DISTILLATION TOWER

Presented by
Ahmed Yehia Mohamed
Process engineer,
Suez Oil Processing Company (SOPC)
Contents
1. Fundamentals of Separation in Towers
2. Crude Distillation
3. Crude Distillation Operation
4. Fractionator Control
5. Operating Difficulties
6. Troubleshooting
1. FUNDAMENTALS OF
SEPARATION IN TOWERS
1. Fundamentals of Separation in
Towers
1.1 Distillation
1.2 Principles of Distillation
1.3 Reflux
1.4 Reboiling
1.1 Distillation
• Distillation is a separation process requires
differences to be recognized and utilized.
• Separation by distillation implies a difference in
boiling points of two or more materials.
• We separate many things by detecting a
difference in a physical properties.
color, size, weight, shape
1.1 Distillation
• The components or compounds making up crude
oil or natural gas are numbered in thousands.
• Many of these components have similar physical
properties including boiling points that may differ
by only a few degrees.
• There are other methods of separation used in a
refinery for example:
• Extraction with a solvent,
• Crystallization, and
• Absorption.
1.2 Principles of Distillation
The basic principle of distillation is simple:
1. When a solution of two or more components is
boiled,
2. The lighter
component
vaporizes
preferentially.
1.2 Principles of Distillation
• this simple distillation concept into a practical
operation as it is used in the refinery
By cooling the over head
vapor, we condense and
remove it from the original
mixture.
• This is a partial separation,
because there are a few
• Light Material
“+ Heavy Material" in the + Heavy Material
distillate product.
1.2 Principles of Distillation
• Therefore, to purify the distillate product, we may
have to conduct a second distillation.
• Obviously, we can
continue to cascade
these simple
distillations until we
achieve the desired
purity of product.
1.2 Principles of Distillation
• This is called Flash Vaporization.
• The liquid is pumped continuously through a
heater and into a drum.
1.2 Principles of Distillation
• Suppose we have 50% of the charge taken
overhead.
• And further, suppose the resulting overhead
product does not contain the desired
concentration of the lighter product.
• As we have seen before, we can increase the
purity by adding a stage of distillation.
1.2 Principles of Distillation
• Although this is accomplishing our
goal of increasing the purity of the
light friction, we are also making
large amounts of the intermediate
product, each of which contains the
same light friction.
1.2 Principles of Distillation
Tower Sections

Stripping stages Rectifying stages

• the lighter component in
the overhead.
• the heavier component in
the bottom product.
• The upper two stages are
called rectifying stages.
• These below the feed are
called stripping stages.
1.2 Principles of Distillation
• The upper rectifying section increases the purity
of the overhead product.
• The lower stripping section increases the
recovery of the overhead product.
• For the bottom, or heavy, product the rectifying
section improves recovery.
1.2 Principles of Distillation
Equilibrium Stage
• A stage, or more specifically, an equilibrium
stage, is defined as:
• Any portion of the distillation column such that the
liquid and vapor leaving it have composition in
equilibrium with each other.
• By definition, then, a stage should be designed in
such a way as to provide intimate contact, or
mixing, of the rising vapor and the descending
liquid.
1.2 Principles of Distillation
• The design of trays has taken many forms.
• Some common ones are :
• Valve trays,
• Bubble cap trays,
• Sieve trays, and many others.
1.2 Principles of Distillation
• Alternate designs include packing instead of
trays.
• Various kinds of packing have used, some of
which are :
• Pall rings,
• Saddles, and
• Mesh.
1.2 Principles of Distillation

