Optimising preash for light tight oil

processing
For a crude unit handling light tight oil feedstock, a semi-preash column can deliver
signicant advantages in energy saving, capacity gain and revamp economics
SOUN HO LEE
GTC Technology

he basic function of a crude

distillation unit is to provide
the initial separation of crude
oil feed into the desired fractions to
feed downstream units. Now,
newly introduced light tight oil
feed processing may limit existing
crude distillation unit capacity. The
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option may improve capacity and/
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oil processing.
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commonly implemented for crude
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has strengths and weaknesses.
This
article
discusses
an
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design that optimises the tradiWLRQDO SUHDVK GUXP DQG SUHDVK
column options. A case study
includes revamp economics for the
arrangement.

Light tight oil

Light tight oil describes petroleum
fractions produced from low
permeability formations such as
shale or tight sandstone.1 Improved
hydraulic fracturing technology
with
directional
drilling
has
increased light tight oil production
in North America, where processing light tight oil can be a
JDPHFKDQJHU IRU UHQHUV /LJKW
tight oil slates produced in North
America have typically light and
sweet natures. However, its characWHULVWLFVYDU\VLJQLFDQWO\
Adapting light tight oil as a new
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UHWURW LQ D UHQHU\ OD\RXW ZKLFK
ZDVRULJLQDOO\FRQJXUHGZLWKWUDGLtional crude oil feedstock. Capacity
imbalance in downstream conver-

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train processing capacity are already
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This imbalance issue is more exagJHUDWHG LQ UHQHULHV ZKLFK DUH
designed with heavy crude slates
and a high conversion ratio. These
mismatches between new light tight
RLO IHHGVWRFN DQG FXUUHQW UHQHU\
FRQJXUDWLRQV DUH LQLWLDWHG LQ WKH
crude
distillation
unit
which
provides initial separation of feedVWRFNIRUHQWLUHGRZQVWUHDPUHQHU\
processing units.

Implementing crude
feed preashing
has been one of the
common options to
debottleneck crude
distillation units
There has been extensive research
to try and identify magic juice,
blending ratios of light tight oil and
traditional heavy crude oil slates to
W H[LVWLQJ UHQHU\ OD\RXWV
Meanwhile, it has been discovered
that blending between light tight
oil and traditional heavy crude oil
can cause asphaltene destabilisation
GXH WR WKH SDUDIQLF QDWXUH RI OLJKW
tight oil.2 This destabilisation can
cause unexpected fouling issues.
This article focuses on debottlenecking and enhancing crude
distillation unit capacity and energy
FRQVXPSWLRQXVLQJYDULRXVSUHDVK
RSWLRQV 2WKHU UHWURW VWUDWHJLHV IRU
light tight oil processing are not
discussed.

Crude distillation unit preashing

,PSOHPHQWLQJ FUXGH IHHG SUHDVKing has been one of the common
options to debottleneck crude
distillation units. Switching feedstock to a lighter crude slate can
cause undesired feed vaporisation
at the feed furnace pass control
valve and limit capacities in the
crude atmospheric column and
overhead
condensing
circuits.
$GGLQJ D SUHDVK GUXP RU FROXPQ
can reduce the charge rate to the
feed furnace. In addition, transfer
line vibration due to capacity limitation can be resolved through
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7ZR SUHDVK RSWLRQV WKDW DUH
commonly implemented in a crude
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GUXP DQG SUHDVK FROXPQ
$QRWKHU SUHDVK RSWLRQ *7,36 LV
D VHPLSUHDVK FROXPQ GHVLJQ WKDW
may be optimised between tradiWLRQDO SUHDVK GUXP DQG SUHDVK
column options.

Preash drum option

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RSWLRQ IRU FUXGH SUHDVKLQJ
&RPSOH[PRGLFDWLRQRIHTXLSPHQW
and instrumentation is not required
for this option compared to the
SUHDVKFROXPQPDNLQJLWWKHPRVW
economical option with regards to
capital expenditure (Capex).
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drum is that this option does not
have the capability to control
SUHDVKHG YDSRXU TXDOLW\ LQ IRDPing prone service. Therefore, the
SUHDVK GUXP LV SURQH WR KDYH
challenges
with
entrainment.
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foaming environment. Improper
ORFDWLRQ RI SUHDVKHG YDSRXU IHHG-

PTQ Q3 2015 51

Case study crude distillation unit

Case
Parameter
Feed
Crude slate
Crude charge, BPD
API
-300F norminal cut fraction, LV%
300-450F norminal cut fraction, LV%
450-650F norminal cut fraction, LV%
+ 650F norminal cut fraction, LV%
Operating parameter
Furnace coil outlet temperature, F
Crude atmospheric column top pressure, psi, g
Unit bottom stripping steam rate, Lb/BBL
Unit kerosene stripping steam rate, Lb/BBL
Unit diesel stripping steam rate, Lb/BBL
Fractionation performance
Naphtha D86 (95 LV%), F
Kerosene ash point, F
Kerosene freezing point, F
Diesel D86 (90 LV%), F
Reduced crude D86 (5 LV%), F

