SPECIAL REPORT

How to
Design
Crude
Distillation

Whether you are making preliminary

or detailed designs for atmospheric
crude distillation columns, this
process design guide should aid you

R. N. Watkins, Sugar Land, Texas*

THE DESIGN and operation of crude oil distillation units

are still done almost exclusively on an empirical basis.
This is because crude petroleum and its products, aside
from light ends products, are made up of a large number
of discrete hydrocarbons-each compound being present
in relatively small amount. It is simpler then to talk of
boiling ranges when describing the gross properties of a
crude and its fractions.

BASIC PRINCIPLES
First let us consider some of the basic steps for separat-
ing crude oil into fractions without regard for the effect
of side strippers or stripping steam. The separation dis-
cussed here will involve a vapor overhead product, five
sidestream products and a residual liquid bottom product.
A small amount of extra vaporization called overflash will
be used to insure the desired vaporization occurs and to
provide some reflux for the bottom section of the tower.

"Present Addre.. : Creole Petroleum Corp., Amuay, Venezuela

gYDROCARBON PROCESSING December 1969

 HOW TO DESIGN CRUDE DISTILLATION •.•

• • • Investment costs must be weighed against operating

The Art of Crude Distillation
The art of process design for crude distil-
lation relies heavily upon' empirical correla-
tions. This article uses the methods proposed
by Packie 1 and Edmister 5 as a background
for making preliminary calculations. Later
correlations can be substituted ,into this de-
sign procedure.
Many designers standardize their pro-
cedure so that it can be. programed for a
computer. Then they can give more atten-
tion to the establishment of an optimum de-
sign. In any event the method usually is simi-
lar to the one given here.
Pa[Je
• Basic Principles . . . . . . . . . . . . . . . . . .. 93
• Design Procedure ..." . . . . . . . . . . . .. 95
• Crude Oil Evaluation 101
• Charge Conditions 102
• Column Conditions 104
• Summary 106
Usually it is not feasible to use a reboiler on a crude
tower. Thus the charge usually is heated to its maximum
temperature before being fed into the column. All distil-
late products are vaporized as they enter the tower. Thus
the total heat required by the process must be contained
in the feed as it leaves the charge furnace.
Various ways of producing distillate products from the
feed vapor are shown in Fig. 1. The symbols used to
dcsignate some of these methods were chosen for easy
association with the type of separation: Type U desig-
nates that the sidedraw points are unrefluxed even though
there is reflux at the top of the last column. Type A uses
an externally-circulated fluid which behaves as an absorp-
tion oil for heat removal purposes. Type R designates the
use of an external reflux which is an equilibrium liquid
with respect to the tray on which it re-enters the tower.
lighter fractions D 2 , D s, D 4 and DB, The overhead from
the seventh drum is a vapor product VB.
Each of these separations occurs from cooling and
equilibrium condensation so that the equilibrium liquid
contains small concentrations of components lighter than
the desired distillate. Also the equilibrium vapor contains
some of the component~ which belong in the liquid so that
the next fraction to be condensed will have some undesir-
able heavy ends. However it would be possible to use liquid
reflux to wash back the heavy components from the vapor
and to use stripping vapors to strip light components
from the liquid.
Type U. The first approach to genuine fractionation is
shown in the second train of Fig. 1. Each of the vessels in
this train represents one separation section. This type of
unit is uneconomical since heat is removed only in the
final condenser and is available at a temperature level
which is too low for recovery and use elsewhere. Further-
more the vapor and liquid traffic throughout the column
increases markedly from the bottom to the top stages.
A plot of the vapor and liquid traffic in each of the
three designated types of fractionation is shown in Fig. 2.
Sizing a tower based on conditions at the top tray results
in a much larger tower diameter for Type U than re-
quired for either a Type A or a Type R unit. These latter
two types of units accomplish heat recovclY by withdraw-
ing one of the internal streams of the tower, cooling it and
returning it to the column. Thus the vapor and liquid
traffic is diminished above these withdrawal sections.

Series of Flash Drums. Before discussing the foregoing

three methods of separation, consider how fractions hav-
ing the desired boiling ranges can be made using a series of
flash drums. Consider the top train of Fig. 1 in which the
furnace effluent enters the first drum where the residual
liquid W is separated from the vapor. The first drum ef-
fluent vapor is cooled just enough to condense the over-
flash L o, so that it will be separated as a liquid in the
second drum. The overflash leaves the system as part of
the residual liquid W.
The vapor from the second drum is cooled again to
some predetermined temperature and enters a· third flash.
There the heaviest distillate product Di is removed as a
Fig. I-Ways of separating a crude into fractions are com·
·liquid. The process is repeated to pl'od~ce successively pared with a series of flash drums. ' .

