1. EVALUATION OF PROGRESSIVE DISTILLATION Dan Dobesh – Jesse Sandlin Dr. Miguel Bagajewicz 04.29.2008

2. This presentation is not about this Insurance Company

3. Not about this one either…

4. Our Mission “Analyze progressive crude fractionation, a technology patented in 1987 that claims to be more energy efficient than conventional fractionaltion.”

5. 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.”

6. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

7. 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_2041 839_siphon-gas-car.html www.freddiesasphaltoval.com/ Fuels Solvents Lubricants Plastics Detergents Nylon Polyesters http://www.lakewoodconfer ences.com/direct/dbimage/ 50241031/Plastic_Toy.jpg Petroleum Products

8. 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 Atmospheric Crude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626 Diagram Source: http://en.wikipedia.org/wiki/Oil_refineryhttp://en.wikipedia.org/wiki/Oil_refinery ** Haynes, V.O. “Energy Use in Petroleum Refineries.” ORNL/TM-5433, Oak Ridge NationalLaboratory, Tennessee, September (1976).

9. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

10. Light Crude Feed Petroleum crude component boiling points range from -161 C (CH 3 ) to over 827 C (C 40 H 82 +)

11. Heavy Crude Feed Petroleum crude component boiling points range from -161 C (CH 3 ) to over 827 C (C 40 H 82 +)

12. 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

13. Product Specifications Generated from Pro/II Computer Model This graph compares the boiling point range of the five products

14. D86 5% point heavy component Product Gaps Explanation - D86 95% point light component 390⁰ C- 360⁰ C = 30⁰ C D86 5% point heavy component D86 95% point light component Positive gaps indicate more distinct separation.

15. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

16. Conventional Distillation

17. Conventional Distillation Simulation

18. Gaps – Conventional Distillation D86 95% point anchors products on the right side, gaps change the left side

19. 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

20. 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 Atmospheric Crude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626

21. 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 Atmospheric Crude Fractionation Units. Part I: Targeting.” Ind. Eng. Chem. Res. 2001, 40, 617-626 Stacked columns from the indirect sequence.

22. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

23. 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.

24. Progressive Crude Distillation Patent

26. Technip’s Progressive Brochure

29. Progressive Crude Distillation - Gaps

30. Gaps – Progressive Distillation Light Crude

31. 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

32. Indirect Direct Conventional vs. Progressive Summary Recover heavy components firstRecover light components first One main column Many columns

33. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

34. Simulation Development Method 1)Build PRO/II progressive crude simulation 2)Obtain correct D86 95% points 3)Synchronize product gaps 4)Mimimize heat duty 5)Compare to conventional heat duty 6)Determine areas for improvement

35. Simulation Assumptions SRK is a valid thermodynamic model for hydrocarbon systems Pseudocomponents represent crude composition PRO/II provides a close representation of reality

36. Basis of Comparison PRO/II Conventional Simulation, 260 ⁰C steam

37. 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.

38. Initial Complex Simulation Unnecessarily complicated Too many products for conventional comparison

39. PRO/II Computer Model Patent Vacuum distillation for residual product is not important for comparison

40. Second Type Simulation Too much furnace heat utility: 200+ MW Each column has a reboiler

41. Third Type Simulation Furnace utility is lower, but steam utility his very high All seven columns have steam input

42. Heating Supply-Demand Temperature ⁰C F*Cp MW Demand Curve – dark line showing heat needed by system Supply 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

43. Final Type Simulation Replaced steam with reboilers in the first series of columns

44. Heating Supply-Demand Temperature ⁰C F*Cp MW

45. Specifications

46. Variables

47. Controller-Variable Systems 1)Naphtha-kerosene gap varies with steam flowrate in Column 1 2)Kerosene-diesel gap varies with steam flowrate in Column 2 3)Diesel-gas oil gap varies withsteam flowrate in Column 3 4)D86 95% points are obtained by varying the condenser duty Column 1 Column 2 Column 3

48. After hours of red simulations and Red Bulls… days… weeks MONTHS After hours of red simulations and Red Bulls… Happy hour

49. 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

50. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

51. Conventional vs. Progressive Light Crude 15% Decrease 9% Decrease

52. Light Crude

54. Progressive Heat usage Light crude heat utility diagram The intersection that is unaccounted for is the cold and hot utility Hot Utility Cold Utility

55. Progressive Heat usage Light Crude Temperature ⁰C F*Cp MW

56. Conventional vs. Progressive Heavy Crude 9% Decrease 14% Decrease

59. Progressive Heat usage Heavy crude heat utility diagram

60. Progressive Heat usage Heavy Crude Temperature ⁰C F*Cp MW

61. 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.”

62. 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

63. 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

64. Overview 1)Background: – Distillation Specifications – Conventional Crude Distillation – Progressive Crude Distillation 2)Methodology 3)Results 4)Accuracy & Limitations

65. 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

66. 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

67. Questions