Base

100% Eagle Ford

50 000
60.7
58.2
14.7
13.4
13.7
674
24
7.9
12.0
6.2
291
100.8
- 58.0
649
617

Table 1

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Case study: unit description and

study basis
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Case study A: preash drum

Figure 1 Crude distillation unit: base conguration

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P/A

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Preflash
drum

Steam
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atmospheric
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Figure 2 Crude distillation unit: case study A preash drum conguration

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Case study B: preash column

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Case study C: GT-IPS semi-preash

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PTQ Q3 2015 55

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80
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Figure 5 Crude atmospheric column distillation equipment capacity

Table 2 shows that the case B

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Case study result summary
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RSWLRQ LV TXDQWLHG 7KH FUXGH
Case
Base Preash drum Preash column GT-IPS
Parameter
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Preash condition
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282
395
353
Preash inlet temperature1, F
PDLQWDLQ EDVH FDVH SURGXFW \LHOGV
Preash vapour/product %, vol% of feed
16%
41%
32%
DQG SURGXFW TXDOLWLHV 7KHVH
Yield structure
Crude charge, BPD
Base
0%
0%
0%
WHPSHUDWXUH GURS YDOXHV WKURXJK
Unstabilised naphtha, BPD
Base
0%
0%
0%
SUHDVKLQJ DQG VKLIWHG SXPSDKerosene, BPD
Base
0%
0%
0%
URXQG EDODQFHV DUH UHHFWHG LQ
Atmospheric gas oil, BPD
Base
0%
0%
0%
SUHKHDW WUDLQ WHPSHUDWXUH SUROHV
Reduced crude (R/C), BPD
Base
0%
0%
0%
Operating parameter
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Furnace inlet temperature, F
Base
- 14F
- 68F
- 38F
SUHGLFWLRQ ,GHQWLFDWLRQ RI WKH
Furnace coil outlet temperature, F
Base
+ 31F
+ 45F
+ 42F
FUDFNLQJ WHQGHQF\ RI WKH FKRVHQ
Absorbed furnace duty, MMBTU/hr
100%
97%
82%
87%
OLJKW WLJKW RLO VODWH FDQ KHOS RSWLPreash condenser duty, MMBTU/hr
100%
Additional
Overhead condenser duty, MMBTU/hr 100%
100%
100%
100%
PLVHIXUQDFHFRLORXWOHWWHPSHUDWXUH
Top pumparound duty, MMBTU/hr
100%
100%
45%
71%
IXUWKHU
Kerosene pumparound duty, MMBTU/hr 100%
86%
100%
77%
7KH FDSDFLWLHV RI FUXGH DWPRVDiesel pumparound duty, MMBTU/hr
100%
76%
100%
91%
SKHULF
FROXPQ
GLVWLOODWLRQ
Fractionation performance
Base
0F
+ 2F
0F
Kerosene 5% -naphtha 95%2, F
HTXLSPHQW DUH FDOFXODWHG ZLWK
Base
0F
0F
0F
Diesel 5% - kerosene 95%2, F
VLPXODWHGWUDIF&DOFXODWHGFDSDFLBase
0F
0F
0F
Reduced crude 5% -Diesel 95%2, F
WLHV DUH EDVHG RQ WKH SDFNHG ZDVK
Kerosene ash point, F
Base
0F
+ 1F
0F
VHFWLRQDQG[HGYDOYHWUD\VIRUWKH
1. Prior to preashing 2. ASTM D86 (LV%)
UHVW RI WKH VHFWLRQ 7KH FDOFXODWHG
FDSDFLW\ IRU HDFK VHFWLRQ LV SORWWHG
Table 2
LQFigure 5

www.eptq.com

PTQ Q3 2015 57

10
EFO: $55/BBL
EFO: $35/BBL
EFO: $25/BBL

Pay-out per year

8
7
6
5
4
3

Conclusion

2
1
0
Preflash drum

Preflash column

GT-IPS

Figure 6 Protability index payback period

In case C, the GT-IPS semiSUHDVK FROXPQ RSWLRQ VKRZV

ORZHU IXUQDFH GXW\ VDYLQJ DQG
GLVWLOODWLRQHTXLSPHQWFDSDFLW\JDLQ
FRPSDUHG WR WKH SUHDVK FROXPQ
RSWLRQ +RZHYHU IXUQDFH GXW\
saving and crude atmospheric
FROXPQ FDSDFLW\ JDLQ DUH VWLOO
substantial compared to the base
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Case study: retrot economic

