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Single & multiple pre-ash designs of the crude distillation unit are studied.
The trade-off between CO2 emissions and the residue yield has been investigated.
Multi-objective optimization was used to nd the trade-off solutions.
Introducing crude pre-ashing reduces the total CO2 emissions.
Optimum vapour feed location has been investigated.
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 6 January 2014
Accepted 8 September 2014
Available online 16 September 2014
The Crude Distillation Unit (CDU) is among the major CO2 emitters in any petroleum renery. In view of
the simultaneous increase in the energy cost and environmental concerns, there is strong motivation to
analyse alternative methods to improve the energy efciency and consequently, to minimize CO2
emissions from conventional crude distillation. Crude pre-ashing is among promising techniques for
minimizing the heating energy requirements of the CDU. However, this might be at the cost of product
yield and/or throughput. This paper investigates the effects of using different pre-ash designs on the
energy efciency and associated CO2 emissions of the CDU. The resulting optimal solutions are presented
and their signicant features are discussed.
2014 Elsevier Ltd. All rights reserved.
Keywords:
Oil rening
Crude distillation unit
Pre-ash design
Heat integration
Multi-objective optimization
CO2 emissions
1. Introduction
The continual increase in the global energy demand and the
decline in fossil fuel reserves provide motivation for energy conservation in energy-intensive industrial processes. Different
methods are used to improve energy efciency of industrial processes such as the implementation of less energy-intensive technologies and the use of waste heat recovery systems. The Crude
Distillation Unit (CDU) is among the largest energy consumers and
consequently a large CO2 emitters in industrial processes. It is
estimated that the energy required for the CDU is equivalent to
about 2% of the energy contained in the crude oil [1]. For this
reason, many attempts have been made over the years to analyse
and improve the energy efciency of the CDU and to identify
promising modications based on pinch analysis and heat recovery
systems [2e6].
Crude pre-ashing is one of the promising energy conservation
methods, which can save a notable amount of energy within the
CDU. The basic principle of crude pre-ashing is to separate the
light fractions of the crude upstream of the furnace. Then, the light
fractions stream obtained is either mixed with the furnace outlet or
separately introduced into the main column at an appropriate
location. This could improve the hydraulic performance of the
furnace and reduce its energy consumption [7,8].
In the literature, research studies have been conducted to
investigate the effect of the implementation of crude pre-ashing
on the energy efciency of the CDU using different retrot strategies. Feintuch et al. found that the implementation of a pre-ash
1205
Offgas
Water
Vapour
Naphtha
PA1
Steam
Kerosene
PA2
Steam
Diesel
Vent
PA3
Steam
Water
AGO
Water
Crude oil
Desalter
Steam
Furnace
Preflash Drum
Furnace
Atmospheric Tower
1206
These products are sent for processing in downstream units to increase the value of nal products whilst the atmospheric residue is
further heated and distilled under vacuum conditions to achieve
the required separation among the heavy components at lower
temperatures.
3. Crude pre-ashing
One of the primary purposes of the crude pre-ash is to reduce
the operating pressure of the main furnace of the CDU by separating light vapours from the pre-heated crude. Pre-ashing can
also help in reducing the furnace duty and decreasing the vapour
load in the atmospheric column [13]. However, implementing
crude pre-ash may have implications on the performance of the
CDU, such as a reduction in the yield and quality of the distillate
products [12]. The impact of the crude pre-ash on the CDU depends on many factors such as the type of the pre-ash, its location
in the crude preheat train and the feed location of ashed vapour in
the main column.
It has been found that the best location for the crude pre-ash is
after the desalter in order to reduce the water content of the crude
which may cause corrosion in the following devices [8,12,14]. Two
main types of pre-ash devices are normally used in the industry:
pre-ash drums and pre-ash towers or pre-fractionators. Pre-ash
drums are simple vessels used to separate light vapours from the
crude before the furnace. Then, the separated vapours are sent
directly to the distillation column. The vapour feed location is a
function of many factors such as the temperature and compositions
of the vapour stream and operating philosophy [12]. Pre-ash
drums are usually used to increase the capacity of the CDU by
reducing the vapour load on the bottom section of the distillation
column. On the other hand, pre-fractionators are used to achieve
more effective separation and improve specications of the distillates. Vapours produced from the pre-fractionator are not sent to
the distillation column [9].