Bec b\ll':.J:969 HYDROGARBON PROCESSING

~ cost's to select the best type of crude distillation . ..
Type A. The more common way of attaining intermedi-
a te heat recovery is shown by Type A. Heavy liquid is
wi thdrawn from the tray above the draw tray, cooled
externally, and returned to the column three trays above
the draw tray. This type is called a pumparound reflux
system. The removal of heat in the side cooler results in
a smaller requirement for overhead reflux. This technique
is generally employed at a low and at an intermediate
point in the column which makes heat available at hvo
different temperature levels for exchange against crude
oil charge.
This method has the advantage of stabilizing vapor and
reflux liquid flow throughout the section where it is used.
I t materially reduces vapor and liquid traffic throughout
the entire column. These two points can be seen in Fig. 2.
The disadvantage of this method is that the three trays
used for heat removal must be considered as only one tray
for fractionation purposes. This is because the pump-
around liquid is foreign to the zone in which it is intro-
duced. This liquid is good for heat removal purposes but
offers no mass transfer advantages.
Type R. A rectifying section employing subcooled reflux
is designated Type R. This is a more efficient method for
recovering heat from the system because it can be used
at every section of the column. It has the additional ad-
van.tage of being true reflux which contributes to frac-
tionation on all trays. As shown in Fig. 2, a fairly uniform
vapOI' and liquid traffic exists in all sections of the tower,
thus making it possible to design the trays to be more
Fig. 2-Vapor and liquid loadings at the top of a column can
be reduced by using interstage coolers, ,
HYDROCARBON PROCESSING' December 1969
efficient. This is the type of separation which will be used
as the basis for the design method to be discussed here.
This method has the severe disadvantage, however, of
requiring higher capital investment. Note that the design
example given later is set up to withdraw the total down-
flow liquid and route it to the side stripper, followed by
crude-ta-product heat exchange. This method incurs a
large stripping cost. The alternate method of stripping
only the product while exchanging against both product
and reflux requires two sets of pumps and exchangers at
each draw point. Thus, an evaluation of a Type R unit
versus a Type A unit can become very complex and must
consider investment and operating costs for the plant site
under study.
DESIGN PROCEDURE
In the sense that engineers understand distillation of
discrete compounds, crude oil fractionation is still a black
art. Packie's work1 at least provides an elementary basis
for analyzing distillation problems. The reader also is
referred to NeJson2 and HengstebeckS for background in-
f0n11ation. Other referencesG- 7 are used to derive the prop-
erty data used in this discussion.
In the separation of chemically similar materials, it is
generally true that the greater the difference in boiling
points of individual fractions, the easier it is to separate
the fractions. The sharpness of separation usually is de-
fined as the gap or overlap of the boiling ranges of
adjacent fractions. For a given separation, a large number
of trays will result in a low reflux requirement. Likewise,
Fig. 3-These pressures a!ld stages are recommended for
making preliminary calculatIons.
95
 HOW TO DESIGN CRUDE DISTIlLATION •••
a higher reflux rate will require a lower number of trays.
Product Specifications. The properties of each fraction
can be varied as required by sales demands, but only at
the expense of the adjacent fractions. Generally the pro-
cess designer must estimate the material balance on the
basis of the specifications given for the desired products.
The basis for most product specifications for a crude
column are derived from the method proposed by Ameri-
can Society for Testing Materials (ASTM). This method
reports the temperatures at which certain portions of the
material are vaporized.
ASTM End Points. One method for setting product
specifications ~s to state the maximum allowable end
points for the fractions. The heaviest distillate product,
called atmospheric gas oil, is excluded from this specifi-
cation since it is withdrawn from the column to provide
adequate fractionation between the other liquid distillates
and the reduced crude.
If the crude processing facilities contain a vacuum col-
umn, economics favor the production of the maximum
Fig. 4--ASTM VS. TBP (0% to 0%. 100% to 100%).
.. .Jl
'..;'" :96'
..
~ ~.;.:.:~~,:' "'1
feasible amount of all distillates in the atmospheric col-
umn. Then the size of the vacuum column can be mini-
mized. A side benefit is the maximization of the crude
preheat prior to entering the furnace.
For the example discussed here, the identity of the
crude oil fractions starting with the lightest are: overhead
vapor, light naphtha, heavy naphtha, light distillate, heavy
distillate, gas oil and reduced crude. Isolation of these
fractions should be computed on two representative
crudes, one light and one heavy.
The material balance will be based on alternately
maximizing the production of gasoline (naphthas), light
distillate and heavy distillate. Some typical ASTM boiling
ranges for these alternatives are given in Table 1.
Key Temperatures. Intermediate temperatures usually
are specified relative to the product streams. These set the
gap between the temperature at 5% ASTM for the
heavier fraction and the temperature at 95% ASTM for
the lighter fraction. For preliminary designs, the gaps
shown in Table 2 can be used when specifications
are not given.
December 1969 HYDROCARBON PROCES~lNO
--r
I
I

These specifications must be transformed into ASTM TABLE l-Typlcal Product Spa<lficatlons
end point specification before continuing with a design.
Temp. for Mal<. Product Given, OF
The method for making this extrapolation will depend
on the way in which the specifications are written. One HeayY
method uses probability graph paper. On this type of
Product
Light Naphtha . 250 I Distillate

graph, the plot of ASTM temperature versus volume

distilled for a well fractionated product will appear as
Heavy Naphtha
Light Distillate
Heavy DisUllate
Atm. Gas Oll
.
.
. i~;f~ 1 l~~t~S EP i~~m
1
, - - - S e t by allowable furnace temp. - - -
a straight line, or at least nearly straight. Thus it is
possible to develop fraction properties from a minimum
of information. TABLE 2-Typlcol Gas Specifications
Material Balance. The material balance is estimated Separation
as a function of the desired characteristics of the frac-
Hvy. Naph.-Lt. Naph . 20 toU
tions and the amount of crude that can be vaporized at Lt. DlsUI.-Hvy. Naph . 25 to 50
Hvy. DlsUI.-Lt. Distil . 10
the outlet conditions of the furnace. It is necessary to Gal Oll-Hvy. Distil . 5 to 10
estimate the number of actual trays in the column and
the operating pressures of the column in order to set the
conditions at the furnace outlet. liminary calculations. Other recommendations are given
A simplified version of the crude column is shown in by Nelson. 2 Packie's method 1 gives an estimate of the
Fig. 3. The number of trays that have been observed in relation between number of trays and reflux ratio.
existing installations are shown along with some recom- Operating pressures are estimated by assuming a pres-
mendations for tray numbers to use when making pre- sure of 0.5 to 1.0 psig. in the final accumulator, i.e., the

FIe. 5-ASTM VS. TBP (5% to 0%. 95% to 100%.)'

