EVALUATION OF PROGRESSIVE DISTILLATION

Dan Dobesh – Jesse SandlinDr. Miguel Bagajewicz

04.29.2008

This presentation is not about this Insurance Company

Not about this one either…

Our Mission“Analyze progressive crude fractionation, a technology

patented in 1987 that claims to be more energy efficient than conventional fractionaltion.”

Punchline“Progressive Distillation can reduce the heat duty

requirement of the distillation process by 17% for a heavy crude, and use 16% less furnace heat utility while

producing more valuable products for a light crude.”

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Petroleum Value Chain

http://en.wikipedia.org/wiki/Image:Oil_well.jpg

Petroleum Production http://en.wikipedia.org/wiki/Oil_refinery

Petroleum Refining

www.ehow.com/how_2041839_siphon-gas-car.html

www.freddiesasphaltoval.com/

FuelsSolventsLubricantsPlasticsDetergentsNylonPolyesters

http://www.lakewoodconferences.com/direct/dbimage/50241031/Plastic_Toy.jpg

Petroleum Products

Oil Refinery Schematic

Over 2% of the energy content in a crude stream is used in distillation.*

Distillation accounts for about 40% of energy use in a refinery.**

* Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626

Diagram Source: http://en.wikipedia.org/wiki/Oil_refinery

**Haynes, V.O. “Energy Use in Petroleum Refineries.” ORNL/TM-5433, Oak Ridge NationalLaboratory, Tennessee, September (1976).

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Light Crude Feed

Petroleum crude component boiling points range from -161 C (CH3) to over 827 C (C40H82+)

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Normal Boiling Point (NBP) of Component (°C)

Barr

els/

day

Heavy Crude Feed

Petroleum crude component boiling points range from -161 C (CH3) to over 827 C (C40H82+)

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Conventional Distillation Products Heavy Crude

NBP of Component (°C)

Barr

els/

Day

ASTM D86-07b, “D86 Point”• American Society for

Testing and Materials (ASTM): international organization that is a source for technical standards

• Rigorously developed method for quantitatively testing the boiling range of a petroleum product

(1) Oil sample heated in glass flask using electric heater

(2) Vapor is condensed and collected

(3) Temperature versus amount collected is recorded

• Not applicable to products containing large amounts of residual

Product SpecificationsGenerated from Pro/II Computer Model

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

1000

2000

3000

4000

5000

6000

Naphtha

Kerosene

Diesel

Gasoil

Resid

Crude FeedNBP of Component (°C)

Barr

els/

day

This graph compares the boiling point range of the five

products

D86 5% point heavy component

-263.2-43.6

31.1 121163

212262

312362

412462

512562

612662

713761

823924

10211107

12251438

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0.18

0.2

NBP of Component

Com

positi

onProduct Gaps Explanation

- D86 95% point light component390⁰ C - 360⁰ C = 30⁰ C

D86 5% point heavy component

D86 95% point light component

Positive gaps indicate more distinct separation.

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Conventional Distillation

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

Crude Composition

NBP of Component

Com

positi

onConventional Distillation

Simulation0

0.020.040.060.08

0.10.12 Naphtha

NBP of Component

Com

posi

tion

-16413.2 73

128183

239294

350405

495597

781

00.05

0.10.15

0.2 Kerosene

NBP of Component

Com

posi

tion

00.05

0.10.15

0.20.25 Diesel

NBP of Component

Com

positi

on

00.05

0.10.15

0.2 Gasoil

NBP of Component

Com

posi

tion

-0.04

0.01

0.06

0.11

0.16 Resid

NBP of Component

Com

positi

on

Gaps – Conventional Distillation

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0.00E+00

1.00E+03

2.00E+03

3.00E+03

4.00E+03

5.00E+03

6.00E+03

Conventional Distillation Products Light Crude

Naphtha

Kerosene

Diesel

Gasoil

Resid

Crude Feed

NBP of Component (°C)

Barr

els/

Day

D86 95% point anchors products on the right side, gaps change the left side

Conventional = Indirect

Takes the heaviest component as the bottom product in each column. Lighter components are sent to the next column.

Source: Smith, Robin, Chemical Process Design

Conventional = Indirect

Stacking these columns on top of each other is essentially conventional distillation.

Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626

Conventional = Indirect

Stacking these columns on top of each other is essentially conventional distillation.

Bagajewicz, Miguel and Ji, Shuncheng. “Rigorous Procedure for the Design of Conventional AtmosphericCrude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626

Stacked columns from the indirect sequence.

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Patent: Process for Distillation of Petroleum by Progressive

Separations• This is an expired patent for crude fractionation that is now being commercialized by Technip.

• Main idea is to heat components only as much as necessary.

• Several companies are excited by this concept that promises large energy savings.

• A new refinery is being built in central Germany using this concept.

Progressive Crude Distillation Patent

Progressive Crude Distillation Patent

Technip’s Progressive Brochure

Technip’s Progressive Brochure

Technip’s Progressive Brochure

Progressive Crude Distillation - Gaps

-164 -42 50 86128

169211

253294

336378

419495

573663

8270

0.005

0.01

0.015

0.02

0.025

0.03

0.035

Crude Composition

NBP of Component

Com

positi

on

-164 -42 50 86128

169211

253294

336378

419495

573663

8270

5001000150020002500300035004000

Top of Column 1

NaphthaKerosene

NBP of Component (°C)

Barr

els/

Day

-16413.2 100

169239

308378

467597

8270

200400600800

10001200140016001800

Top of Column 2

KeroseneDiesel

NBP of Component (°C)

Barr

els/

Day

-164 -42 50 86128

169211

253294

336378

419495

573663

8270.00E+002.00E+024.00E+026.00E+028.00E+021.00E+031.20E+031.40E+031.60E+031.80E+03

Top of Column 3

DieselGasoil

NBP of Component (°C)

Barr

els/

Day

-164 -42 50 86128

169211

253294

336378

419495

573663

8270

0.02

0.04

0.06

0.08

0.1

0.12

Naphtha

NBP of Component

Com

positi

on

-164 -42 50 86128

169211

253294

336378

419495

573663

8270

0.020.040.060.08

0.10.120.140.160.18

Kerosene

NBP of Component

Com

positi

on-164 -42 50 86

128169

211253

294336

378419

495573

663827

0

0.05

0.1

0.15

0.2

0.25

Diesel

NBP of Component

Com

positi

on-164 -42

13.2 50 73100

128155

183211

239266

294322

350378

405439

495549

597663

7810

0.02

0.04

0.06

0.08

0.1

0.12

Gasoil

NBP of Component

Com

positi

on

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

Resid

NBP of Component

Com

positi

on

Gaps – Progressive DistillationLight Crude

-164 -4213.2 50 73

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266294

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439495

549597

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0

1000

2000

3000

4000

5000

6000

NaphthaKeroseneDieselGasoilResidCrude Feed

NBP of Component (°C)

Barr

els/

Day

Progressive = Direct

Takes the lightest component as the top product in each column. Heavier components are sent to the next column.

Source: Smith, Robin, Chemical Process Design

Indirect Direct

Conventional vs. Progressive

Summary

Recover heavy components first Recover light components first

One main column Many columns

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Simulation Development Method

1) Build PRO/II progressive crude simulation2) Obtain correct D86 95% points3) Synchronize product gaps 4) Mimimize heat duty5) Compare to conventional heat duty6) Determine areas for improvement

Simulation Assumptions

• SRK is a valid thermodynamic model for hydrocarbon systems

• Pseudocomponents represent crude composition

• PRO/II provides a close representation of reality

Basis of ComparisonPRO/II Conventional Simulation, 260 ⁰C steam

PRO/II Computer Model(s)Progressive Model – 4 column direct

Furnace heat duty = 89 MW This is higher than 58.7 MW for conventional distillation

Previous work suggested that this setup provided no furnace heat utility benefit over conventional distillation. Our results verify this.

