, c = 680 for 32.5in
Surface tension = 11.27
Using Souders-Brown method:

wc v  l v  
1
2

w680 0.3681 39.460.3681 

1
2

 2579.4lbs / hr  2579
 ft  1548 .84
12.946.4ftlb / sec 3
hr ( .ftft ) 22

Tower 3600 sec 0.3681

 795.lb / ft
9 ft 2
3

cross-section area 1.946

Diameter 4 
1
2
   795.9  31.83 ft  9.7 m
 
Using Hunt equation:
Assume: hc = hw + how = 1.5in
Si = St - 2.5hc = 32.5in - 2.5 (1.5in)
= 28.75in
At surface tension = 11.270 dynes/cm
For ρw = 5％ = 0.05

Fig. 8 -121 feeds: allowable tower velocity = 10.2ft/sec

Required tower area 
1548.84 ft 3 / sec
 151.85 ft 2  152 ft 2
Diameter 10
4. 2 ft / sec 
1
2
   152 ft 2   13.9 ft  4.24m
Select tower diameter =  
14ft
Tray layout based on 14ft diameter tower
32.5  7.48
  27.0
2
Downcomers area = = 6.0ft 4561.489
 7.04  7 ft 2
32
27 .5  0.4
(60 1)
 0.36  0.4
Total Tower Area 9
  (14) 2  153.9 ft 2
4
Percent of Tower Area 
6.0
 100 0 0  3.9 0 0
153.9
Using figure 8-100 for segmental downcomers at 3.9% downcomer area, the weir
length is 39.2% of tower diameter.

Weir length  39.2 

(30)
 11 .76
Downcomer Area = 100
0.068(153.9ft2) = 10.47ft2
Hole size
34
 广东石油化工学院

Try 3/16-in, pitch

This is spacing of 2.66 d0, and is as close as good design would suggest.
Use 1/8-in. tray thickness.
Ratio d0/c 3
Percent Hole Area =14.5% (of  16  3  0.375
perforation area only) as shown 1 8
in fig. 8-143. 2
Minimum Hole Velocity: Weeping
Assume: V0 = 23.9 (0.3672) 1/2 = 14.5 1
(V ) 2  / 2 
Assume: Submergence = 1.5-in  neglecting
= hsi = hdi
Dry Tray Pressure Drop, hdt

VC 222
0 0
water
= 0.003 (V) () (1-) / L

The Hole diameter/tray thickness 3

 16  1.5
1
ratio 8

From fig. 8-128, orifice coefficient, Co = 0.78, = 0.128
0.003(14.5) 2 (62.3 / 39.46)(1  (0.128) 2 )
hdt = = 1.61
(0.78) 2

in.liquid

Effective Head

For hsi = 1.5, Fs < 14

Read figure 8-130; effective head = 1.58 in.liquid

Total Wet Tray Pressure Drop

ht = 1.61 + 1.58 = 3.2 in.liquid

Weep Point

Using figure 8-131,curve A1 and ht = 3.2 in.liquid

1
Real Weep Velocity = 16.4 = Vom (v ) 2

35
 广东石油化工学院

Curve A is used when in doubt, and it gives a higher minimum Vom, which is on safer

side for design.

1
Because Vom = 16.4 is greater than the (v ) 2 assumed value of 14.5, therefore 14.5

will be used.

Maximum Hole Velocity at fluid conditions

1
Assume Fs = V0 = 20max (V ) 2

Dry Tray Pressure Drop = Fs [  ](1   ) / C0
2 water 2 2

0.003
0.003( 20) 2 (62.3 / 39.46)(1  (0.128) 2 )
== 3.06
(0.78) 2

in.liquid

Effective Head, he = 3.1 in.liquid

For Fs > 14 and hsl = 1.5

Total Wet Tray Pressured Drop, ht=3.06+3.1=6.16 inches liquid

Liquid Back-up or height in downcomer

Hd  ht  (hw  how )    hd

Hd = 6.16+1.5+0+0(assumed

to be confirmed) = 7.66 inches liquid

32
St.5
The limit on Hd for flooding is = = 2 16.25 in.

Therefore Fs = 20 appears to be close to maximum

Design Hole Velocity

Select a velocity represented by Fs factor between minimum and maximum limits.