December 1969 97
HOW TO DESIGN CRUDE DISTILLATION ...
. . . The desired product specifications determine the
vessel which serves as a suction drum for the compre~sor
which feeds the gas recovery plant. Ordinarily, this \I,ill
be the only accumulator in the system although units
have been designed using a primary condenser to generate
reflux followed by a secondary exchanger for condensing
overhead product. In this latter case, this final drum also
serves as a suction drum for the recovery plant feed com-
pressor: this drum will operate at a pressure of 0.5 to 1.0
psig. For pressure drop through the condensers, use 2.5
psig. per shell which will also take care of piping. Use 5
psig. across the tower itself. Use 5 psig. drop between the
furnace outlet and the entrace to the tower flash zone.
Product specifications determine the cut points between
fractions. These temperatures, in turn, determine the
quantity of each fraction which will be produced. The
method to calculate the material balance is as follows:
1. Convert the TBP curve of the whole crude into an
equilibrium flash vaporization (EFV) curve for the pres-
sure at the charge furnace outlet.
2. Calculate the heat content for both vapor and
Fig. ~ASTM VS. TBP (10% to 0%.90% toi .'0Q.9Io).
liquid phases of the charge at the furnace outlet tempera-
ture and pressure.
3. Repeat the preparation of the EFV curve for the
total pressure at the flash zone inlet.
4. By trial-and-error, find the crude vaporization at
the flash zone total pressure which results in the same
heat content as at the furnace outlet.
5. Plot a line of constant heat content as determined
by the two conditions of Steps 2 and 4. The volume of
flashed crude leaving the flash zone will lie on this line at
a flash zone temperature of 1_2 0 F lower than the flash
zone inlet temperature of Step 4.
6. The net distillate is equal to the total crude flash
minus the overflash. Overflash is taken to insure adequate
vaporization and to make sure there will be sufficient
reflux in the gas oil and heavy distillate fractionating
zone.
7. Set the stripping steam rate to the bottoms stripping
zone at 10 pounds per barrel of net bottoms. Net bottoms
is the sum of flash zone liquid and condensed overflash
from Step 6.
e cut points to use for separating crude fractions . ..
8. Calculate the hydrocarbon partial pressure at flash
zone conditions.
9. The volumetric yields of the distillate fractions are
determined by converting their ASTM specifications into
TBP initial and end points using Figs. 4-6. The TBP cut
points on either side of a fraction establish the volu-
metric yield ·of that fraction.
10. The ASTM, TBP and EFV data for aU fractions
are determined with the aid of Figs. 4-6 and the correla-
tions of Edmister. 5 The ASTM and EFV curves are
plotted and checked for consistency with specified key
temperature data.
11. Extrapolate the EFV curves from their initial
points to the points representing minus 11.1 volume per-
cent to account for the removal of 10 percent front ends
from the product streams by the product strippers.
12. The separation of the light naphtha in the con-
denser-accumulator is established by vapor-liquid equilib-
rium calculations. The front end analysis of the crude
and the TBP estimates for the light naphtha are used
for this step.
sections of the tower. It seems particularly suspicious in
light of stating that heat removal is more effective on one
of two adjacent trays. Until more operating data is avail-
able, the assumption of linear temperature drops between
draw trays is recommended since it results in a higher
value of circulating reflux, cooler size, and tower size.
Thus, any error inherent in the assumption is on the safe
side.
Draw tray temperature assumptions are checked by cal-
culating the bubble-point temperature of the unstripped
product at the partial pressure of the product vapor in
the total vapor leaving the draw tray. This is done by
making a heat balance around the draw tray and calcu-
lating the amount of internal reflux required to absorb
the excess heat. This first requires making a heat balance
at the first tray below the draw tray in order to establish
circulating reflux requirements.
Side strippers are calculated in different ways for the
steam stripper than for the reboiled stripper. The steam
stripper is tl:e simpler of the two cases. The steam rate
is arbitrarily set at 10 pounds per barrel of stripper net

Heat Balance. Aside from heat accompanying the strip-

ping steam, the only heat to the column is added by the
charge furnace. For most cases, the furnace outlet tem-
perature is assumed to be 700 0 F. The furnace outlet tem-
perature should not exceed this temperature without spe-
cific reasons to the contrary. Some refiners limit furnace
outlet temperatures to 650° F for kerosine and jet fuel
productions.
The influence of charge heat balance on the flash zone
already has been discussed in the section on material
balance. The bottoms product is assumed to leave the
column at a temperature 30° F lower than the tempera-
ture of the flash zone. The other fractions are withdrawn
from the column at dra\-I' tray temperatures determined
by Fig. 7.
Note the conditions for using Fig. 7 since it correlates
draw tray temperature against the EFV temperature of
the product on the tray. Gas oil and bottoms are assumed
to be steam stripped while all other products are reboil
stripped. For side draw products, bubble point tempera-
tures for the unstripped liquid are used. For the overhead
product, the dew point temperature is used.
For Fig. 7, the flash zone pressure is assumed to be 24.7
psia. If a higher flash zone pressure is used, higher tem-
peratures will result. If steam stripping is used instead of
reboiling, lower temperatures will result. If only the prod-
uct portions are stripped, lower temperatures result.
The number of trays and the position of the draw trays
is estimated on the basis of the data given earlier in Fig.
3. These estimates will be confirmed by calculations. Esti-
mated temperatures and pressures are plotted versus tray
number to approximate a column profile.
Some investigators have stated that 40° F temperature
rises are experienced between -the draw tray and the first
and second trays below the draw and a 15° F drop occurs
between the draw tray and the one above. This does not
seem logical in many cases, particularly in the lower Fig. 7-The EFV of a product sets draw tray temperature.

HYDROCARBON PROCESSING December 1969 99

HOW TO DESIGN CRUDE DISTILLATION ...

bottoms. For distillate fractions, this will result in a strip- The temperature of the liquid on the top tray is cal-
ping rate of between 6 and 10 volume percent of the gross culated as discussed previously by making a heat balance.
stripper charge. This is shown by Envelope III of Fig. 8. On this tray however, instead of using the bubble point
The trend in recent years has been to specify reboiled temperature, the dew point temperature is adjusted to
strippers wherever thermally possible. This is due to two the partial presure of the condensible hydrocarbons in
factors: Primarily, stripping steam increases the size of the total vapor leaving the top tray. The applicable en-
the crude tower, the size of the condenser, and increases velopes for top tray calculations are Envelopes V and VI
the load on the effluent water treating facilities. Secon- on Fig. 8.
darily, in jet fuel production, it is mandatory that this
finished product be completely water-free.
Care should be exercised in specifying reboiled strip-
pers to insure that an economical heat source is available.
For the reason that a high temperature oil source is sel-
dom plentiful, the light gas oil is usually steam stripped.
Heavy distillate and lighter streams can be reboiled in
most refineries.
For steam strippers, the temperature of the stripped
material leaving the bottom of the stripper is assumed
to be 30° F lower in temperature than the corresponding
draw tray temperature. For reboiled strippers, this tem-
perature is assumed to be 30° F higher than the corre-
sponding draw tray temperature.