Initial Complex Simulation

• Unnecessarily complicated

Too many products for conventional comparison

PRO/II Computer ModelPatent

Vacuum distillation for residual product is not important for comparison

Second Type Simulation

• Too much furnace heat utility: 200+ MW

Each column has a reboiler

Third Type Simulation

• Furnace utility is lower, but steam utility his very high

All seven columns have steam input

Heating Supply-Demand

Temperature ⁰C

F*C

p M

W

Demand Curve – dark line showing heat needed by systemSupply boxes – heat utility able to be recovered from system• Heat can be transferred down and left by second law• Heat can only move right across pinch via a pumparound

Final Type Simulation

Replaced steam with reboilers in the first series of columns

Heating Supply-Demand

Temperature ⁰C

F*C

p M

W

Specifications

Variables

Controller-Variable Systems

1) Naphtha-kerosene gap varies with steam flowrate in Column 12) Kerosene-diesel gap varies with steam flowrate in Column 23) Diesel-gas oil gap varies withsteam flowrate in Column 34) D86 95% points are obtained by varying the condenser duty

Column 1

Column 2

Column 3

After hours of red simulations and Red Bulls…days… weeks MONTHS

After hours of red simulations and Red Bulls…After hours of red simulations and Red Bulls…After hours of red simulations and Red Bulls…

Happy hour

Final Simulations

• Conventional: four simulations– 260 ⁰C steam, 135 ⁰C steam– Heavy feed, light feed

• Progressive: eight simulations– Reboilers, steam– 260 ⁰C steam, 135 ⁰C steam– Heavy feed, light feed– High heat exchanger temperatures, low heat

exchanger temperatures

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Conventional vs. ProgressiveLight Crude

15% Decrease

9% Decrease

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Conventional Distillation Products

NaphthaKeroseneDieselGasoilResidCrude Feed

NBP of Component (°C)

Barr

els/

day

Light Crude

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

1000

2000

3000

4000

5000

6000

Progressive Distillation Products Light Crude

NaphthaKeroseneDieselGasoilResidCrude Feed

NBP of Component (°C)

Barr

els/

Day

Progressive Heat usageLight crude heat utility diagram

-50 0 50 100 150 200 250 300 3500

50

100

150

200

250

300

350

400

Progressive DistillationLight Crude

H

T

The intersection that is unaccounted for is the cold and hot utility

Hot Utility

Cold Utility

Progressive Heat usageLight Crude

Temperature ⁰C

F*C

p M

W

Conventional vs. ProgressiveHeavy Crude 9% Decrease

14% Decrease

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

2000

4000

6000

8000

10000

12000

14000

16000

Conventional Distillation Products Heavy Crude

NaphthaKeroseneDieselGasoilResidCrude Feed

NBP of Component (°C)

Barr

els/

Day

-164 -4213.2 50 73

100128

155183

211239

266294

322350

378405

439495

549597

663781

0

2000

4000

6000

8000

10000

12000

14000

16000

Progressive Distillation Products Heavy Crude

NaphthaKeroseneDieselGasoilResidCrude Feed

NBP of Component (°C)

Barr

els/

Day

Progressive Heat usageHeavy crude heat utility diagram

-50 0 50 100 150 200 250 300 3500

50

100

150

200

250

300

350

400Progressive Distillation

Heavy Crude

H

T

Progressive Heat usageHeavy Crude

Temperature ⁰C

F*C

p M

W

Our Conclusion

“Progressive Distillation can reduce the heat duty requirement of the distillation process by at least 17%

for a light crude, and at least 16% for a heavy crude, while producing similar amounts of products.”

Economic Analysis

• 120,000 BPD plant• Gross profit = Product sales – Utility costs• Progressive provides gross profit increase of

$10.2 million each year using light crude feed and $27.3 million each year using a heavy crude feed

Vacuum Economic Analysis

• Gas oil and residue profits are recovered in equal amounts in both cases

• Progressive provides gross profit increase of $25.7 million each year using light crude feed and $57.2 million each year using a heavy crude feed

Overview1) Background:

– Distillation Specifications– Conventional Crude Distillation– Progressive Crude Distillation

2) Methodology3) Results4) Accuracy & Limitations

Limitations

• Different column sequences and setups may offer lower heat utility

• Optimum setup is based on composition of crude feed

• Simulations are a simplification of reality• Heat exchanger network in the simulation is

not optimized

Accuracy

• D86 95% point comparisons between conventional and progressive are within 0.1 degrees Celcius

• Product gap comparisons between conventional and progressive are within 1.0 degrees Celcius

• Flowrate comparisons between conventional and progressive are within 10 cubic meters per hour

Questions