Mesh
Pall rings

Saddles rings
1.2 Principles of Distillation
• The type of column internal used depends on the
application.
• The considerations being :
 Purity of feed,
 Efficiency,
 Capacity,
 Pressure drop,
 Liquid holdup, and
 Cost.
1.2 Principles of Distillation
• The column shown is a
simple binary column
with trays.
• There is only one feed
and two products, the
overhead and bottoms.
• More complex columns
may have several feed
streams.
1.3 Reflux
• The word reflux is defined as: "flowing back“
• reflux is: The liquid flowing back down the tower
from each successive stage.
• Kinds of Reflux
• Cold Reflux
• Hot Reflux
• Internal Reflux
• Circulating Reflux
• Side Reflux
1.3 Reflux
Cold Reflux
• The liquid that is supplied at temperature a little
below that at the top of the tower.
• Each pound of this reflux removes a quantity of
heat equal to the sum of its: latent and sensible
heat
1.3 Reflux
Hot Reflux
• It is the reflux that is admitted to the tower at the
same temperature as that
maintained at the top of
the tower.
• It is capable of removing
the latent heat because
no difference in
temperature is involved.
1.3 Reflux
Internal Reflux
• It is the liquid that overflow from one plate to
another in the tower, and may be called hot
reflux because it is always substantially at its
boiling point.
• It also capable of removing the latent heat only
because no difference in temperature is involved.
1.3 Reflux
Circulating Reflux
• It is able to remove only the sensible heat which
is represented by its change in temperature as it
circulates.
• The reflux is withdrawn and is returned to the
tower after having been cooled.
1.3 Reflux
Side Reflux
• This type of reflux (circulating reflux) may
conveniently be used to remove heat at points
below the top of the tower.
• If used in this manner, it tends to decrease the
volume of vapor the tower handles.
1.3 Reflux
Reflux Ratio
• It is defined as the amount of internal reflux
divided by the amount of top product.
• It is denoted by R which equals L/D.
• Since internal hot reflux can be determined only
by computation.
1.3 Reflux
The Importance of Reflux Ratio
• In general, increasing the reflux:
 Improves overhead purity, and
 Increases recovery of the bottom product.
• The number of stages required for a given
separation will be dependent upon the reflux ratio
used.
1.3 Reflux
Two points to consider
1. A minimum number of plates (stages) required
at total reflux.
2. There is a minimum reflux ratio below which it
is impossible to obtain the desired enrichment
(separation) however many plates are used.
1.3 Reflux
Total Reflux
• Total reflux is the conclusion when all the
condensate (distillate) is returned to the tower as
reflux, no product is taken off and there is no
feed.
• At total reflux, the number of stages required for a
given separation is the minimum at which it is
theoretically possible to achieve the separation.
• Total reflux is carried out at:
1. Towers start-up and shutdown.
2. Testing of the tower.
1.3 Reflux
Minimum Reflux
• At minimum reflux, the separation can only be
achieved with an infinite number of stages.

Optimum Reflux Ration

• The optimum value will be the one at which the
specified separation is achieved at the lowest
annual cost.
• For many systems, it lie between: 1.2 to 1.5 times
the minimum reflux ratio
1.4 Reboiling
• In all distillations processes
• Heat being added by:
 Feed, and
 Reboiler.
• Heat is transferred to the bottom materials which
cause vaporization of the lighter components.
• This vapor travels up the column to provide:
 The stripping action, and
 The additional heat necessary to vaporize the
down coming reflux.
Thermosyphon Reboiler Internal Reboiler

Kettle reboiler
2.CRUDE DISTILLATION
2.CRUDE DISTILLATION
2.1 Process Description
2.2 Product Specifications
2.CRUDE DISTILLATION
• The purpose of crude oil distillation is primarily to
split the crude into several distillate fractions of a
certain boiling range.