The efciency of crude pre-ashing can be improved by using
multiple pre-ashing where multiple pre-ash drums can be used
at different temperatures and pressures. Various vapour streams of
different compositions are produced and sent to different tray locations in the distillation column. The present work investigates
the implications of using crude pre-ashing on the environmental
performance of the CDU. Both single and multiple pre-ashing are
considered, and different vapour feed locations in the atmospheric
column are examined.
4. Multi-objective optimization
Often, optimization of real problems have two or more objectives. Many of these objectives such as prot, safety, and emissions
cannot be represented by a single objective function. Also, these
objectives are often conicting, and so consideration of the tradeoff is essential leading to a set of optimal (non-dominated) solutions. These so called Pareto-optimal solutions provide better
insight into the process, for decision making. MOO has been
implemented for studying many chemical process operations
including the CDU [15]. Inamdar et al. [16] used MOO to simultaneously optimize the selected conicting objectives associated with
an industrial CDU. Recently, Al-Mayyahi et al. [2] investigated the
trade-off between operating revenue and CO2 emissions from the
CDU using a blend of two crudes.
As has been previously mentioned, the implementation of a
crude pre-ash system would cause conicting impacts on some
objectives of the CDU such as energy consumption and product
yields. Therefore, these conicting impacts can be evaluated using
MOO and an optimized, trade-off solution can be found. In the
present study, the elitist non-dominated sorting genetic algorithm
(NSGA-II) implemented in Excel [17] is employed to investigate
the effects of crude pre-ashing on the economic and environmental performance of the CDU. NSGA-II is an upgraded version of
an optimization algorithm, and uses a special ranking criterion to
classify solutions into different non-dominated fronts. In the Excel
implementation of NSGA-II, potential solutions (represented by
decision variables) are encoded numerically using binary encoding;
see Ref. [17] for more details on the Excel-based NSGA-II.
to tray 4
V1
to tray 8
V2
D1
Desalter crude
to tray 16
F1
V3
D2
to tray 21
F2
V4
D3
F3
D4
F4
to the furnace
44
Table 1
Decision variables and their bounds.
Units
Lower bound
Upper bound
MS
FT
(V/F)1
(V/F)2
(V/F)3
(V/F)4
kg mol/h
C
vol/vol
vol/vol
vol/vol
vol/vol
10
340
0
0
0
0
1000
380
2 or 4a
1
1
1
5. Case studies
In the present study, Arab light crude is used as a feedstock to
the CDU unit. Information of the crude oil assay can be found
elsewhere [18]. The atmospheric column consists of 29 trays, a total
condenser, three side strippers and three pump-around circuits. A
naphtha product is produced overhead, whilst kerosene, diesel and
atmospheric gas oil (AGO) are produced from the three side strippers. All side strippers are steam stripped where steam is injected
into the strippers to remove light components.
Three different cases are considered wherein the residue yield is
minimized (which corresponds to maximizing the total yield of the
distillates), as an economic objective, while minimizing the total
CO2 emissions (the environmental objective). Different emission
sources (furnaces, electrical energy, and steam) were considered in
the calculation of CO2 emissions. It is estimated based on energy
integration using pinch analysis to reduce the emissions that are
incurred as a consequence of using different utilities. Six decision
variables are allowed to vary within a realistic range to achieve
optimum values for the objectives. These variables are: the owrate
of the main stripping steam (MS), the furnace outlet temperature
(FT) and the volume fraction of the vapour from each of four preash drums (V/F). The decision variables and their bounds are
summarized in Table 1. The objective functions are optimized
subject to relevant constraints (Table 2). The temperature limits of
the fractions on the ASTM D86 curve, which are called Cut Points,
are used to dene the boiling range of fractions whilst the overlap
between adjacent fractions (so called Gap) is used to dene the
degree of separation between two adjacent fractions. The Gap is
commonly represented by the difference between the boiling
temperature of 5% ASTM of heavy fraction and boiling temperature
of 95% ASTM of light fractions. The gaps between the D86 95% and
5% cut points are used as quality constraints. The D86 95% cut
points of naphtha, kerosene and diesel are used as active specications in the CDU simulation. They were held constant at 182, 271
and 327 C respectively, to ensure that each product meets a basic
composition specication. Another active specication is used to
maintain the internal reux (overash) between rst tray above the
ash zone and ash zone. The overash is held constant at 2% to
prevent the dry out of the trays below the AGO withdrawal tray.
