Section 04 - Fractionation

Fractionation
Task Checklist
X Introduction TOWER SIMULATION
Z Basic Concepts Z Specifications
DEVICE SELECTION
Z Contacting Devices Z Tray Hardware Definitions Z Tray Hydraulics Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
Did You Know?

Oldest and most important petrochemical manufacturing process
Equipment accounts for 30% of all investments today
Consumes 70% of all energy at plant
More on Fractionation
Separate feed into products according to boiling point
Products sent to finished product tank or further processed by other units
Multiple products and feeds common
Objective Questions
How can you improve separation efficiency?
How do you decide on the optimum number of trays for a new tower?
What sets a towers operating pressure?
What are my options to increase a towers vapor / liquid handling capacity?
Designers Role
Perform HMB calculations to develop tower loadings New Towers
Select optimum tower size, contacting device, and internals to meet process requirements
Existing Towers
Select optimum contacting device and internals to improve performance or expand capacity Screening - Apply Concepts to Troubleshoot Problems
Prepare Design Package (Consult with Specialist)
Engineers Toolbox
XOM DP Section III (Intranet)
Simulation Tool (PRO/II or HYSIS)
Pegasys ExxonMobil Tower Internals Program - EMoTIP
Fractionation Specialists
Task Checklist
X Introduction
TOWER SIMULATION X Basic Concepts

Z Specifications
DEVICE SELECTION
Conventional Tower
R D
Reflux Ratio = R / D
Rules of Thumb
More Reflux
More Trays
More Separation
Lower Pressure
10
BINARY DISTILLATION: MCCABE - THIELE DIAGRAM
11
MINIMUM REFLUX
12
TOTAL REFLUX - MINIMUM STAGES
13
Stages Versus Reflux
14
Optimum Reflux Ratio
15
ESTIMATING ACTUAL REFLUX RATIO AND ACTUAL NUMBER OF STAGES
General Rule of Thumb-R ACTUAL = (1.1 TO 1.35) x R MIN
16
Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts
X Specifications DEVICE SELECTION

17
Operating Pressure
Factors to consider:
Temperature of available condensing fluid (air, water, etc.) Wheres the overhead product go? Is the overhead totally condensed? Possible Limitations:
+ Bottoms temperature (cracking / color) + Reboiler + Critical Point (poor separation)
How much pressure drop is acceptable?
18
Operating Temperature
Fixed once product specifications and pressure are set
Dew Point Calculation

Overhead temp.
Bubble Point Calculations

Bottoms temp.
Flash Calculations
Reflux temp.
19
Feed Condition
If not specified, start with bubble point feed - Then optimize.
Adjust temp. to balance tower loading
Other Considerations:
Reflux vs. Reboiler Duty / Costs Quenching
20
HIGH FEED TEMPERATURE
RECYCLE GAS COMPRESSOR
PRODUCT
OVERRIDE
A
VAPOR PRESSURE SULFUR
FEED
FUEL GAS CONTROL: FEED RATE PRODUCT VAPOR PRESSURE PRODUCT SULFUR OVERHEAD DRUM LEVEL
21
Simulation Inputs
Feed Rate and Composition VLE Data Method Specifications & Control Variables Operating Pressure Initial Guess (If Required) For Rating:
Plant Test Data
Pressure, Temperature Profile Lab Data (Complete Set of Samples)
Tray Efficiencies
See DP III-I Table 2; Estimates from Past Designs
22
Tower Specifications
Specifications: usually on product quality or temperatures
Can be mathematical Avoid specifying rate. Better to specify % recovery or fraction. Condenser temperature
Variables: usually condenser / reboiler duty
23
ProII Condensers
Stage 1, if present Different Types
24
ProII Reboilers
Last Stage(s) Kettle or Thermosiphon
Kettle Thermosiphon specify if have baffle or not
25
KETTLE REBOILER
Advantages: + Additional fractionation stage Disadvantages: - Low NPSH to downstream pump - Very low hold-up - Tubes can dry out - High temperature increase - Large plot space
26
VERTICAL THERMOSIPHON REBOILER

