Assignment 5

Develop a process flow sheet consisting of following process units:

1. Pre-flash Column (PF column).

2. Atmospheric Crude Distillation Unit (CDU).

3. Vacuum Distillation Unit (VDU).

Two different crude assays crude oil-1 and crude oil-2 are mixed in a ratio 20:80 (volumetric) and sent to PF
column followed by CDU and VDU.

1. Draw TBP curve for Oil-1, Oil-2 and mixed crude oil.
2. Draw PF column temperature profile.
3. Draw TBP curve for mixed crude oil and PF column outlet crude.
4. What is the optimum distillate flow rate to achieve naphtha design spec. in PF column.
5. Tabulate the furnace result for CDU column.
6. Tabulate the pumparounds result for CDU column.
7. Draw ASTM-D 86 curve for CDU column products.
8. What is the optimum distillate flow rate to achieve heavy naphtha design spec. in CDU column.
9. What is the optimum bottom flow rate to achieve diesel design spec. in CDU column.
10. Tabulate the pumparounds result for VDU column.
11. Draw TBP curve for LVGO, HVGO and Residue.
Process conditions for mix Crude oil entering in PF column:
Flow rate = 100000 bbl/day
Temp. = 200 oF
Pressure = 60 psi

PF column steam process conditions:

Flow rate = 5000 lb/hr
Temp. = 400 oF
Pressure = 60 psi
PF column parameters:
PF column parameters: Condenser temp. = 170 oF
No. of stages = 10 Furnace specification:
Condenser = Partial-Vapor-Liquid Temp. = 450 oF
Reboiler = None-Bottom feed Pressure = 50 psi
Crude entering stage = 10 (through furnace) Single stage flash
PF-steam entering stage = 10 Design Spec. for Naphtha:
Condenser pressure = 39.7 psi Type: ASTM D86 temp. (dry liquid volume basis)
Stage 2 pressure = 41.7 psi Target = 375 oF
Bottom stage pressure = 44.7 psi Liquid = 95%
Process conditions for CDU steam:
Flow rate = 12000 lb/hr
Temp. = 400 oF
Pressure = 60 psi
Steam for kerosene stripper:
Flow rate = 3300 lb/hr
Temp. = 400 oF
Pressure = 60 psi
Steam for diesel stripper:
Flow rate = 1000 lb/hr
Temp. = 400 oF
Pressure = 60 psi
Steam for gasoil stripper:
Flow rate = 800 lb/hr
Temp. = 400 oF
Pressure = 60 psi
CDU parameters:
No. of stages = 25
Condenser = Total
Reboiler = None-Bottom feed
Crude entering stage = 22 (through furnace)
CDU-steam entering stage = 25
Condenser pressure = 15.7 psi
Stage 2 pressure = 20.7 psi
Bottom stage pressure = 24.7 psi
Furnace specification:
Single stage flash
Pressure = 24.18 psi
Fractional overflash =0.03 (Stdvol)
 Pump around -1:
Kerosene side stripper: Draw stage = 8
No. of stages = 4 Return stage = 6
Main column connecting stages: Flow = 49000 bbl/day
Liquid draw = 6 Heat duty = -40.0
Overhead return = 5 MMBtu/hr
Bottom product = 11700 bbl/day
Pump around -2:
Draw stage = 14
Diesel side stripper: Return stage = 13
No. of stages = 3 Flow = 11000 bbl/day
Main column connecting stages: Heat duty = -15 MMBtu/hr
Liquid draw = 13
Overhead return = 12 Design Spec. for HNaphtha:
Bottom product = 16500 bbl/day Type: ASTM D86 temp. (dry liquid volume basis)
Target = 375 oF
Gasoil side stripper: Liquid = 95%
No. of stages = 2
Main column connecting stages: Design Spec. for diesel:
Liquid draw = 18 Type: ASTM D86 temp. (dry liquid volume basis)
Overhead return = 17 Target = 640 oF
Bottom product = 8500 bbl/day Liquid = 95%
Process conditions for VDU steam: VDU parameters:
Flow rate = 20000 lb/hr No. of stages = 6
Temp. = 400 oF Condenser = None-Top pumparound
Pressure = 60 psi Reboiler = None-Bottom feed
Crude entering stage = 6 (through furnace)
Pump around -1: CDU-steam entering stage = 6
Draw stage = 2 Stage 1 pressure = 60mmHg
Return stage = 1 Stage 6 pressure = 70mmHg
Flow = 20000 bbl/day
Heat duty = -28.6 MMBtu/hr Furnace specification:
Single stage flash with liquid runback
Pump around -2: Pressure = 2.03 psi
Draw stage = 4 Fractional overflash =0.006 (Stdvol)
Return stage = 3
Flow = 49000 bbl/day
Heat duty = -80.0 MMBtu/hr

Design spec:
Stage temp. = 150
Stage =1.
Crude OIL-1 (API = 31.4)
TBP Distillation Light Ends Analysis API Gravity Curve
Liq. Vol. (%) Temp (F) Component Liq. Vol. Frac. Mid. Vol. (%) Gravity
6.8 130 Methane 0.0010 5.0 90.0
10.0 180 Ethane 0.0015 10.0 68.0
30.0 418 Propane 0.0090 15.0 59.7
50.0 650 Iso-butane 0.0040 20.0 52.0
62.0 800 N-Butane 0.0160 30.0 42.0
70.0 903 2-Methyl-Butane 0.0120 40.0 35.0
76.0 1000 N-Pentane 0.0170 45.0 32.0
90.0 1255 50.0 28.5
60.0 23.0
70.0 18.0
80.0 13.5
Crude OIL-2 (API = 34.8)
TBP Distillation Light Ends Analysis API Gravity Curve
Liq. Vol. (%) Temp (F) Component Liq. Vol. Frac. Mid. Vol. (%) Gravity
6.5 120 Water 0.001 2.0 150.0
10.0 200 Methane 0.002 5.0 95.0
20.0 300 Ethane 0.005 10.0 65.0
30.0 400 Propane 0.005 20.0 45.0
40.0 470 Iso-butane 0.01 30.0 40.0
50.0 550 N-Butane 0.01 40.0 38.0
60.0 650 2-Methyl-Butane 0.005 50.0 33.0
70.0 750 N-Pentane 0.025 60.0 30.0
80.0 850 70.0 25.0
90.0 1100 80.0 20.0
95.0 1300 90.0 15.0
98.0 1475 95.0 10.0
100.0 1670 98.0 5.0