• A crude distillation tower, producing 6 fractions

has 40 to 50 trays.
2.CRUDE DISTILLATION
• By distillation at atmospheric pressure, crude oil
can be separated into:
 Fuel Gases
 Gasoline,
 Kerosene,
 Gas oil,
 Diesel oil, and
 Residue (Fuel Oil)
2.CRUDE DISTILLATION
• Crude is generally pumped to the unit directly
from a storage tank, and it is important that
charge tanks be drained completely free from
water before charging to the unit.
• If water is entrained in the charge It will vaporize
in the exchangers and in the heater, and cause a
high pressure drop through that equipment.
• Water expands in volume 1600 times upon
vaporization at 100ºC at atmospheric pressure.
2.1 Process Description
Heat Exchange
• In order to reduce the cost of operating a crude
unit.
• As much heat as possible is recovered from the
hot streams by heat exchanging them with the
cold crude charge.
• A record should be kept of heat exchanger outlet
temperatures so that fouling can be detected and
possibly corrected before the capacity of the unit
is affected.
2.1 Process Description
Crude Flashing
• Desalted crude is heat exchanged against what
ever other heat sources are available before it is
charged to the heater which has a temperature
vary from 325ºC to 430ºC, depending on:
 The type of crude, and
 The pressure at the bottom of the
fractionating tower.
2.1 Process Description
Fractionation
• Crude entering the flash zone of the fractionating
column.
• The degree of fractionation between cuts is
generally judged by measuring the number of
degrees centigrade between the 95% point of the
lighter product and the 5% point of the heaving
product.
• Some people use IBP and FBP But the IBP varies
with stripping.
Recommended
Gab between
products
2.1 Process Description
• Sometimes fractionators will be “pulled dry.”

• The rate at which a product is being withdrawn is

greater than the quantity of internal reflux in the
fractionators.