The CO2 emissions of the CDU are estimated based on energy
integration using pinch analysis. Energy integration is used to
42
Variable
1207
40
38
without pre-flashing
with pre-flashing
36
34
32
30
41
42
43
44
45
CO2 emissions (t/h)
46
Constraint
Specication
16.7 C
0 C
11 C
181 C
271 C
327 C
2% vol
48
Table 2
Constraints in the optimization problem.
47
1208
450
400
350
T (o C)
300
250
without pre-flashing
with pre-flashing
200
150
100
50
0
0
50
100
H (MW)
150
200
Fig. 6. The change in the total CO2 emissions for multiple pre-ash design.
At minimum CO2 emissions, the consumption of the main stripping steam (MS) was minimized, whilst maximizing the pre-ashed
vapour (V/F). On the other hand, maximum steam must be used for
minimum residue, if no pre-ash is allowed (Table 3). In addition,
with pre-ash, it is necessary to operate at the maximum furnace
outlet temperature (FT) in order to achieve the required overash
specication. However, when there is no pre-ash, a lower temperature can be used due to the high amount of the light vapour in the
feed. The high residue yield associated with a high pre-ash fraction
can be attributed to the loss of the carrier effect of the light vapours in
the main feed stream, as explained by Ji and Bagajewicz [9].
HYSYS tray sizing utility was used to compare different mechanical designs of the distillation column. Table 3 shows that
design for minimum residue yield requires a higher column
diameter (Dmax) than the minimum CO2 emissions cases, because of
the high amount of vapour owing inside the column. Furthermore,
the crude pre-ash reduces Dmax of the atmospheric column.
Introducing all vapour streams into the column at the same tray
may cause hydrodynamic problems such as increasing the ooding
factor, and the signicant reduction in the vapour load below the
vapour feed location may lead to a lower separation efciency in
this section. Both these effects may be countered by changing the
type of tray or packing.
5.2. Effect of multiple pre-ashing
The effect of using multiple pre-ash drums on the reduction in
the total CO2 emissions is studied in Fig. 6. Up to four pre-ash
44
42
CO2 (t/h)
Residue yield (vol%)
MS (kg mol/h)
FT ( C)
(V/F) (vol/vol)
QHmin (MW)
FQ (MW)
HPS (MW)
MPS (MW)
Dmax (m)
Without
pre-ash
With
pre-ash
Without
pre-ash
With
pre-ash
44.3
40.4
29.4
360
e
163.7
108.7
35.1
19.9
8.2
41.9
40.4
112.6
380
3.43
155
107.3
30.5
17.2
7.9
47.0
30.9
1000
380
e
167
116.5
32.1
18.4
9.3
47.0
30.9
998
380
0.0
166.7
116.2
32.1
18.4
9.3
40
Table 3
Comparison of the optimum results of the CDU with and without pre-ash.
4 pre-flash drums
single pre-flash drum
38
36
34
32
30
41
42
43
44
45
CO2 emissions (t/h)
46
47
48
44
Table 4
Optimum results of multiple pre-ash drum case at minimum CO2.
Minimum CO2
41.5
40.4
160
380
1.9
0.73
0.68
1
154.5
109.8
28.7
15.9
7.3
47.0
30.9
989
380
0.0
0.0
0.0
0.0
166.3
116.4
32.0
17.9
9.1
42
CO2 (t/h)
Residue yield (vol%)
MS (kg mol/h)
FT ( C)
(V/F)1 (vol/vol)
(V/F)2 (vol/vol)
(V/F)3 (vol/vol)
(V/F)4 (vol/vol)
QHmin (MW)
FQ (MW)
HPS (MW)
MPS (MW)
Dmax (m)
1209
40
38
34
32
30
drums in series are used upstream of the furnace. The four vapour
streams produced from the four pre-ash drums are fed to tray 4, 8,
16 and 21. Fig. 6 shows that the minimum CO2 emissions of the CDU
reduces as the number of pre-ashes increases. However, after 2
pre-ashes, the reduction in the CO2 emissions tends to be negligible. Fig. 7 compares the Pareto-optimal solutions of the single
pre-ash of Case study 1 and the multiple pre-ash case with four
pre-ash drums. For the residue yield of greater than 34%, the latter
case yields a slight reduction in the minimum CO2 emissions from
the single pre-ash case due to the slight reduction in the minimum heating duty; see Tables 3 and 4. However, for residue yields
below this value, the two Pareto-optimal curves are identical.