-Advantages: + Partial fractionation stage + Low plot space + Low temperature increase Disadvantages: - Partial fractionation stage - High circulation rate - Pressure drop critical - Limited duty - Difficult to clean
27
HORIZONTAL THERMOSIPHON REBOILER

-Advantages: + Partial fractionation stage + Large duty + Low temperature increase + Lower P than vertical Disadvantages: - Partial fractionation stage - High circulation rate - Pressure drop critical - Large plot space - Large piping
28
Column Stage Summary

Number of Stages
Condenser (1) Theoretical Trays (#)
Can also use Actual Trays * Tray Efficiency Efficiency will be different above and below feed
Reboiler (1 or 2)
29
Simulation Strategy
Optimize Reflux Ratio, Stages, Feed Condition, and Feed Location
30
Simulation Pitfalls
Save / Backup cases often.
Viscosity (high temperature), other properties may need to be verified.
Others?
31
SIMULATION RESULTS
32
Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION X Contacting Devices

Z Tray Hardware Definitions Z Tray Hydraulics Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
33
Device Categories
Conventional Trays High Capacity Trays

(Proprietary)
Random Packing Structured Packing Baffles, Sheds, and Grid
34
Conventional Trays
Sieve
Most Widely Used 2:1 Turndown Low Cost (Nonproprietary)
Valve
Up to 5:1 Turndown 5-10% higher capacity over sieve Marginally higher cost Not recommended for fouling services
Bubble Cap
Standard until 1950s High Cost Maintenance / Inspection Difficult Excellent Turndown
Jet
hExxon Design for High Liquid Loads Efficiency ~20% less than sieve Mainly used in pumparounds
35
Pumparound Definition
Method to provide tower reflux by cooling tower liquid
Draw-off intermediate liquid Cool liquid by pumping it through heat exchanger Return liquid to tower Use trays/packing to return
Can provide high value heat

Reduces OH condenser duty Reduces furnace duty
Reduces liquid traffic in tower

Can reduce tower diameter Increases tower height since pumparound trays are for heat transfer, not fractionation
36
High Capacity Trays

High Performance Fixed Valves (Increase vapor handling capacity)
Koch-Glitsch
PROVALVE
Sulzer
MVG

37
Directional effect reduces fouling and vapor jetting/entrainment 10-15% jet flood capacity advantage to 1/2 (13mm) sieve trays
High Capacity Trays (Cont.)

Enhanced Downcomer (Increase vapor handling capacity)
Koch-Glitsch
Nye MaxFrac SuperFrac Triton
Sulzer
MVG-T (not shown)
38
High Capacity Trays (Cont.)

Multiple Downcomers
UOP
MD and ECMD
Sulzer
Shell HiFi
~20% higher capacity, but lower efficiency than conventional sieve tray Limited access; not recommended for fouling (Very difficult to clean / inspect)
39
MD and ECMD Tray Unit Cells
40
Want More High Capacity Tray Information?

Read recently released:
EE48E2008, Application Guidelines For Debottlenecking Light Ends Towers With Enhanced Capacity Fractionation Trays
41
Random Packing
3RD Generation
CMR IMTP Nutter Ring Rashig Super-Ring
2ND Generation
Pall Ring Flexirings Ballast Rings Slotted Rings
1ST Generation
Berl Saddle Intalox Saddle Rashig Ring
42
Random Packing (Cont.)

Packing can usually provide higher capacity and better efficiency than trays. As size increases, the capacity increases while the pressure drop, cost, and efficiency decrease. Usually not first choice for new designs
Consider for:
Small tower diameter (<3 or 915mm) Low [critical] pressure drop applications (i.e. vacuum distillation, etc.) Need to minimize tower size (offshore) Revamps where acceptable tray design cannot be achieved See DP III-A, p. 34 for others applications
43
Packing Warning
DP III-G (Packing and Grid)
Fire Hazard: Some sites prevent hot work above a packed bed
44
Structured Packing
Conventional
Koch-Glitsch: Flexipac, Intalox Sulzer: Mellapak Montz: Montz-Pak Type B1
High Capacity
Koch-Glitsch: Flexipac HC, Intalox Sulzer: Mellapak Plus Montz: Montz-Pak Type M
45
Structured Packing (Cont.)
Why Structured Packing?

