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Report on
Mr. Ahaduzzaman
Lecturer,
Lecturer,
BUET
BUET
Lecturer,
Assistant Professor,
BUET
BUET
Noor Mohammad
Lecturer,
Department of Chemical Engineering,
BUET
1202011
1202012
1202013
1202014
1202015
0902058
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Abstract
Crude Tower is a crude distillation unit (CDU) system which is the most fundamental process of
petroleum refining. This work aimed at the fundamental design of crude tower using Aspen
HYSYS.In this project, Crude distillation unit system constituted a furnace, a three phase separator
and an atmospheric distillation tower. The atmospheric distillation aims to fraction the crude oil in
their products: naphtha, kerosene, gas oil, etc. Steady state simulation of a real crude tower was
performed using Aspen HYSYS.
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Acknowledgements
First and foremost we would like to thank God because without him none of this would have ever
been possible. We would also love to thank our wonderful parents, friends and benefactors who
have wished nothing but the best for us. We would also like to give special thanks to our teachers
who were constantly patient with us as we were doing the project.
Date: 6.11.2016
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Contents
Abstract ....iii
Acknowledgements...iv
Contents.....v
List of Figures...vi
List of Tables ...vii
Chapter 1: Introduction..1
Chapter 2: Process Description..2
Chapter 3: Simulation Process Description3
3.1 Crude Assay.4
3.2 Defining Simulation Basis...7
3.3 Oil Characterization.7
3.4 Preheat furnace...13
3.5 Three-phase separator..14
3.6 Atmospheric Distillation Unit..15
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List of Figures
Figure 1: TBP vs percent liquid volume. .............................................................................................8
Figure 2: Critical temperature vs percent liquid volume. ....................................................................8
Figure 3: Critical pressure vs percent liquid volume....................................9
Figure 4: Distribution plot of the oil...............10
Figure-5: Kerosene Boiling Point Curve.........11
Figure-6: Diesel Boiling Point Curve..12
Figure-7: Installing heater........13
Figure-8: Overview of the heater.13
Figure-9: Installing three-phase separator14
Figure-10: Overview of the three-phase separator...15
Figure-11: Overview of the distillation unit streams....16
Figure 12: Overview of the atmospheric Distillation tower.....17
Figure 13: Process block diagram........18
Figure 14: Process flow diagram..19
Figure-15: Kerosene Product Stream Properties for the simulation.20
Figure-16: Diesel Product Stream Properties for the simulation..21
Figure-17: Temperature vs tray position in the distillation column..22
Figure-18: Flow rate vs tray position in the distillation column...22
Figure-18: Overview of the process..23
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List of Tables
Table 1: Assay Data for Light Crude...........................................................4
Table 2: Assay Data for Medium Crude..........................................5
Table 3: Assay Data for Heavy Crude.........................................6
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Introduction
Today, distillation of crude oil is an important process in almost all the refineries. Crude distillation
is the process of separating the hydrocarbons in crude oil based on their boiling point. The crude
oil fractioning is very intensive process. The complexity due to large number of products, side
stripper, and pump around made the task of improving energy efficiency into tedious. Aspen
HYSYS Engineering is a market leading suite of products focused on process engineering and
optimization. Process modelling analysis and design tools are integrated and accessible through
Aspen HYSYS and Aspen Plus. Steady state simulation of a real crude tower was performed using
Aspen HYSYS.
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Process Description
Distillation of crude oil or petroleum refers to fractioning crude oil into the following cuts: gas,
naphtha, JP or kerosene, light and heavy gas oil and atmospheric residue. Generally, it is used to
make the separation in one single column, which operates under a pressure slightly higher than the
atmospheric one, possessing side extractions.
Nowadays, distillation unit of crude oil is a fractionation single unit, on contrast with a set of units
that were the first fractionation units. The crude oil feed to a fractional distillation tower is heated
by flow through pipe arranged within a large furnace. The heating unit is known as a pipe-still
furnace, and the heating unit and the fractional distillation tower make up the essential parts of a
distillation unit.
The crude oil feed is heated by furnace to a predetermined temperature. The vapor is held under
pressure in the pipe-still furnace until it discharges as a foaming stream into the fractional
distillation tower. Here the vapors pass up the tower to be fractionated into light and heavy gas oil,
JP or kerosene, and naphtha. While the nonvolatile or liquid portion of the feed descends to the
bottom of the tower to be pumped away as a bottom product. The stripping section is the part of
the tower below the point at which the feed is introduced, the more volatile components are
stripped from the descending liquid. Above the feed point, the rectifying section, the concentration
of the less volatile components in the vapor is reduced. The tower is divided into a number of
horizontal sections by metal trays, and each of them is equivalent to a distillation unit. The feed to
a tower may be at any point from top to bottom with trays above and below the entry point,
depending on the kind of feedstock and the characteristics desired in the products.
The temperature of the trays is progressively cooler from bottom to top. The bottom tray is heated
by the incoming heated crude oil feed. As the hot vapors pass upward in the tower, condensation
occurs onto the trays until refluxing (simultaneous boiling of a liquid and condensing of the vapor)
occurs on the trays. Vapors pass upward through the tower, whereas the liquids spill onto the tray
below, and so on. Until the heat at a particular point is too intense for that fluid to remain in liquid
condition; then it becomes vapor and joins the other vapors passing upward through the tower.
The whole tower thus simulates a set of several distillers, with the composition of the liquid at any
point or any tray remained fairly constant. This allows part of the refluxing liquid can be collected
at various points as side stream product.
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In this case a 3-phase separator is used to simulate the Desalter. A 3-phase separator in general is
used to separate the feed into vapor light liquid and heavy liquid (aqueous phase). The water phase
is considered as the pure phase and thereby we neglect any effects of salt in both water and oil
phase. A calculation block can be used to set the proper flow of another water stream based on the
desired residual water content of the treated crude oil. It can also be simulated using a component
splitter.
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Figure-1 shows true boiling point vs liquid volume percent by which crude oil can be characterized.
Figure-2 and figure-3 shows critical temperature vs percent liquid volume and Critical pressure vs
percent liquid volume.Figure-4 shows the distribution plot of the crude oil.Figure-17 and figure18 shows the temperature and molar flow rate variation of crude oil in the different stage of
distillation column
Figure-18 shows the input output stream specifications of different unit operation.
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Conclusion
This work has considered a fundamental design of crude tower consisting of a furnace, a three
phase separator and an atmospheric distillation tower with minimal number of stages/plates, pump
around and strippers of the columns. Simulation software is one of the best tools for a crude oil
refinery. This can be used during the conceptual design as well during the entire lifespan of the
equipment's. Aspen HYSYS enables the simulation of very complex crude distillation systems in
an easy manner. The goal is achieved by using Aspen, which provide capability to design the entire
process accurately. For the analysis of the crude distillation unit simulated and experimental curves
of kerosene, light gas oil and true boiling point curve of atmospheric residue is taken into account.
The optimization can be done very easily, together with the advanced process control tools, make
it profitable in the operation in real time. The goal is achieved by using Aspen, which provide
capability to design the entire process accurately.
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References
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6. C.D. Holland. Multicomponent Distillation Prentice Hall Englewood Cliff, pp. 6089, New Jersey, 1963.
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