TABLE 3-Narrow Fractions of 36.3* API Gravity Crude 011

TBP Cum. % on Crude Cut Mol. Cum.

Cut Cut Pt., GraTlty, Wt. Mola per
No. OF Wt. Vol. °API Celc. 100 Bbl.
1- 0.59 1.00 42.1\ .41
2-- '67 8.12 4.70 114:i 68.1 13.25
3 108 5.62 8.04 93.0 72 23.49
4 145 6.93 9.70 81.1 85 28.03
5 172 8.5.~ 11.63 71.0 87 33.45
6 200 10.56 13.98 62.9 94 39.82
7 212 12.31 15.96 5$.2 96 45.20
8 231 14.18 18.03 64.6 99 00.77
9 2Ii7 15.96 20.01 55.1 104 55.82
10 269 17.89 22.16 5U 113 60.86
11 288 19.72 24.13 50.0 116 65.51
12 aoo 21.16 25.67 48.7 119 69.08
13 317 23.04 27.69 48.8 125 73.52
14 335 24.95 29.73 47.8 132 77.79
15 350 26.29 31.15 46.0 136 SO.70
16 373 28.26 33.23 45.7 142 84.79
17 382 30.13 35.18 43.1 148 88.52
18 400 31.35 36.45 42.3 154 90.85
19 425 33.28 38.44. 41.1 162 94.36
20 437 35.24 40.44 39.9 167 97.82
21 460 87.24 42.45 87.2 176 101.17
22 480 39.28 44.48 36.1 186 104.40
23 496 41.50 46.69 36.2 193 107.79
24 500 42.24 47.42 34.7 198 108.89
25 620 44.27 49.42 84.1 202 111.85
26 543 46.38 61.49 38.4 210 114.81
27 664 48.48 63.55 33.3 221 117.61
28 681 50.61 65.65 33.6 236 120.27
29 699 52.63 57.64 83.2 244 122.71
30 616 54.84 59.79 81.7 250 125.32
31 625 65.SO 60.72 SO.8 258 126.42
32 650 67.94 62.76 29.1 254 126.81
83 670 60.08 64.SO 28.8 276 131.10
34 695 62.33 66.94 27.9 287 133.41
86 700 63.36 67.92 27.7 298 134.~

36
37
718
737
66.42
67.48
69.87
71.82
27.5
27.4
...
...
......
. .....
88
39
762
777
69.66
71.66
78.78
75.76
26.9
26.3
...
...
......
. .....
40 804 78.76 77.72 25.8 ... ......
41 821 76.87 79.69 25.4 ... .......
42
43
44
837
870
918
77.98
80.27
82.66
81.66
83.78
85.97
25.1
24.2
23.1
...
...
... .. .....
.....
.....
Residuum 99.64 100.44 1U ... ......
• Cut No. lis C. throulb Ca',.
... Cut No.2 II Co·... FIg. 8--Envelopes used for making heat balances.

100 December 1969 HYDROCARBON PROCESSING

 Example Calculations TBP Slope = (TrO% - T,o'if,) /60
= (717 -144)/60 = 9.55°F/%
To elaborate on the generalizations made in the earlier
section, an example problem will be calculated for a col- For volumetric average boiling point,
umn using subcooled reflux (Type R). The charge ca- VAPB = (T2 0% + T 6o% + TsO$) /3
pacity will be 55,000 barrels per day of a 36.3° API crude = (255 + 531 + 819) /3 = 535° F
oil having an analysis as given .in the following section.
From a generalized correlation~:
CRUDE OIL EVALUATION
MeABP = VABP - 75
The design of a crude oil distillation unit requires a
knowledge of the type of crude to be charged. The crude = 460° F or 920 0 R
oil analysis usually is given in the form of a true boiling The characterization factor is defined as
point (TBP) curve and a light ends analysis. For the
example to be discussed here, Table 3 gives the boiling = (MeABP, °R)1. / 3/S p. Gr.
point data from which the TBP curve of Fig. 9 is plotted. = (920)1./3/0.843 = 11.5
The light ends analysis is given in Table 4. The other
properties of the crude needed for subsequent calcula- Equilibrium Flash Vaporl%ationo When a crude is
tions are derived from these tabular data. heated and allowed to vaporize so that all the vapor is
in equilibrium with the remaining liquid for anyone tem-
Characterization Factor. Enthalpy data needed for heat perature, a plot of percent vaporized versus temperature
balance calculations usually are correlated with the char- gives an equilibrium flash vaporization (EFV) curve.
acterization factor for gross hydrocarbon fractions. The These data are laborious to obtain experimentally. There-
characterization factor for each fraction is assumed to be fore, they are usually derived from TBP data.
the same as for the whole crude. To estimate the char- The method of Packie' assumes a straight distillation
acterization factor, it is first necessary to convert TBP
data into a mean average boiling point (MeABP) as
follows:

TABU 4-Llght Ends Analysis of Crucle

Compo Vo]•• %
Cl. .•......................... -269 0.01
C2 •.......................... -128 0.Q7
Ca .. -44 0.92
IC . 11 1.44
nC . 31 2.26
lC . 82 1.90
nC . 97 1.80
CP ••........................ 121 0.15
2. SDMB .. 136 1.15
2MP . 141
SMP . 146 0.75
n.Co . 166 1.10
MCP . 161 0.66
CH . 177 0.67
Benz .. 176 0.34
IC .. 194 3.77
nC . 209 0.95
DMP . 211 1.13
MCH . 214 1.88
Tot . 231 1.17