Lowest pressure drop per stage Best capacity / efficiency combination device Less sensitive to liquid maldistribution than random packing Recently, cost is much more competitive with random packing
Why Not Structured Packing?

Not recommended for high pressure towers - above 100 psia (7 kg/cm2) due to poor test results, or where liquid rate exceeds 20 gpm/ft2 (13.6 dm3/s*m2) unless application is high pressure aqueous system.
46
Grid
Used for entrainment removal where fouling is too severe for a crinkle wire mesh screen (CWMS) High Open Area
Prevents plugging
Low Surface Area

Low efficiency
47
Baffles
Large Open Area

Prevents plugging
Low Liquid Residence Time

Prevents coking
48
Practice Tower Internal Type

What type of tower internal would you use for the following?
Desuperheating reactor effluent in bottom of a fractionator? Vacuum fractionator High pressure light ends tower 24 (610mm) diameter absorber Recycle gas absorber (remove H2S from H2) Tail gas absorber (remove H2S from Sulfur Plant effluent) Pumparound section of large fractionator
49
Device Selection Criteria

Fouling Tendency Good Liquid & Vapor Handling Capacity Good Contacting efficiency Acceptable Pressure Drop Predictable Turndown Characteristics Economical
See DP III-A Tables 3-5
50
Device Selection Procedure

New Design
Start with trays, unless pressure drop is critical. If need low dP, consider 2 (50mm) random packing. Calculate optimum tray spacing, diameter, and layout (i.e. bubble area and downcomer dimensions) by trial and error to avoid downcomer and jet flood limitations.
(Use Pegasys / EMoTIP)
Revamp
Rate existing contacting device to identify potential limitations (i.e. downcomer, jet flood, etc.)
(See Table 1 Design Principles in appropriate DP III Section)
Identify new layout and device where all design parameters are satisfied
(Use Pegasys / EMoTIP)
Consider:
Multi-pass Conventional Trays High Performance Fixed Valves Enhanced Downcomer Trays Multiple Downcomer Trays Packing
Then select best device type based on Device Selection Criteria.

(See DP III-A Tables 3&5 Decision Trees)
Dont consider High Capacity Trays for new towers - Instead Increase Diameter, etc.
51
Trays vs. Packing

XOM DP III-A Table 3D -- Fouling Tendencies
52
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices
X Tray Hardware Definitions

Z Tray Hydraulics Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
53
Common Pass Arrangements
54
Downcomer Types
Stepped / Sloped: Provide sufficient DC inlet area for adequate vapor / froth disengagement while maximizing bubble area
55
Downcomer Expansion
Can expand downcomer without welding
Commonly called Z-bar or downcomer adapter
Exiting Tray Support Ring
Exiting Downcomer Bolting Bar
Koch-Glitsch supplied Downcomer Adapter
56
Weir Types
Picketing: Can reduce spray regime operation by increasing effective liquid height; Also used to balance multipass designs by making their effective weir lengths the same.
57
Downcomer Seal Techniques

Design should ensure vapor cannot bypass a tray by flowing upward through the DC resulting in poor efficiency.
Process Seal
Mechanical Seals
58
Area Definitions
Also see DP III-A, Figures 12-13
59
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions
X Tray Hydraulics
Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
60
Hydraulic Limitations
VAPOR Jet Flooding Ultimate Capacity Flow Regimes Entrainment
LIQUID Downcomer Backup Secondary Limitations:

Liquid Rate per Inch of Weir Downcomer Choking Velocity Under the Downcomer Downcomer Seal
61
FRI VIDEO
62
Jet Flooding
At high vapor rates, liquid is jetted to tray above Vapor handling limitation; sets design in most cases Expressed as Percent; Rigorously Calculated
(See DP III-B / Use Pegasys)
Related to vapor velocity through the free area
Strong function of:

Tower Diameter Tray Spacing
63
Jet Flooding and Efficiency

XOM Jet Flood Limit
85
Late Breaking News: XOM Jet Flood Limit now 80% for new designs
64
Problem Jet Flood