• at the same time there is insufficient material to

maintain the level in the stripper.
• the product pump will tend to lose suction.
2.1 Process Description
Product Stripping
• the sidecut products have been in contact with
lighter boiling vapors that must be removed to
meet flash point specifications.
• Steam (usually superheated steam) is used to
strip these light ends.
• While further increases in the quantity of steam
may raise the IBP of the product slightly.
• increasing the IBP of one product is to increases
the yield of the next light product.
2.1 Process Description
• All the stripping steam is condensed in the
overhead receiver and must be drained off.
• Refluxing water will upset the fractionators
• If the endpoint of the overhead product is very
low, water may not pass overhead, and will
accumulate on the upper trays and cause the
tower to flood.
2.1 Process Description
The effect of steam
• Steam is frequently used in fractionating columns,
strippers and sometimes in furnaces.
• The partial pressure of steam is subtracted from
the total system pressure resulting lower
pressure.
• In other words steam has the same effect as
lowering the pressure.
2.1 Process Description
Example
• Calculate the top
temperature
when the top
product contains,
in addition to H.C
components, 4%
by wt of steam.
Total pressure at
the top is 20 psia.
2.1 Process Description
• The mole percentage steam amounts to
88.89
 100% = 19.0%
378.65  88.89
• the steam partial pressure amounts to
19.0% of 20 psia = 3.80 psia
• The hydrocarbon partial pressure equals,
20–3.80 = 16.20 psia.
• The dew point calculation as described is carried
out at a pressure of 16.20 psia.
2.1 Process Description
Desalting
• Most crude contain traces of salt which can
decompose in the heater to from hydrochloric
acid and cause corrosion of the fractionator's
overhead equipment.
• In order to remove the salt, water is injected into
the partially preheated crude and the stream is
thoroughly mixed so that the water extracts
practically all the salt from the oil.
2.1 Process Description
• The mixture of oil and water is separated in a
desalter, which is a large vessel in which may be
accelerated by the addition of chemicals or by
electrical devices.
• If the oil entering the desalter is not enough
heated, it may be too viscous to permit proper
mixing and complete separation of the water and
the oil, and some of the water may be carried into
the fractionators.
2.1 Process Description
• If the oil is too hot, some vaporization may occur,
and the resulting turbulence can result in
improper separation of oil and water.
• The optimum temperature depends upon:
 The desalter pressure, and
 The quantity of light material in the crude.
• but is normally about 120ºC  10ºC being lower
for low pressure and light crudes.
• The average water injection rate is 3 – 5% of the
charge
2.1 Process Description
• Good desalter control is indicated by the chloride
content of the overhead receiver water.
This should be : 10 – 30 ppm chlorides
• If the desalter operation appears to be
satisfactory but the chloride is greater than 30
ppm, then caustic should be injected at the rate of
1 to 3 lbs. per 1000 barrels of charge.
• Thus pH should be controlled between 6.5 and
7.5 and ammonia injection can be used to control
this.
2.1 Process Description
Product Disposal
• All products are cooled before being sent to
storage.
• Light products should be below 60ºC to reduce
vapor losses in storage, but
• Heavier products need not be as cold.
2.1 Process Description
• If a product is being charged to another unit,
there may be an advantage in sending it out hot.
• A product must never leave a unit at over 100ºC.
• If there is any possibility of it entering a tank with
water bottoms.
• The hot oil could readily boil the water and blow
the roof off.
2.2 Product Specifications
• The composition of a distillation product is
determined by performing laboratory tests. then
the results are compared with product
specifications or standards that have been set for
the product.
• If the product is meeting specifications, column
operations do not have to be adjusted.
• But, if the products are off-specification, a change
in column operations must be made.
2.2 Product Specifications
Initial Boiling Point (IBP)
• Is the temperature at which the first drop of
condensate is collected during a laboratory
distillation test.
• In a mixture of hydrocarbons, the first molecules
to vaporize are the light ones.
• So, the IBP test is used to check for light
hydrocarbons that are present in a product.
2.2 Product Specifications
• Suppose specifications on the bottom product call
for an IBP between 100 – 110°F.
• Lab tests show an IBP of 95°F.
• So, the bottom product in this example contains
material that is too light.
• One way is to strip some light components off
with steam.
• Another way is to increase the temperature of the
feed or the reboiler temperature so more light
components are vaporized.
2.2 Product Specifications
End Boiling Point (EP)
• Is the temperature at which the last drop of liquid
vaporizes during the test.
• In a mixture of hydrocarbons, the last molecules
to vaporize are the heavy ones.
• So, the EBP (EP) test is used to check for heavy
hydrocarbons that are present in a product.
2.2 Product Specifications
• Specifications call for an overhead product with
an EP between 150 – 160° F.
• Lab results indicate an EP of 170° F.
• So, the top product does not meet specifications
because it contains material that is too heavy.
• One way is to decrease the feed or reboiler
temperature so that fewer heavy components
vaporize.
• Another way is to lower the top temperature by
increasing the reflux rate.
2.2 Product Specifications
Flash Point
• Is the temperature at which a petroleum product
generates ignitable vapors.
• Light hydrocarbons tend to flash more easily than
heavy hydrocarbons.
• A sample that contains traces of light
hydrocarbons flashes at a lower temperature than
a sample without these traces.
2.2 Product Specifications
•A side draw product carries flash point
specifications of 125 – 130° F.
• The lab test shows a flash point of 110° F.
• The sample contains material that is too light.
We can bring the product back to specification by:
 Decreasing the reflux rate, or
 Using more stripping steam, or
 Increasing the reboiler temperature.
2.2 Product Specifications
API Gravity
• Is used to designate the "heaviness" or
"lightness" of products.
 Kerosene is measured at about 42° API
 Gasoline is measured at about 60° API
• The lighter the oil, the higher API gravity.
2.2 Product Specifications
Color
• Light hydrocarbons are light colored while Heavy
hydrocarbons are dark in color.
• A light hydrocarbon product that is dark colored
probably contains too many heavy molecules.
7. TOWER HARDWARE
7. TOWER HARDWARE
7.1 Trays
7.2 Bottom Strainer
7.3 Reflux distributor
7.4Top Tower Demister
7.1 Trays
7.1 Trays
Downcomers
• Reflux flows down from one
tray to the next through
downcomers.
• Downcomers must be large
enough to allow for drainage
from one tray to the next or
flooding might occur on some
of the trays.
7.1 Trays
Inlet Weirs
• These contribute to the uniform distribution of
liquid as it enters the tray from the down comer.