TABLE S--Crude EfV Calculations

EFV-FRL
Vol.
% TBP DRL FRL TBP-DRL TBP-DRL EFV-FRL EFV
6
1-
62 96
----
203 -34 0.39 -13 tQ,J
10 t« 144 235 0 235
20 256 240 299 ]5 0:86 '5 304
30 344 335 363 9 0.34. 3 S66
40 437 431 427 6 0.34 2 429
50 631 626 491 1\ 1I.34 2 493
60 623 622 US 1 0.34 0 US
70 717 717 619 0 619
80 819 8111 683 6 0:84 '2 686
85 897 861 715 36 0.34 12 727

Basis: Packie's method

DRL alope= (TBP70% -TBP 10%)/60 =
9.55 0 F/%
DRL 50% =]44 +40(9.55) = 526 0 F
FRL 50% = DRL50% - 35 = 491 0 F
FRL slope =6.4 0 F/% (from Packic curve1)
Fig. 9--The TBP of the crude is converted to EFV data.

HYDROCARBON PROCESSING December 1969 101

 HOW TO DESIGN CRUDE DISTILLAnON ...

. . . The conditions in the flash zone are determined by

reference line (DRL l through the 10 percent and 70 per- the furnace outlet temperature. For this example, make
cent TBP points. Then the cun'es reported by Maxwell G the first estimate 4 0 F less.
are used to perIOlm the calculations depicted in Table
5. The results are plotted in Fig. 9 as EFV at 14.7 psia. QFZ = Q.ro = 370,550,000 Btu/hr
T(FZ)l = 700 - 4 = 696° F
CHARGE CONDITION V(J'Z)l = 75.0 vol % or 70.9 wt %
= 0.709(675,800)
Charge Furnace. Fig. 3 gives a furnace pressure range = 479,100 lb/hr @ 46.1 0 API
of 14.9-15.4 psig. For this example, a furnace outlet pres-
sure of 15 psig (29.7 psia) will be used. Vaporization of L C1I'Z)1 = 675,800 - 479,100
the charge is dete1111ined by converting the atmospheric = 196,700 lb/hr @ 12.4 0 API
EFV curve to an EFV curve at the pressure of the furnace H(FZ)l @ 696° F & 46.1 0 API = 589 Btu/lb
outlet. This can be done by extending the atmospheric h CFZ )l @ 696° F & 12.40 API ~ 453 Btu/lb
EFV points on a generalized plot of vapor pressure versus
temperature (Cox chart). The results are shown in Fig. Q(J'Z)l = V(FZ)lH UI'Z)l + L(J'z)lh cJ.z)l
10 which is an enlarged view of the upper portion of = 479,100(589) + 196,700(453)
Fig. 9. = 371,300,000 Btu/hr. Too high.
The furnace outlet temperature is assumed to be 700° F.
The EFV curve fOl' 29.7 psia and 700° F in Fig. 10 shows Make the second estimate at 5° Flower.
72.5 volume percent crude will be vaporized. Referring
to Table 3, this volume percent is equivalent to 68.2 T(Fz)2 = 700 - 5 =
695° F
weight percent vaporized. V(FZ)~ = 74.8 vol % or 70.6 wt %
Since the total crude has a specific gravity of 0.843, the = 477,100 lb/hr @ 46.2° API
L(n)! = 198,700 lb/hr @ 12.5° API
equivalent of 36.3° API, the density of the vapor and
liquid portions is determined by Q(J'Z)'2 = 370,500,000 Btu/hr. OK

(sp. gr.)v = (sp. gr.) crude (wt frac) v/ (vol frac) V Therefore, 695 0 F is OK.
(sp. gr.h = (sp. gr.) crude(wt frach/ (vol frach

For 72.5 volume percent vaporized

(sp. gr.) v = 0.843 (0.682/0.725)
= 0.792 or 46.8° API
(sp.gr.)r. = 0.843 (1- 0.682)/(1 - 0.725)
= 0.976 or 13.5° API
Calculate the total heat content of the column charcic
at the conditions of the furnace outlet.
F = 675,800 lb/hr
V po = 0.682(675,800)
= 460,800 lb/hr @ 46.8° API
L po = 675,800 - 460,800
= 215,000 lb/hr @ 13.5° API
H po @ 700° F & 46.8° API = 591 Btu/lb
h po @ 700° F & 13.5° API = 457 Btu/lb
Qpo = V FoHpo + L1I'ohPO
= 460,800(591) + 215,000(457)
= 370,550,000 Btu/hr

Flash Zone. Assume the pressure in the flash zone will be

5 psi less than that at the furnace outlet; i.e., 29.7 - 5.0
= 24.7 psia. Construct an EFV curve for 24.7 psia as
shown in Fig. 10.
By trial-and-error, find the amount of crude vapori-
zation at the flash zone pressure which results in the same
total heat content as at the charge furnace outlet. This
Fig. IG--The EFV i,s corrected for column pressure.
wiII occur normally at a temperature of 4-6 0 F less than