What steps can we take to reduce jet flood, and what are the drawback for each?
65
Ultimate Capacity
Highest vapor rate tower can handle -- Stokes Law Cannot be increased by hardware changes; only way to increase it is by increasing the tower diameter
66
Flow Regimes
To Eliminate Spray Regime:

Use Picket Fence Weirs Increase Open Area Use Smaller Sized Orifices Use Valve Trays
67
Entrainment
Liquid [drops] carried by the vapor to the tray above
Design should limit entrainment to 10% of the tray liquid rate
Function of:
Vapor Rate Liquid Rate Tray Spacing Other Hardware Parameters
68
Downcomer Backup
DC froth height expressed as percent of tray spacing plus the weir height
DC Filling Components:
hi = inlet head; f(inlet & outlet weir) ht = total tray dP hud = head loss under DC; f(DC Clearance) hdc = head loss due to two-phase flow in DC
69
Percent Downcomer Flood

Performance criteria to see how close a tower is to flooding as a result of excessive froth height in the downcomer Represents actual vapor / liquid rates as a percent of the rates which cause 100% DC Backup Rigorously Calculated
(See DP III / Use Pegasys)
70
Flooding Symptoms
Jet Flooding
Tower unstable Liquid entrainment into overhead system; sharp increase in reflux rate with no separation improvement Pressure drop increases sharply with a small incremental increase in vapor rate Separation efficiency gradually decreases
Downcomer Flooding
Tower unstable, surging High pressure drop with a small increase in either vapor or liquid rate Separation efficiency suddenly decreases Loss of tower bottoms liquid level
71
Problem Downcomer Backup

What parameter has a 2x affect on downcomer filling? Name steps we can take to lower downcomer filling, and what drawbacks for each.
72
Secondary Liquid Hydraulic Limitations

Liquid Rate per Inch of Weir
The accuracy of the Jet flood and DC Flood correlations can only be ensured within the range of liquid rates used to develop them.
Downcomer Choking results when the DC inlet area is too small. Velocity Under the Downcomer
If too high, can produce channeling effect leading to vapor / liquid maldistribution on the tray.
Downcomer Seal
If not sealed, vapor can bypass the tray and flow upward through the downcomer resulting in reduced efficiency. Two types:
Mechanical [Static] Process [Dynamic]
73
Tray Hydraulics
DP III-B P.20-22 SIEVE TRAY DESIGN PARAMETERS
74
DP III-B P.20-22 SIEVE TRAY DESIGN PARAMETERS
75
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics
X Packing Hydraulics
Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
76
Packing Hydraulics
Packing Hydraulics
Flooding -- (Use Pegasys)
Harder to define than tray hydraulics (i.e. no tray spacing or downcomer
to fill with liquid)
As vapor rate increases, liquid accumulates and the pressure drop begins to rise more sharply. With further increases in vapor rate, the pressure drop rises almost vertically and liquid stacks up on top of the packing.
Ultimate Capacity -- (Use Pegasys)

Similar to tray hydraulics
77
Packing Hydraulics
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics
X Other Process Considerations

Z Other Tower Internals Z Tower Revamps
78
Packing Hydraulics
Tray Efficiency
Overall Efficiency, EO, is a measure of the effectiveness of an entire tower or tower section. Allows designer to determine the number of actual trays to provide and sets the tower height.
Actual Trays = Theoretical Stages / EO

Calculated Rigorously - Use Pegasys
(See DP III-I)
Factors affecting EO:

Weir Height Flow Path Length and Number of Passes (i.e. Residence Time) Weeping or Vapor Recycle VLE Properties and Tower Loading
79
Other Process Considerations
Calculation of Tray And Packing Efficiency

# of theoretical trays = # of actual trays x tray efficiency Screening Estimates - See DPM III-I Table 2 for historical efficiencies Figure 8 for heavy hydrocarbons Rigorous Methods - DPM III-G (Packing) & DPM III-I (Trays) Plot y* vs x for light key and heavy key y* = vapor mole fraction in equilibrium with liquid x = liquid mole fraction Input slope into PEGASYS tray program
80
Estimating Tray Efficiency
81
Estimating Tray Efficiency, Heavy Hydrocarbons
82
Packing Height
To specify correct packing height, designer must calculate height equivalent to a theoretical plate (HETP)
Packing Height = Theoretical Stages x HETP