• It is not recommended for

fluids that are dirty or tend
to foul surfaces.
7.1 Trays
Outlet Weirs
• These are necessary
to maintain seal on the
tray, thus insuring
bubbling of vapors
through liquid.
7.1 Trays
Weep Holes
• Holes for drainage must be adequate to drain the
tower in a reasonable time, yet not too large to
interfere with tray action.
7.1 Trays
Flow Pass
• In a one-pass system,
liquid flows completely
across each tray.
• In the two-and
three-pass systems,
liquid flows across
the trays in different
direction(s).
7.1 Trays
7.1 Trays
Drawoff Pan (trapout pans)
• trays where a side stream is being drawn off.
• These low areas on
trays are called
trapout pans.
7.1 Trays
• The risers on a tray where a side stream is being
drawn off are much taller than normal to prevent
vapor-liquid contact on this tray.
• Because the tall
risers and caps
look something
like a "top hat",
this type of tray
is often called
a hat tray.
7.1 Trays Sieve Deck
Sieve Deck Tray
• This tray is a sheet of light metal with a large
number of holes drilled through it.
• Vapor rising through the
holes keeps the liquid on
the tray and bubbles up
through it.
• The overflow weir keeps a constant depth of
liquid on the tray.
7.1 Trays Sieve Deck
• A sieve deck tray is:
 Inexpensive,
 Easy to clean, and
 Maintains good liquid
and vapor contact as
long as it is operated at
its design load.
• Because the sieve deck tray has fixed openings
and does not have covers over the holes, it does
not perform well if tower loads are constantly
changing.
7.1 Trays S-section
S-section tray
• The S-section tray is also inexpensive to
construct.
• It is made of overlapping
S-shaped sections
• which form:
 Long,
 Continuous bubble caps, and
 Troughs for the liquid and the vapor.
7.1 Trays S-section
• Each long cap has slots cut in its lower edge
which act like bubble cap teeth, forcing vapor to
bubble, or flow through the liquid on the troughs.
• The S-section tray must
be put together exactly
in order to work well.

• Small differences in the position or leveling of the

S-sections affect the efficiency of vapor-liquid
contact.
7.1 Trays Valve
Valve Tray
• A valve tray has a variable opening for vapors to
flow through.
• The hole has a cover
that consists of a cap
held in place by guides
which go down through
the plate, or tray and
hook underneath it.
7.1 Trays Valve
7.1 Trays Bubble Cap
Bubble Cap Tray
• The vapor is broken into small bubbles which
increases the surface area for vapor-liquid
contact.
• The bubble cap sits on top of a riser.
• The riser channels vapors into the bubble cap.
7.1 Trays Bubble Cap
7.1 Trays
Selection of Tray Type
• The principal factors to consider when comparing
the performance of bubble-cap, sieve and valve
trays are:
 Cost,
 Capacity,
 Operating range,
 Efficiency, and
 Pressure drop.
7.1 Trays
Cost:
• Bubble-cap trays are appreciably more expensive
than sieve or valve trays.
• The relative cost will depend on the material of
construction used;
• For mild steel the ratios, bubble-cap: valve: sieve,
are approximately
• 3.0 : 1.5 : 1.0
7.1 Trays
Capacity:
• There is little difference in the capacity rating for
the three types (the diameter of the column
required for a given flow-rate).
• The ranking is:
• sieve, valve, and bubble-cap
7.1 Trays
Operating range:
• This is the most significant factor.
• By operating range is meant the range of vapour
and liquid rates over which the plate will operate
satisfactorily (the stable operating range).
• Some flexibility will always be required in an
operating plant to:
 Allow for changes in production rate, and
 Cover start-up and shut-down conditions.
7.1 Trays
Turn-down Ratio
• The ratio of the highest to the lowest flow rates.
• Bubble-cap trays have a positive liquid seal and
can therefore operate efficiently at very low
vapour rates.
7.1 Trays
Turn-down Ratio
• Sieve trays rely on the flow of vapour through the
holes to hold the liquid on the tray and cannot
operate at very low vapour rates, but, with good
design, sieve trays can be designed to give a
satisfactory operating range; Typically, from 50 to
120 % of design capacity.
• Valve trays are intended to give greater flexibility
than sieve trays at a lower cost than bubble-caps.
7.1 Trays
Efficiency:
• The Murphree efficiency of the three types of
trays will be virtually the same when operating:
 Over their design flow range, and
 No real distinction can be made between
them.
7.1 Trays
Pressure Drop:
• The pressure drop over the trays can be an
important design consideration, particularly for
vacuum columns.
• The trays pressure drop will depend on the
detailed design of the tray but.
• sieve plates give the lowest pressure drop,
followed by valves, with bubble-caps giving the
highest.
7.1 Trays
Summary
• Sieve trays are the cheapest and are satisfactory
for most applications.
• Valve trays should be considered if the specified
turn-down cannot be met with sieve trays.
• Bubble-caps should only be used where:
 Very low vapour (gas) rates have to be
handled and
 A positive liquid seal is essential at all
flow-rates.
 7.1 Trays