102 December 1969 HYDROCARBON PROCESSING

the conditions at the outlet of the charge furnace . ..
Sf'ripplng Steam Effect. Construct a line of constant
heat content, Q,o. The volume of flashed crude leaving
the flash zone will lie on this line at a temperature of
approximately 2° F lower than the temperature computed
for the non-steam condition. Then
T(J'Z)ll = 695 - 2 = 693° F.
V(J'Z)S = 75.2 \'01 % or 71.0 wt %
= 480,500 lb/hr
Next set overflash at 2 volume percent of the total crude
charge. Then the net product distillates including over-
head vapor are
~D = 73.2 vol % or 69.0 wt %
= 466,300 lb/hr @ 46.5° API
= 3259 mol/hr
L OF = 480,500 - 466,300
= 14,200 Ib/hr @ 28.6° API
= 42 mol/hr
W = 675,800 - 466,300
= 209,500 lb/hr @ 13.6° API
= 614.2 Bbl/hr
Set steam rate at 10 pounds per barrel of bottoms rate.
S = 10(614.2) = 6,142 lb/hr
= 341 mol/hr
The partial pressure of the hydrocarbon portion is esti-
mated from a ratio of the mole rates.
PHO = P (vapor) / (vapor + steam)
= 24.7 (3301/3642) = 22.4 psia
Using the EFV curve for 14.7 psia, the point for 75.2
volume percent vaporized occurs at 653° F. Using a gen-
eralized chart of vapor pressure versus temperature (Cox
chart), the atmospheric conditions are equivalent to
693° F at 22.4 psia-eonfirming the estimated tempem-
ture and partial pressure for the hydrocarbons. Thus, the
flash zone conditions are
PFZ = 24.7 psia
T Fz = 693° F
QFZ = 370,550,000 Btu/hr
Bottoms Stripping. Assume bottoms temperature is
30° F lower than that of the flash zone.
T w = 693 - 30 = 663° F
h w @ 653° F & 13.6 ° API = 433 BtuJlb
Qw = 209,500(433) = 90,710,000 Btu/hr

Fig. 12-The ASTM and EFV data are computed from TBP.

Fig. ll-Material and heat' balance In the flash zone.

HYI:?ROCARBON- PRoOES'SING December 1969 103

 HOW TO DESIGN CRUDE DISTILLATION •..

With stripping steam available at 50 psig saturated FIRST DRAW TRAY

(65 psia & 298° F), the heat added is The draw tray which is used to withdraw gas oil D 1 is
H sw = 1179 Btu/lb calculated first. Make a heat balance about the bottom
=
Qsw 6,142( 1179) =
7,240,000 Btu/hr of the column which includes the tray below the draw
Summary. The results of the foregoing calculations are tray. This is Envelope I as shown in Fig. 8 and repeated
shown in Fig. 11. in Fig. 14. Tray temperature is read from Fig. 13 and
cooled reflux is at 400° F.
COLUMN CONDITIONS hRo1 @ 400 0 F& 26.6° API = 287 Btu/lb
The usual specifications for crude oil products are H R01 @ 623 0 F& 26.6° API = 514 Btu/lb
ASTM end points. and the gaps between the 5% ASTM Hxn @ 623 0 F& 46.5 0 API = 541 Btu/lb
and 95% ASTM. These specifications are listed in Table
HS1 @ 623 0 F& 24.3 psia = 1,347 Btu/lb
6 for this example. From these data, TBP cut points are
estimated by using Figs 4-6. The estimates are shown in Heat in = Heat out
Table 6. Q..z + Qsw + Qr..no1 = Qxn + QV.R01 + QS1 + Qw
The TBP curve for each product is reproportioned to 370,550,000 + 7,240,000 + R o1 (287) = 466,300(541)
°
extend from to 100 volume percent as shown in Table
7. Intermediate TBP data are read from the curve for
+ R o1 (514) + 6,142(1,347) + 90,710,000
R 01 = 116,900 lb /hr
the whole crude. Then Figs. 4-6 and Edmister's methodll
are used to estimate the final ASTM data for each prod-
uct. These results are added to Table 7 and plotted in TAILE 6--Ptoduct Specification.
Fig. 12. These calculated data are consistent with the
Eatimated
specified key temperature data. - -Gben
-,- ------
T100% TS-9S% T100% TBP $:;1~ ~i.'
Light Naphtha and Gas. Combine the light ends analy- Stream ASTM "8TM TBP TO%TBP oal % %
sis of Table 4- with TBP. data for the lighter boiling por- LI.Naph.... ~5 298 ... ----
22.lJ 22.0
20 273
tions of Table 3 to determine the composition distribution Hvy.Naph.. 380 399 248 11.8 33.8
35 379
shown in Table 8. Assume the overhead accumulator pres- Lt. Dlatll.... 560 587 359 19.2 63.0
sure is in the middle of the range suggested by Fig. 3, or 10 558
Hvy.D1stll.. 650 584 529 10.4 63.4
15.2 psia. 5 654
GuOll ..... 735 780 624 9.8 73.2
5 750
Use the calculation method shown in Table 8 to de- Bolloms.... ... ... 720 .. . 100.0
termine the distribution between vapor and liquid. The
calculation is made by trial-and-error, but only one trial
is shown as an example. These data will permit the com- TABle 7--Prodvct Et'V Calculations
pletion of the TBP curve for the liquid portion, or light
naphtha. CIUIl.
Vol. Wt.
Remember that the vapor portion is water-saturated. Stteam % % TBP toTBP toASTM toEFV ASTM EFV
For the conditions of 100° F and 15.2 psia Lt. Naph. ... 0 0
1-
-65
-- --- ---- -
3 66
10 2.2 -3 62 35 14 32 70
p....aler = 0.95 psia 30
50
6.6
11.0
41
156
44
115
24
100
13
67
56
156
83
150
PHO = 14.25 psia 70
90
100
15.4
19.8
22.0
206
255
298
50
49
43
36
39
40
18
18
18
192
231
271
168
186
204
The calculations of Table 8 show - 283 -313-
VII = 361 mol/hr Hvy.Naph.. 0
10
22.0
23.18
248
277 29 ia '(, 296 318
30 25.54 304 27 13 7 309 325
Then total vapor including water is 50 27.9 326 22 12 6 321 331
70 80.26 345 19 12 6 333 . 337
(361) 15.2/14.52) = 385 mol/hr 90
100
32.62
33.8
370
399
25
29
18
26
7
7
351
377
344
351
Water in the overhead vapor is Lt.Dietil.... 0 33.8 359 398 447
385 - 361 = 24 mol/hr or 4341b/hr 10 35.72 395 a6 ii '6 415 453
30 S9.56 432 87 19 10 434 463
50 43.40 467 35 21 10 455 473
70 47.24 504 37 25 12 480 489
Column Profile. Note Fig. 12 shows an extension of the 90 61.08 542 58 28 12 508 501
100 53.0 587 45 42 14 550 515
EVF curves to minus 11.1 volume percent. Since the
Hvy. Distil.. 0 53.0 529
r--- -- -542--596-
products will be stripped by removing 10 percent of the 10 64.04 657 28 13 5 555 601
front ends, this extension is made to estimate the lighter 80 56.12 587 80 15 7 670 608
50 58.20 606 19 10 5 580 613
properties of the products existing on the trays. 70
90
60.28
62.36
628
655
22
27
14
19
6
8
594
613
619
627
Draw tray temperatures are estimated from Fig. 7. 100 63.4 684 29 26 7 639 634
These temperatures along with estimates of hydrocarbon Guou..... 0 63.4 6U
-- -624--693-
10 64.58 650 26 :i.2 '4 636 697
vapor pressure are shown in Table 9. Draw tray locations 80 66.34 680 30 15 7 651 704
50 68.30 700 20 11 5 662 709
are estimated by Fig. 3. Now it is possible to construct 70 70.26 718 18 11 6 673 714
the temperature and pressure profile of the column as 90 72.22 745 27 19 8 692 722
100 78.2 780 85 32 9 724 731
shown in Fig. 13.