HETP must be calculated rigorously - Use Pegasys
(See DP III-G)
Other methods for packing efficiency exist, but HETP applies to most systems Factors affecting HETP:
Distributor Design Packing Size / Geometry VLE Properties and Tower Loading
83
Turndown
Defines range of loadings for acceptable device performance Excessive Weeping Decreases Efficiency
84
Dry Tray Pressure Drop, hed

Dry tray dP is important because:
If its too high --- Entrainment If its too low --- weeping at turndown
Calculated based on vapor flow through device with no liquid present
hed (Vapor Velocity )

Function of:
Vapor Rate Open Area / Device
85
Foaming
Foaming Mechanisms:
Presence of surface active materials or solids HC entrainment or condensation in aqueous systems
Compensate design by using:

Lower percent of Jet and Downcomer Flood Low dry tray dP Low DC entrance velocity and filling Radial tips (shaped lips) and large DC clearance Provide antifoam injection facilities (Since degree of foaminess varies and is generally unpredictable, experience in similar towers may be used instead - Contact a Fractionation Specialist)
Known Foamers
Amine and Glycol Absorbers Caustic Towers Ethylene Demethanizers Sour Water Strippers
86
EXISTING T-2851 RE-DISTRIBUTOR

509
20" Manway
Top Bed, 5334 deep (17.5') 2" Pall rings
254
74
357
180
Redistributor
100
20" Manway
800
480
Top of Packing
25
Bed Limiter
Bottom Bed, 5334 deep (17.5') 2" Pall rings
87
286
Bed Support
This FLEXSORB absorber tower foams. What changes would you make to improve it? Units are in mm (25mm=1) unless stated.
650
396
110
1830
Design Contingency
To insure 90% chance of successful operation, safety margins should be adhered to and are built into EMoTIP.
Examples
Jet Flooding (Trays) Downcomer Filling Packing Flooding Tray efficiency Packing HETP 80-90% of predicted 35-50% 80-85% of predicted Point efficiency debited 10% Predicted divided by 0.85
88
Trayed Tower Thoughts

Review all designs with Fractionation Specialist Use EMoTIP as starting point
Will not optimize open area or downcomer slope
Design for vacuum if can occur

Check vapor pressure of contents if reduced to ambient temperature
Try high capacity designs instead of packing for revamps Prevent water from entering tower
#1 cause of refinery tray damage
Specify additional static pressure drop for design pressure

Use water filled basis if not high cost
Consider if can condense water on top tray BEWARE of foaming

A well designed tower for non-foaming service will still flood if it foams
89
CONTACTING DEVICE PROBLEM
90
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics X Other Process Considerations
X Other Tower Internals

Z Tower Revamps
91
Other Tower Internals
Tray Internals
92
Perforated Pipe Distributors

Usually directed against a downcomer
Use baffle to prevent downcomer boiling
Hole/Slot Area should give 0.25-0.5 psi (0.018-0.035 kg/cm2) pressure drop
(See Fluid Flow Equations, DP III-H)
Four common types:
93
Tower Internals Details (DP III-H)

Pay special attention to tower inlets and outlets
Follow directions in DP III-H Leave extra tray spacing for distributors and manways
Figure out where the manways will be Distributors will create high velocity areas where flooding can start
Insulate baffle to prevent vaporization in downcomer 0.25-0.5 psi (0.02-0.04 kg/cm2) for distributor hole/slots Chimneys
Long rectangular lowest cost, then round, last square
Size CWMS for 100% Vc, unless foaming service Useful fluid flow equations hidden in DP III-H Some drawoffs require self venting flow (eq 13)
Chance that vapor can enter drawoff line
Low residence time Lack of seal in drawoff pan (coking or fouling services)
See also Distillation Operations, p. 89-94 (Kister)

