Divide and conquer

Dividing wall column technology as a way of removing benzene from gasoline

streams in oil refineries

Bill Townsend and Bhari Bhujan Singh KBR

T
he primary separation method in the petro-
chemical industry is distillation, or
fractionation, which is an energy-intensive
process. Dividing wall column (DWC) technology
represents a mechanical implementation of fully
thermally coupled distillation that not only saves
significant amounts of energy but is both more
efficient and cost effective than conventional
distillation methods.

What is DWC and how does it work?

Simple distillation sequence (eg, two-distillation-
column-in-series or distillation column with
side-stripper configuration) is the commonest
way of separating a multicomponent feed stream
into three or more product streams (see Figure 1
and Figure 2). The same task can be performed
with DWC technology while using less energy
and plot space compared with simple distillation
sequence, which requires two separate distilla-
tion columns along with their ancillaries. It also
utilises more energy because it boils the same
material twice to perform the same separation
task as DWC technology.
DWC technology utilises the customised design
of a single column in performing the combined
separation task of two conventional columns.
The pre-fractionator is integrated within the
shell of the main fractionator by vertically divid-
ing a conventional distillation column with a gas
and liquid-sealed wall as shown in Figure 2. This
permits the low-energy separation of the low
and high boiling fractions in the feed section,
while the medium boiling fraction is concen-
trated in the draw-off section of the column.
The wall separates the feed and pre-fractionator
section from the main fractionator section and
side-draw. The main fractionator and pre-frac-
tionator are linked by vapour and liquid streams.
Figure 1 Simple distillation sequence (column with
side-stripper)
It’s nothing new
The concept of DWC technology has existed for
more than 50 years (first patent 1949). But lack
of design experience, fear of operational and
control problems, and availability of inexpensive
energy have prevented its widespread use. It’s
now been commercialised with great success and
no operability and control problems. It’s also
finding wider acceptance as plant operators are
seeking intelligent solutions to increase their
profitability by reducing their operating expendi-
ture with low cost investments.
Towers of power
In March 2011, KBR announced the successful
start-up of its DWC tower design for Valero
Energy at three of the refiner’s US-based refiner-
ies. The start-ups marked the first successful

www.digitalrefining.com/article/1000866 May 2011 1

 Figure 2 The pre-fractionator is integrated within the
shell of the main fractionator by vertically dividing a
conventional distillation column with a gas and
liquid-sealed wall FEED
implementation of DWC towers in the US. The
units were designed to concentrate and remove
benzene from gasoline streams to meet US regu-
latory mandates limiting the benzene content of
gasoline. The DWC towers were designed and
optimised by KBR for each unique project and
allowed Valero to meet the regulatory
requirements.
The project objective was to provide a design
that not only complied with the new stringent
gasoline benzene content specifications in the
US, but to do so in the most cost-effective way.
The challenge provided an opportunity to apply
the efficient, elegant solution that is DWC tech-
nology. As previously mentioned, it is
thermodynamically more efficient, with studies
proving that DWC applications can save up to
30% capital investment and use approximately
30% less energy compared with conventional
two-column configurations for reformate
benzene management.
Historical studies
KBR began developing DWC technology in the
late 1980s through pilot-plant studies. Since
then, the KBR London Technology Centre has
performed several studies to identify potential
grassroots and revamp applications in the refin-
ing and chemical industries. KBR designed and
2 May 2011
Figure 3 Simple distillation sequence (two column-in-
series)
commissioned two commercial DWC units
before offering the technology to Valero. In April
1998, in co-operation with BP, the first tower
was commissioned at BP’s UK Coryton refinery.
It was a revamp of an existing stabiliser column
that produced a gasoline-blend compound.
In 2004, a grassroots tower was designed
and commissioned for an Asian client for
production of pure iC5, light naphtha and heavy
naphtha.
Custom made
Where applicable, a DWC installation can be
designed to meet all product specifications as
per a client’s requirements. A DWC unit can be
designed to increase system throughput using
the same energy as a conventional twocolumn
sequence, thus saving in steam and fuel demand
and reducing the overall energy requirement per
unit of feed processed. A new DWC system can
easily be incorporated within current refinery
infrastructure; a unit requires no more plot
space than a conventional single-column system
and can be designed to utilise the available site’s
heating and cooling media, meaning less capital
outlay. The mechanical revamp of existing distil-
lation towers with DWC technology is
straightforward and can be done within a normal
turnaround period.
www.digitalrefining.com/article/1000866
Pros, cons and uses
The design process for a DWC unit is far more
complex than for a conventional distillation
column system, but within 1-2 years the savings
achieved from a reduction in capital and energy
cost or revenue generated from increased
productivity definitely outweighs any complexi-
ties in the design efforts.
There are diverse possible applications of
DWC technology in the chemical industry and
the key is to identify the specific separation
options where it will provide an advantage over
simple distillation sequence.
Gasoline benzene specification in Europe is
not as strict as in the US but European refiners
are under pressure to operate more efficiently to
boost margins. Also, refiners are exploring ways
to reduce energy consumption and green-
house-gas emissions. DWC units offer an
efficient separation solution to refiners to reduce
energy consumption or increase productivity.
KBR has identified several applications for DWC
www.digitalrefining.com/article/1000866
technology in Europe where these benefits can
be realised, such as straight-run naphtha frac-
tionation upstream or downstream of reformers,
full-range FCC naphtha fractionation, FCC debu-
tanizer, C4 isomer separation and BTX
separation.
We are confident, then, that it won’t be long
before DWC technology becomes a common
sight in refineries all around the world.
Bill Townsend (bill.townsend@kbr.com) is manager at KBR
London Technology Centre. Bhari Bhujan Singh, (bharibhujan.
singh@kbr.com) is DWC principal technologist at KBR.
LINKS
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May 2011 3