1.04 December .1969 HYDROCARBON PROOESSING

 -'--:-r
, ~,
!
I I
~'.

Another Heat Balance. Make a second heat balance
around the bottom of the column which includes the draw
tray (Envelope II).
hL8 @ 590 0 F & 26.6° API = 401 Btu/lb
hLs @ 579 0 F & 26.6 0 API = 394 Btu/lb
H Ls @ 590 0 F & 26.6 0 API = 495 Btu/lb
H(~D.Dl) @ 590 F & 50.0 0 API = 529 Btu/lb
0
0
H S8 @ 590 F & 24.15 psia = 1,331 Btu/lb
To establish flow rates, make a hydrocarbon material
balance around the stripper assuming V La is ten percent
of L, (Envelope III.)
La = ROT+ VL8 + D 1
= 116,900 + 0.1 La + 70,300
= 187,200/0.9 = 208,000Ib/hr
Then the heat balance becomes
Heat in = Heat out
Qn + Qsw + QaOT + Qr.s + QV>L8 = Q(~Dl)
+ QV,LS + Qsa + Qw .
Qr.s
370,550,000 + 7,240,000 + 116,900(287) + L (394) 9
+ 20,800(394) = (466,300 - 70,300) (529)
+ 208,000(401) + L s (495) + 6,142(1,321)
+ 90,710,000
La =: 274,800 lbjhr or 903 mol/hr
Check original estimate of column temperature by com-
puting the partial pressure of La using a mole ratio
PXO = 24.1(902/4271)
= 5.09 psia
T o% TBP @ atmospheric is the same as
595 0 F @ 5.09 psia. Thus, OK.
Stripping Steam. Steam is used at a rate of 10 pounds
per barrel of total stripper bottoms which is

TABLE a-Separation of Overhead Into light Naphtha and Gas

TABP, Vol. Mol.

CODIP. 'p 9'0 Gal/Dt Lb/Gal Lb/1Ir MW M.I/I1r %
C, ........... -259 om 10 2.6
--- so 16 -1.8
I- --0.13-
C............ -128 0.07 87 3.144 210 80 7.0 0.40
Ca ........... - 44 0.92 888 4,220 3,740 H 85.0 5.98 ,
.~

ic. ........... 11 1.44 1.386 4.886 6,400 68 111.9 7.84

.c. .......... 81 2.28 2.178 4,865 10,680 68 182.4 12.78
iC............ 82 1.00 1,829 6.199 9.600 72 13U 9.24
DC........... 97 1.80 1,733 6,253 0,100 72 120.4 8.86
116-1U°1'...•. 130 1.6 1,640 4.388 6,760 86 78.6 5.60
144-176'1'.... , 160 2.5 2,406 6.806 14,180 80 160.3 11.16
176-203'1'.... , 189 2.5 2,~06 6.336 12.840 05 136.l 9.47
203-229"1'..... 216 2.5 2,~06 6.470 1MOO 00 157.1 11.01
22ll-256"F.... , 243 2.5 2,406 5.616 13,510 103 181.1 0.10
266-298"J..... 277 2.0 1,926 7.020 13.610 113 119.6 8.37
Tola! OR... ... 22.00 21,175
--- - - -I - 1,427.0
.... 116,000 .. - -- -
100.00

TABLE a cantlnuecl--Vapor·L1quld Equlllbrium' Calculations

(OB) (K)
(Lm +](
K@
---
FUit Loat X.b"id. Ds
14.25
p.ia
Compo 10000F La- Ln-
Trial,
5 .0
Trial,
2 .3
Vapor, Va
Mol/ll1 LbjH.r
----,---
Mol/Ilr
(]Iy
1./111
illereD'.)
Gal/Hr Vol. '1l>
0, 197.0 0.18 0.13 1.8 80 o 1-----
0 0 ....
c. ".0 0.49 0.46 6.6 100 .4 20 0 Nil.
0. 11.& 6.40 4.71 67.2 2,~ 17.8 790 187 1.1
~ U 6.42 4.76 67.9 3,930 44.0 2,MO 548 8.3
DC. 3.8 9.76 6.71 96.7 6,840 86.7 6,040 1,030 8.2
lC. U14 U2 UO 41.4 2,080 90.5 6,520 1,254 7.6
DC. 1.10 4.67 2.37 33.8 2,430 92.6 6,670 !,i70 7.7
130"11 6.603 2.06 0.93 18.3 1.140 65.2 6,610 1,278 7.7
180'11 0.887 2.80 1.14 16.3 1,480 143.0 12,730 2.159 13.0
180'11 0.182 1.44 0.56 7.8 740 127.3 12.100 2.208 13.7
216"F 0.10ll 1.00 0.39 6.6 650 151.6 Is.o10 2,320 14.0
243"11 0.068 Q.l5O 0.18 2.6 280 128.5 18,250 2,369 lU
'D'M! 0.026 0.21 0.07 1.0 110 118.5 18.400 1,909 11.6
ToW 40.24 26.30 881.0 22,800 1,066.0 93.700 16.502 100.0
Lo... OX:

TAIIlE 9--P... Umlnary EstImates of Column Condition.

