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GT-DWCSM
Achieving Better Product Specs
in Existing Naphtha Splitters

Engineered to Innovate®
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

GT-DWCSM
Achieving Better Product Specs in Existing Naphtha Splitters
Dividing Wall Column (DWC) technology is being more widely accepted throughout the process
industries as a means to increase efficiency and reduce capital and energy costs. To illustrate the
advantages of applying DWC for the revamp of existing distillation columns, we will observe a fluid
catalytic cracking (FCC) unit at a refinery owned by a major refinery corporation in India.

This unit separates cracked naphtha into three streams, including wide boiling cracked naphtha.
However, a significant overlap was noticed between the side cut and the bottom product due to
poor degree of separation. In the process flow scheme, the side cut product (heart cut naphtha) is
transported as feed to a platformer unit. Due to the high amount of heavy boiling components in the
stream, additional processing is required to meet the platformer unit feed specifications.

A possible solution to this problem is to construct an additional column for removing the heavies
from the stream. However, this requires the added challenges of new equipment costs, higher
operating costs and limited space available in the refinery.

The refinery considered the following options for the proposed revamp: 1) a two-column
configuration, or 2) a Dividing Wall Column (DWC).

The existing naphtha splitter column has additional margins in the hydraulic capacity of the column,
reboiler and condenser. Hence, in this particular case, retrofitting the column with a dividing wall
will eliminate the need for an extra column for more efficient separation. Having reviewed all the
options, the refinery came to the conclusion that incorporating DWC technology will not only meet
the desired product specifications but also lower OPEX and CAPEX substantially when compared to
adding a second column.

The FCC naphtha splitter column separates the feed into three products—light, heart cut and heavy
naphtha. The light and heavy products are routed to different gasoline blending pools, while the heart
cut naphtha goes to a CCR platforming unit to be used as feed in a future application.

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 1
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

Light Naphtha

Heart Cut Naphtha

LCO Reboiler

Depentanizer Bottoms

HCO Reboiler

Heavy Naphtha

Fig. 1: FCC Naphtha Splitter Unit

The heart cut naphtha stream contains high amounts of aromatic-rich streams (C8A and C9A
precursors) that maximize the conversion in the CCR platformer unit to para xylene precursors and,
as a result, increase profits. Figure 1 shows the original design of the FCC naphtha splitter unit.

In the original design, the heart cut naphtha product is removed as side cut from the column, while
light and heavy naphtha products are removed from the column top and bottoms respectively. Feed
enters the column above the side draw location. Withdrawing the side draw from below the feed
nozzle generally results in a spill over of heavy boiling components, thereby downgrading the quality
of the heart cut. On the other hand, a side cut location above the feed nozzle downgrades the quality
of the initial boiling point for the heart cut naphtha and increases the reboiler duty. Therefore, in
attempting to reduce the reboiler duty to some degree, the original design placed the feed nozzle
above the side cut product tray by compromising on end point specifications.

Consequently, a high overlap (heart cut naphtha D86 95% – heavy naphtha D86 5%) of 37oC
in the side cut and bottom streams was observed. It became necessary to remove the heavier boiling
components in the side cut to lower the final boiling point from the original operation value of
190 –198oC to below 180oC. A boiling point higher than that leads to rapid coke formation and
catalyst deactivation in the downstream platformer unit.

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 2
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

A A

B
Feed Feed
(A, B, C) (A, B, C)

C C

Fig. 2: Thermodynamic inefficiencies observed in side cut columns based on the location of the feed and side cut

Objective
In revamping the naphtha splitter column, the main objective is to improve the heart cut naphtha
throughput by maximizing C8A and C9A precursors in the existing column. Adding a new column
in series to the existing column can be a possible alternative, but the refinery wants to identify an
option that requires minimal capital and operating costs as compared to a two-column configuration.

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 3
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

(A)

0
Column 1

(B) 10
Feed 15
(A, B, C)

Tray Number
20
Column 2

25
30

35 Remixing

40

45
0 0.2 0.4 0.6 0.8 1
(B, C) Composition: Mole Fraction

(C)

Fig. 3: Thermodynamic inefficiencies observed in a two-column configuration as seen in its performance

Analysis of Different Options

Two-Column Configuration: Adding a second column to process the heart cut naphtha requires
maximum heating and cooling duties due to unavoidable thermodynamic inefficiencies in the system.

In separating three components (A, B and C) using a two-column configuration as shown in Figure 3, A is
removed from the first column top while B and C are sent to the second column in series to be separated.
Separation of B has already happened at the middle of the first column. However, this concentrated
stream of B subsequently remixes with C and travels to the second column for a second separation. This
eventually increases the heating and cooling medium required for the separation of the three components.