94
Packing Internals
95
Packing Liquid Distributors

Gravity Type
Most important packing internal Trough type preferred, but high cost Design details by vendor but must meet DP III-G, Appendix A criteria Must be installed level
96
Packing Distributor
97
Packing Spray Nozzles

Provide poor liquid distribution Plug easily; strainers required upstream Low cost, but often require demister above
Sprays in action: Water Test of BTRF PS 8 VPS Wash Oil Distributor at Turndown Rate - 2003
98
Distribution Quality
All packing distributors should be tested at vendor shop
Distributor should be fully assembled during test
Area samples and individual random sample are compiled to verify performance
99
Packing Supports
Located at bottom of packed bed Open Area sized for at least 100% of tower cross section to prevent flooding Design details by vendor
100
Bed Limiters
Restrain packing during upsets - keep out of draw nozzles, etc. Fastened to clips welded to shell or suspended from distributor
101
Packed Tower Details

First, dont use packed tower unless necessary
Low pressure drop (vacuum or atmospheric pressure tower) Very small diameter tower (3 ft or 915mm or less) Possibly foaming, but still try trays first Revamp where high capacity trays still cant provide necessary capacity/efficiency
Specify liquid distributor to meet criteria in DP-III-G Appendix A

3/8 (10mm) minimum orifice desired, but can reduce to (6mm)
Smaller holes may plug, resulting in poor fractionation
Be careful of high turndown requires small orifices
Specify liquid distributor to meet flow test criteria in Appendix B

Copy both appendices and give to vendor
Provide dual strainers on liquid feed to prevent plugging

No bypass recommended SS piping downstream of strainers (especially if at grade)
102
Liquid Draws - Trays and Packing

Two types:
Downcomer (Sump) Chimney Tray
Either type may be a partial or total draw Reboiler Draws are unique (see DP III-H)
103
Reboiler Draw and Return Design

11"
1 1/2"
11" 4"
1' - 0" 71
4" 15
2' - 10"
4' - 10"
1' - 6"
2"
4" 1' - 4" 6"
9" 4" 2" 2"
2' - 0"
1' - 3" 8"
1' - 9" 5' - 0"
3' - 3"
104
8"
1' - 12"
4"
3' - 10"
Task Checklist
X Introduction
TOWER SIMULATION
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics X Other Process Considerations X Other Tower Internals
X Tower Revamps
105
Tower Revamps
Tower Revamps
Always consider process alternatives first!!!
(e.g. increase tower pressure, etc.)
Revamp Strategy: Rate existing tower to identify limitations

Vapor Handling Limitation? Liquid Handling Limitation? Poor Separation Efficiency? Different Service?
Explore high capacity tray options discussed previously before considering packing Fundamental design concepts remain the same. However, sometimes design criteria are too conservative - consult with a Fractionation Specialist.
106
Tower Revamps
Options Guide
Revamp Objective: Increased capacity at constant separation efficiency
(XOM DP III-A Table 4A)
107
Tower Revamps
Debottleneck Examples
Cheap Operational changes Reduce weir height, increase DC clearance or add a shaped lip to lower DC filling Change tray decks Packed Towers:
Increase Packing Size Install Structured Packing Replace liquid distributor(s)
Expensive Install sloped or mod. arc downcomers Increase number of liquid passes Install high capacity trays Changing tray spacing Install packing Change amine type or concentration
108
Tower Revamps
Packing Selection
Can easily compare different packing types using this chart

(see DP III-G, Figure 3)
109
Tower Revamps
Expansion Example
What consider for expansion?
Top Trays Jet Flood Limit Base Expansion <85% 42% 45% DC Flood <85% 90% 95% DC Choke <100% 150% 160%
Bottom Trays Jet Flood Limit Base Expansion <85% 29% 31% DC Flood <85% 62% 66% DC Choke <100% 97% 103%
Preheat: 6.1 MBtu/hr (6.4 M.kJ/h) Base, 6.5 MBtu/hr (6.9 M.kJ/h) Expansion Reboiler: 60% of capacity
110
Tower Inspection
All vessels need technical inspection Inspect every tray, every pass, recording dimensions
DC clearance, DC rise, weir heights, number of holes (within reason) Verify bolts are tight Make sure internals are put together correctly Levelness of weirs Helmet mounted and hand held flashlights (explosion proof recommended) Rechargeable spotlight for large vessels/furnaces Knee pads, and maybe seating pad Wrench (to check bolts) Ruler, tape measure, and wooden blocks cut to measurement tolerances Water bottle Level (consider laser type) Hardhat, gloves, clear safety glasses, pool FRCs Marker or paint pen Shoulder bag
Tools