Prusure, Eat.
Temp.• OF Millimeters ab•. D...."
Stream Te~••
UllItdppecl O%EFV 100% EF'V p PRO
Lt. Nallh. ......... 56 204 1.044 916
860
216
i:t'?'Dl:tie~:::::::: 308 361 1.096 316
436 816 1.168 670 400
Hvy. Dl.tU, ....... 685 634 1.205 840 525
Atm. Gas Oil...... 686 731 1,251 2W 590
1:11- 13--Column temperature and pressure profile.

H'£DROCWUmN ,PROCESSING December 1969 105

 HOW TO DESIGN CRUDE DISTILLATION ... Liquid loading is
~. = Rc • + R I•
= 116,900 + 165,600
= 282,500 lb/hr@ 26.6 0
.-\PI
Vapor loading is
4V = V~D + R!, + Sw
= 466,300 + 282,500 + 6,14-2
= 754,942 lb/br or 4,529 mol/hr
TABU: 1~roduct Stream Summary

Stream
ASTM TBP
EP,oF ~VoJ. %
I BbJ/D "API Lb/llr
Gas.V•.......... 22.0 2.U20 22,300
Lt. N~b., D•..... Zii 273 9,~SO 7i 93.700
75,400
6,490 46
r~))lstu.'~?~: : :
377 379 11.8
650 558 19.2 10,5flO 34 131,600
Hvy. Distil. D•... 6a9 654 10.4 5.720 30 73,000
Atm. Ga. Oil, D•.. 724 750 9.8 5.390 26.6 70,aoo
... -...-
Total Stream., 1:D
Reduced Crude. , .. ." ... I 73.2
26,8 I
I
40,260
14,740
I 46.5
la.6
1'466,300
200.500
Crude Cbatle ..... .. , - ...-!loo.O 55,000
I 36.3
I 675,800

SUMMARY OF CALCULATIONS
Each of the draw trays are computed in a manner
similar to the first draw tray. Note ho\\"e\'er that the re-
boiled strippers are assumed to have temperatures 30 0 F
R e• +D = 116,900 + 70,300
1 higher than their associated draw trays, instead of 30 0 F
=
137,200 lb/hr @ 26.6 0 API lower as in the steam stripper. A summary of the final
or 598 Bbl/hr product is given in Table 10.
S1 =
10(598) = 59801b/hr
or 332 mol/hr NOMENCLATURE
QSl = 5980( 1179) = 7,050,000 Btu/hr D distillate rate
DRL distillation reference line
Then the stripper bottoms cooler duty is EFV equilibrium flash evaporization
F feed rate
QOl = 187,200(381-275) H
h
vapor enthalpy
liquid enthalpy
= 19,840,000 Btu/hr K vapor·liquid equilibrium constant
L liquid rate
Product heat content is MW molecular weight
MeABP mean avera~e boiling point
Qnl = 70,300(275) NBP normal boiling point
OH overhead rate
= 19,330,000 Btu/hr P total pressure
partial pressure
Tray 7 Conditions. The induced reflux is &
R
heat content
reflux rate
S steam rate
R tf '= Ref [ (h8'23°1i'- h,oo°li') / SpGr specific gravity
(H838o F - hG230p) h6.00 API T temperature
= 116,900(428 - 275) /(536 - 428) TBP true boiling point
V vapor rate
= 165,600 lb/hr VABP volumetric average boiling point
W residual rate
Operating conditions are Subscripts
c cooled
T7 = 623 0
F and P7 = 24.15 psia FO
FZ
furnace outlet
flash zone
HC hydrocarbon portion
i internal
OF overflash
About the author
R. N. WATKINS joined Creole Peflro- LITERATURE CITED
leum Corp., Amuay, Venezuela, after 1 PaclI;i';t J. w.~ "Diltillation Equipmcnt in the Oil Relining Industry," 1'ra.,.
p"eparing this article. He has wewked AlCM. 'Vol. ,7. l!*l'. p. 5lo.
• Ne1Ion. W. L,. "Petroleum Refinery Engineering," <lth Ed., McGraw·HiII,
as a process engineer few Monsanto Co., 1958.
Celanese Chemical Co., Fluo'1' CO'fp. • Hengstebeck R. J., "Petroleum Procesung," McGraw·Hill, 1959.
• Prater, N, H. and BoYd. C. W,. "How to Calculate Multidraw Towers,"
Ltd. and Bechtel Corp. He holds B.S. Oil anil Gas Jo~",al May 2, 1955. p. 72.
degrees in chemistry and chemical en- • Edmister. w:C.• "Applied Hydrocarbon Tbermodynantk.," Gul£ Publish.
jnJf Co:. 19H.
gineering f'1'om University of Kentucky • Maxwell. J. ll" "Data llook on Hydrocarbons," D. van Nuotrand Co.• 1965,
and is a '1'egistered p'1'ofessional engi. , American "'petrOleum Institute, '\Technical Data Book-Petrolcum Re6mng,"
1966.
neer. Mr. Watkins specializes in the
process design of petroleum and petro- lndex!.o.J Terms: Boiling Poinu-6,7. Columns/Process/·910, Crudes· I , De.
chemical plants with pa'1'ticula'1' emphasis on distillation. sjgn-4,8, Distillation.4.8,9, Equations·IO. Heat·6. Oils-I,2. Pbysical Prop_erties.
6,7. Properties/Charactemtic:s/.6,7, Proportioning.7, Sepa,·ation-4,8,9, Vapori.
zabon-7,

December 1969 HYDROCARBON PROCESSING