Comparison between Common Conventional Trays.

No. Factors Sieve Tray Valve Tray Bubble-Cap Tray
1 Capacity High medium medium
2 Efficiency High medium medium
3 Turndown ~50% ~25-30% 10%
4 Entrainment Low medium High
5 Pressure Drop Low medium High
6 Cost Low ~1.2 times ~ 2-3 times
7 Maintenance Low medium High
8 Fouling Low medium High
9 Effects of Corrosion Low medium High
7.2 Bottom Strainer
• During the operation of a tower:
 The bubble caps,
 Bolts, and
 Other foreign objects

• may be dislodged and carried along with bottom

stream.
7.2 Bottom Strainer
• To prevent these objects leaving the tower and damaging
pumps, a strainer is installed in the bottom outlet line.

• The holes in the strainers must

be kept open so that the flow of
liquid out of the tower will not be
stopped, or hindered.
7.3 Reflux distributor
• Reflux entering the top of the tower should be
spread evenly across the top tray to avoid dead
spots.

• One way to disperse

reflux is to place a
reflux distributor in
front of the inlet line.
7.3 Reflux distributor
• A reflux distributor is simply a plate or baffle that
prevents liquid from spraying across the tray.

• Reflux entering the

tower is forced to flow
under the baffle so that
the liquid is distributed
evenly across the tray.
7.4 Top Tower Demister
• Sometimes small drops of liquid suspended in
vapor are carried up from one tray to the next or
into the overhead vapor line.
• This is called entrainrnent.
• When the overhead product must be a dry vapor
or gas, entrainment is a more serious problem.
• Entrainment between trays can usually be
prevented by controlling vapor velocity.
7.4 Top Tower Demister
• Entrainment at the top of a tower can be cut down
by placing a demister on the vapor outlet line.
• Demisters are constructed
of fine-gauge wire knitted
into mesh.
3. CRUDE DISTILLATION
OPERATION
3. CRUDE DISTILLATION OPERATION
3.1 Reflux Rate Changing