Do not enter vessel without signing in through hole watch

Do not even put head inside vessel without permission Gas test required to make sure safe Sign out through hole watch when leaving
111
NEW T-2851 RE-DISTRIBUTOR

509
20" Manway
Top Bed, 5334 deep (17.5') Cascade Minirings #3

649 112
Bed Support
Replace packing with one with higher capacity. Newer packings can give similar performance with higher capacity (at lower % jet flood).
Old Redistributor (removed)
396
20" Manway
New Redistributor Old Bed Limiter Old Top of Packing

152
Velocity through chimneys was 21.5 ft/sec (6.6 m/s), with only 3 (76 mm) gap between top of chimney and bed support. Chimneys were missing hats. Lower distributor and install hats on chimneys.
633
825
New Bed Limiter (supported by clips) New Top of Packing
Bottom Bed, 5182 deep (17.0') Cascade Minirings #3

1830
112

Section 04 - Fractionation

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Section 04 - Fractionation

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Fractionation

Did You Know?

Equipment accounts for 30% of all investments today

Consumes 70% of all energy at plant

Separate feed into products according to boiling point

Products sent to finished product tank or further processed by other units

Multiple products and feeds common

What sets a towers operating pressure?

What are my options to increase a towers vapor / liquid handling capacity?

Prepare Design Package (Consult with Specialist)

Simulation Tool (PRO/II or HYSIS)

Pegasys ExxonMobil Tower Internals Program - EMoTIP

TOWER SIMULATION X Basic Concepts

BINARY DISTILLATION: MCCABE - THIELE DIAGRAM

TOTAL REFLUX - MINIMUM STAGES

Stages Versus Reflux

Optimum Reflux Ratio

ESTIMATING ACTUAL REFLUX RATIO AND ACTUAL NUMBER OF STAGES

General Rule of Thumb-R ACTUAL = (1.1 TO 1.35) x R MIN

X Specifications DEVICE SELECTION

How much pressure drop is acceptable?

Dew Point Calculation

Bubble Point Calculations

If not specified, start with bubble point feed - Then optimize.

Adjust temp. to balance tower loading

HIGH FEED TEMPERATURE

RECYCLE GAS COMPRESSOR

VAPOR PRESSURE SULFUR

Variables: usually condenser / reboiler duty

VERTICAL THERMOSIPHON REBOILER

HORIZONTAL THERMOSIPHON REBOILER

Column Stage Summary

Viscosity (high temperature), other properties may need to be verified.

DEVICE SELECTION X Contacting Devices

Conventional Trays High Capacity Trays

Random Packing Structured Packing Baffles, Sheds, and Grid

Can provide high value heat

Reduces liquid traffic in tower

High Capacity Trays

High Capacity Trays (Cont.)

High Capacity Trays (Cont.)

MD and ECMD Tray Unit Cells

Want More High Capacity Tray Information?

Random Packing (Cont.)

DP III-G (Packing and Grid)

Structured Packing (Cont.)

Why Structured Packing?

Why Not Structured Packing?

Low Surface Area

Large Open Area

Low Liquid Residence Time

Practice Tower Internal Type

Device Selection Criteria

See DP III-A Tables 3-5

Device Selection Procedure

Then select best device type based on Device Selection Criteria.

Trays vs. Packing

X Tray Hardware Definitions

Common Pass Arrangements

Exiting Tray Support Ring

Exiting Downcomer Bolting Bar

Koch-Glitsch supplied Downcomer Adapter

Downcomer Seal Techniques

VAPOR Jet Flooding Ultimate Capacity Flow Regimes Entrainment