20 > design > 14.5

36
 广东石油化工学院

Select a medium value of Fs=17, because freedom to operate above and below the

design value is preferred in this case.

Design Basis

Fs = 17
hw
1) Weir height selected = = 1.0 inch
how
2) Height of liquid over weir,= 0.52 in.
lw
From figure 8-104 at 4561.48gpm and = 11.5ft
( f )(hhwsl)  how
3) Submergence,= = (1) (1.0) +

0.52 = 1.52 in.liquid

4) Downcomer pressure loss. Clearance between bottom of down comer and plate =

1-inche max.Underflow area = (9.5in)(1in)/144=0.065ft2. Because this is less than

the downflow area (of 0.334ft2), it must be used for pressure drop determination. No

inlet weir used in this design.

2 2
 lg   4561.68 
hduacross  0.56   0.56   13681in  liquid
 449( Ad )   449(0.065) 

restriction.

5) Dry Tray Pressure Drop

hdt = 0.003 (17)2 (62.3/39.46) [1- (0.128)2] /(0.78)2 = 1.33 in.liquid

6) Effective Head

hsl=1.52in.

He = 3.1in.liquid for Fs >14, Fig.8-130

7) Total wet tray pressure drop

ht=1.33+3.1=4.43in.liquid
37
 广东石油化工学院

8) Total tower pressure drop for 52 trays.

( 4.43)(52) 39.46  47.77
 P (tower )  ( )  5.8 psi
An actual 1728cu.in / cu. ft 2
operating tower measured 6Psi + or -. it is satisfactory to average the conditions for
top and bottom of tower when flows do not vary significantly. Otherwise, parallel
determination must be carried through for top and bottom (and even feed in same
cases) conditions.
9. Number of holes required
Hole size selected = 3/16 inches
Hole spacing or pitch = 1/2 inches
From figure 8-144, holes/inches2 . plate area =4.62
Area of 3/16 inches hole = 0.0276 inches2

Calculation summary
Maximum velocity Design Velocity Weep velocity
Fs = 20 17 14.5
Vo top
17 14.5
=20/(.3681)1/2o 1
 28.0 1
 23.9
= 32.9ft/sec (0.3681) 2
(0.3681) 2

Vo Bottom 17 14.5
= 20/(0.0416)1/2 1
 83.3 1
 71.1
= 98.1ft/sec. (0.0416) 2
(0.0416) 2

No. Holes required:

CFs at top = 1548.84
No. Of holes
1548.84(144)
 245620.19 1548.4(144) 1548.84(144)
32.9(0.0276)   288521.74   338113 .15
= CFs at Bottom = 158.0 28.0( 0.0276) 23.9( 0.0276 )
No. Of holes
186.04(144) 186.04(144)
 9894.43   13651.81
98.1(0.0276) 186.04(144) 71.1(0.0276)
  11652 .38
= 83.3(0.0276)

38
 广东石油化工学院

Reference
Applied Process Design For Chemical And Petrochemical Plants, Volume 2 化工装置实用工业设
计
Process Simulation Refinery Process Sampler Modelling and Optimization John E. Edwards
Process Simulation Engineer, P & I Design Ltd. First Edition, June 2013
P&I Design Ltd
Refiners' Total Operable Atmospheric Crude Oil Distillation Capacity as of January 1, 2016. Energy Information
Administration
Refinery Process Design Dr. Ramgopal Uppaluri Department of Chemical Engineering
Indian Institute of Technology Guwahati North Guwahati – 781039, Assam, India
Separation Process Principles: Chemical and Biochemical Operations. 3rd ed. Hoboken, NJ: Wiley,
2011. Print.Seader, J. D., Ernest J. Henley, and D. Keith. Roper.
Transport Processes and Unit Operations, Third Edition, Prentice Hall PTR (1993)C.J. Geankoplis,
Operating Instructions for Complete Model "A", Laboratory Distillation Unit, SDSM&T, Serial No.
4269, Brighton Corporatio n (196
Perry, Green and Maloney, Chemical Engineers' Handbook, Sixth Edition McGraw-Hill Book Co.
(1984).

39
 广东石油化工学院

40