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 4
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

Dividing Wall Column: The refinery considered revamping the existing column using DWC
technology. Following recent commercialization successes, DWC has seen a revival as plant operators
seek intelligent solutions to increase profitability by reducing operating expenditure with low cost
investments.

DWCs are capable of producing high purity products within a single column shell with less energy
consumption as compared to regular distillation columns. The wall divides the column into two halves,
with one side of the column acting like a pre-fractionator as shown in Figure 4. The wall separates the
feed and pre-fractionator section from the main fractionator section and side-draw. This permits better
separation of the low and high boiling fractions in the feed section with minimal change in energy
requirements. The medium boiling fraction is concentrated in the draw-off section of the column.

A A

B B

Feed Feed
(A, B, C) (A, B, C)

C C

Fig. 4: Typical Divided Wall Column Configuration

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 5
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

Results and Discussions

The naphtha splitter column was revamped using GTC’s GT-DWCSM technology in early 2015. As
shown in Figure 5a & 5b, the naphtha splitter is shown pre and post-revamp. Figure 5b indicates the
modifications made in the column during the revamp. No major modifications were performed outside
the column. These modifications were implemented while the FCC unit was shut down.

Light Naphtha

Heart Cut Naphtha

LCO Reboiler

Depentanizer Bottoms

HCO Reboiler

Light Naphtha

Heart Cut Naphtha

LCO Reboiler

Depentanizer Bottoms

HCO Reboiler

Heavy Naphtha

Fig. 5a (top): Original design of Naphtha Splitter Column; Fig. 5b (bottom): Naphtha Splitter after revamp to GT-DWCSM

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 6
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

Test runs conducted after the FCC start-up to evaluate the performance of DWC shows substantial
improvements in terms of quality. Following are observations based on the test results:

. The overlap between the heart cut naphtha and heavy naphtha was reduced from 37oC to
-3oC. The positive gap indicates good separation between heart cut naphtha and heavy naphtha
product. Reboiler duty utilized was much less as compared to the expected requirements in the
two-column solutions.

. The naphtha splitter overhead air condenser duty increased by 15%. This did not require any
modification due to the excess hydraulic capacity available before the revamp.

. Compared to the standard two-column configuration, DWC provided major savings in

operating costs and capital costs.

. The modifications outside the column were kept to a minimum which would have not been
possible if an additional column was required.

Naphtha Splitter Naphtha Splitter after

Parameter Units
before Revamp Revamp to GT-DWCSM

Side Draw Flow Rate TPH 180.4 151.0

D86 (IBP/FBP) Deg˚ C 110.5 to 190.6 110.5 to 172.0

Table 1: Heart cut naphtha product specifications before and after revamp

Fig. 6: Top view of a Dividing Wall Column Fig. 7: GT-DWC tray with Dividing Wall

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 7
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

. The application of DWC in this particular case provides ample benefits to the refinery.
However, one must always keep in mind that applying DWC technology to existing units can
be a challenge and needs a thorough review of the design. To optimize the design, following
guidelines may be considered prior to making a decision.

. DWC essentially combines two columns into a single column. Hence, extra hydraulic margins
are required in the column to accommodate the increased vapor-liquid loads.

. Additionally, as shown in this case, a middle DWC utilizes a common column overhead
condenser and reboiler. The overhead reflux flow required to distribute the liquid between both
sides of the dividing wall column will increase after revamp. A hydraulics adequacy check must
be performed for the overhead reflux pumps, the overhead condenser and its piping. Similarly,
additional reboiler duty will be required to generate surplus vapor and send it to both sides of
the dividing wall. If extra margin is not available in the associated equipment, revamp to DWC
will require supplemental equipment to provide the same. This might lead to an increase in the
CAPEX for the revamp.

Fig. 8: GT-Smart LiquidSM Arrangement

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 8
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

Fig. 9: Testing Facility for GT-Smart LiquidSM Arrangement

Conclusions
.
DWC technology was successfully implemented for the first time in a unit for a FCC naphtha
splitter column at a major refinery complex in India. Considerable benefits have been realized in
terms of:

ºº Improvement in the separation of heart cut naphtha and heavy naphtha product. The
improved heart cut naphtha quality greatly enhances the CCR platformer conversion.

ºº Improved separation has been achieved within the original design reboiling and cooling
duties, thereby eliminating the necessity for new equipment.

. DWC becomes highly profitable in cases where adequate hydraulic margins are available in the
original column and the associated equipment. Otherwise, new equipment will be required
affecting the CAPEX for the project.

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 9
 Achieving Better Product Specs
GT-DWCSM in Existing Naphtha Splitters
M. Bhargava and R. Kalita, GTC Technology US, LLC, Houston, Texas; Engineered to Innovate®
and B. Fleming, GTC Process Equipment Technology, Euless, Texas

GTC Technology US, LLC

Please send inquiries to rkalita@gtctech.com or visit GTC’s web site at www.gtctech.com.
page 10