evaluations
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SURYLGHV WKH VLPSOHVW XQLW PRGLcation among the three cases. The
UHTXLUHG SORW IRU WKH SUHDVK GUXP
implementation is also smaller than
IRU WKH RWKHU FDVHV +RZHYHU WKH
aforementioned higher discharge
pressure of the new booster pump
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7KH FDVH % SUHDVK FROXPQ
option provides the best perforPDQFH LPSURYHPHQW EXW LW UHTXLUHV
an additional overhead condenser
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column and complex piping modiFDWLRQ ZKLFK LQXHQFH UHWURW
cost. The highest Capex is identiHG IRU WKH FDVH % SUHDVK FROXPQ
RSWLRQ 7KH ODUJHU SORW UHTXLUHPHQW
IRU WKH PRGLFDWLRQ LV DQRWKHU
GUDZEDFN LQ FDVH % ,I VSDFH LV
limited in the existing unit,
this case is not viable for
implementation.
In case C, GT-IPS does not necessitate substantial addition of
HTXLSPHQW DV LV UHTXLUHG LQ WKH
FDVH % SUHDVK FROXPQ $OVR QHZ
booster pump differential pressure
DQG FDSDFLW\ UHTXLUHPHQWV LQ FDVH

58 PTQ Q3 2015

heating values are used for heating

medium consumption predictions.
Figure 6 shows that case Cs
*7,36 LV LGHQWLHG WR SURYLGH
EHWWHU UHWURW HFRQRPLFV FRPSDUHG
to the other two cases. Adding
H[WUD SURW WKURXJK FDSDFLW\ JDLQ
FDQ IXUWKHU LPSURYH UHWURW
SURWDELOLW\

C are lower than those in case A.

&DOFXODWLRQV RI SD\EDFN SHULRG
DUH FRQGXFWHG WR JDXJH UHWURW
economics. Gains in crude atmosSKHULF FROXPQ FDSDFLW\ DQGRU
IXUQDFHWUDQVIHU OLQH FDSDFLW\
VLJQLFDQWO\ LPSURYH UHWURW SURWDELOLW\ +RZHYHU SURWV WKURXJK
WKHVH IDFWRUV YDU\ QRWLFHDEO\ SHU
UHQHU\OD\RXWDQGHTXLSPHQWOLPLtations. Therefore, these factors are
QRW FRQVLGHUHG LQ WKH SD\EDFN

The GT-IPS semipreash column can

deliver signicant
energy savings and
capacity gains
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furnace heating medium saving is
used for economic evaluations.
3URWDELOLW\
LQGH[HV
DUH
H[SUHVVHG ZLWK UHJDUG WR SD\EDFN
period. These indexes are shown in
Figure 6 7KH PRGLFDWLRQ FRVWV DUH
estimated based on the US Gulf
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ERWK UHQHU\ IXHO JDV DQG QDWXUDO
gas as furnace heating mediums.
+RZHYHU WKH PL[LQJ UDWLR EHWZHHQ
two different utilities depends
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7KHUHIRUH D VLQJOH HTXLYDOHQW IXHO
oil (EFO) basis is selected. Three
different fuel oil prices are selected
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and natural gas trend.6 7\SLFDO
IXUQDFH HIFLHQF\ DQG ()2 ORZHU

The technical results and economic

evaluations from three case studies
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FROXPQ FDQ GHOLYHU VLJQLFDQW
HQHUJ\ VDYLQJV DQG FDSDFLW\ JDLQV
FRPSDUHG WR WKH SUHDVK FROXPQ
option. Meanwhile, the lower
investment
cost
for
GT-IPS
SURYLGHV EHWWHU UHWURW HFRQRPLFV
FRPSDUHG WR WKH SUHDVK GUXP
FDVH 7KHVH EHQHWV VKRZ WKDW
*7,36 LV D YLDEOH RSWLRQ IRU HIcient light tight oil processing.
$FWXDO SUHDVKLQJ RSWLRQV DQG
designs can be customised after
UHYLHZLQJ WKH VSHFLF FLUFXPstances of a crude distillation unit
FRQJXUDWLRQ DQG UHQHU\ OD\RXW
5HWURW HFRQRPLFV FDQ EH SUHFLVHO\
JDXJHG DIWHU UHHFWLQJ DFWXDO SURW
gains.
This article is an updated version of a
presentation given at AIChE 2015 Spring
Meeting Kister Distillation Symposium, 27-30
April 2015, Austin, Texas.
GT-IPS is a mark of GTC Technology US, LLC.
References
1 Mills R, The myth of the oil crisis: overcoming
the challenges of depletion, geopolitics, and
global warming, Greenwood Publishing Group,
2008.
2 Sandu C, et al, Innovative solutions for
processing shale oils, Hydrocarbon Processing,
July 2013.
3 Golden S W, Prevent preash drum foaming,
Hydrocarbon Processing, May 1997.
4 Golden S W, Crude unit preash drums and
columns, PTQ Revamps, 2005.
5 Libermann N P, Troubleshooting Process
Operations, PennWell Books, 4th Edition.
6 US Energy Information Administration Web
Site.
Soun Ho Lee is Manager of Rening
Application with GTC Technology in
Euless, Texas, specialising in process design,
simulation modelling, energy saving design
and troubleshooting for rening and aromatic
applications.
Email: sounho@gtctech.com

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