Similar to the single pre-ash, maximum furnace outlet temperature is required to achieve the 2% overash specication.
The GCCs of the single and multiple pre-ashing cases have
almost the same trend which shows the slight effects of the multiple pre-ash on the heating/cooling demands of the CDU
compared to the single pre-ash drum (Fig. 8). Besides the slight
improvement of the multiple pre-ashing over the single preashing regarding the reduction in the total CO2 emissions, introducing the ashed vapour streams into different trays reduces Dmax
which will reduce the ooding problem and increase the column
throughput (see Table 4). At minimum residue yield, the loads on all
pre-ash drums are negligible and therefore, the results are nearly
identical to the previous case study with no pre-ashing.
5.3. Effect of vapour feed location
The feed location of the ashed vapour is an important
parameter in the pre-ash design. As previously mentioned, the
vapour is usually fed either to the ash zone or to the tray where
41
43
44
45
CO2 emissions (t/h)
46
47
48
the end points of the ashed vapour nearly match the internal
liquid compositions. This case study compares two vapour feed
locations: above and below the ash zone. In the latter option, the
ashed vapour is fed to the bottom tray of the column (one tray
below the main feed location).
Fig. 9 compares the Pareto-optimal solutions of different cases
considering different vapour feed locations for single and multiple
pre-ash designs. In the gures, bottom feeding refers to the case of
introducing all vapour streams into the bottom tray one tray just
below the ash zone. Top feeding refers to introducing vapour
streams into different trays above the ash zone based on the end
points of each vapour stream. One additional case is considered,
where only the vapour from the rst ash drum is introduced into
the bottom tray whilst other vapour streams from the remaining
ash drums are introduced into the above-ash zone trays. The
latter case is referred to as 1st bottom feeding in Fig. 9. The results
show that using the bottom tray as the only vapour feed location
(bottom feeding curves in Fig. 9) records higher CO2 emissions with
a slight improvement in the multiple pre-ash designs over the
single pre-ash. On the other hand, sending the ashed vapour to
trays above the ash zone (top feeding curves in Fig. 9) reduces the
total CO2 emissions of the CDU with a slight preference for the
multiple pre-ash design as shown in Case study 2. However, the
decrease in the CO2 emissions is accompanied by a signicant increase in the residue yield as shown in Fig. 9 which can be
Table 5
Comparison of the optimum results for different vapour feeding locations.
450
400
350
300
T (o C)
42
250
4 pre-flash drums
single pre-flash drum
200
150
100
50
0
0
50
100
H (MW)
150
200
CO2 (t/h)
Residue
yield (vol%)
MS (kg mol/h)
FT ( C)
(V/F)1 (vol/vol)
(V/F)2 (vol/vol)
(V/F)3 (vol/vol)
(V/F)4 (vol/vol)
QHmin (MW)
FQ (MW)
HPS (MW)
MPS (MW)
Dmax (m)
43
38.5
42.6
38.5
41.6
38.5
10
371
3.2
e
e
e
163.4
118.7
29.4
15.3
8.2
10
371
2
0.5
0.57
0.46
164
123
27
13.8
8.2
12
380
1.5
1
1
1
158.5
116.2
28.5
13.8
7.9
1210
450
400
350
T (oC)
300
250
4 pre-flash drums-bottom feeding
200
150
100
PA
QHmin
V
50
0
0
50
100
H (MW)
150
furnace duty, MW
furnace outlet temperature, C
grand composite curve
high pressure steam, MW
multi-objective optimization
medium pressure steam, MW
owrate of the main stripping steam, kg mol/h
a binary coded elitist non-dominated sorting genetic
algorithm
pump around circuit
minimum heat duty, MW
vapour volumetric owrate from each pre-ash drum
200
AGO
CDU
D
Dmax
F
FQ
FT
GCC
HPS
MOO
MPS
MS
NSGA-II
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