3.2 Feed Temperature Changing

3.3 Side Product (Draw off) Rate Changing

3.1 Reflux Rate Changing
• Reflux as a "coolant" that removes heavy
fractions by condensing them.
• Suppose the reflux rate is increased from 1,000
to 1,200 barrels per hour, and the other tower
operating conditions are held constant.
• the temperature on each tray to decrease then :
 Lighter overhead,
 Lighter bottom, and
 Lighter side draw products are produced.
3.1 Reflux Rate Changing
• If we decrease the reflux rate from 1,000 barrels
to 800 barrels, the cut point changes are
reversed.
• The temperature on each of the trays increases.
• overhead, bottom, and side draw products
become heavier.
• The amount of overhead product produced
increases and the amount of bottom product
formed decreases.
3.2 Feed Temperature Changing
• Suppose we raise the temperature of the feed
and hold the reflux rate and other tower variables
constant.
• more of the feed is vaporized.
• the amount of top product formed increases.
• the amount of bottom product formed decreases.
• By increasing the feed temperature: Heavier
overhead, Heavier bottom, and Heavier side draw
products are produced.
3.2 Feed Temperature Changing
• If we reduce the temperature of the feed, the cut
point changes will again reverse.
• the top, side draw and bottom products become
lighter.
• the amount of top product produced decreases
and the amount of bottom product formed
increases.
3.3 Side Product (Draw off) Rate Changing
• Another way to change the cut point in a crude
column is to vary the amount of liquid that is
drawn to the stripper columns.
• Suppose we increase the kerosene draw by 100
barrels.
• less reflux flows to the trays below the draw-off
tray.
3.3 Side Product (Draw off) Rate Changing
• the temperature of trays below the kerosene draw
increases.
• more heavy material begins rising up the tower.
• the kerosene draw will be heavier.
• The products formed below the kerosene draw
also become heavier.
3.3 Side Product (Draw off) Rate Changing
• Now suppose we want to make the kerosene
product heavier without changing the composition
of the gas oil and reduced crude products.
• To do this we must increase the kerosene draw
and at the same time not change the amount of
reflux, and decrease liquid on the gas oil tray.
3.3 Side Product (Draw off) Rate Changing
• Let’s reverse the situation and look at what
happens when the kerosene draw is decreased.
• Low temperatures produce light products, so
reducing the kerosene draw results in a lighter
kerosene product.
• The products formed below the kerosene draw
also become lighter.
3.3 Side Product (Draw off) Rate Changing
• Suppose we want a lighter kerosene product but
do not want to change the composition of the gas
oil and reduced crude products.
• Since there is more reflux flowing down to the gas
oil tray, we will have to increase the gas oil draw.
• Another way is decrease kerosene draw and
increase gas oil draw.
3.3 Side Product (Draw off) Rate Changing
• The composition of crude distillation products can
be changed by changing, or varying the amount
of liquid that is drawn to a stripping column.
• Opening a stripper draw makes this product and
products formed below this point heavier.
• Closing a stripper draw makes this product and
products below this tray lighter.
4. FRACTIONATOR CONTROL
4. FRACTIONATOR CONTROL
4.1 Feed Section Control
4.2 Top Section Control
4.3 Bottom Section Control
4. FRACTIONATOR CONTROL
• The fractionator operates by using:
 A controlled temperature gradient from top to
bottom.
 The composition of the top product is fixed by
its bubble point or dew point.
 The bottom product is controlled by its bubble
point.
4. FRACTIONATOR CONTROL
Older control systems
• Attempt to accomplish these functions by the use
of pressure, temperature, level and flow controls
on each stream independently.
The next plateau
• was to:
 Recognize that these streams were not
really independent, and
 Address the interaction between them by
means of control loops.
4. FRACTIONATOR CONTROL
The next level of sophistication
• Is to add a chromatograph to sense directly those
composition changes that are critical and transmit
the proper signal to the controls.
• A simple analog system may be used to
accomplish this.
4. FRACTIONATOR CONTROL
The final plateau
• Is reached by "marrying" all of these to a
computer which has been properly programmed.
• All streams being sensed feed their information
into this computer or programmable logic
controller (PLC) which runs through a dynamic
simulation and then tells the controls what to do.
• A computer does not solve the control problem; it
can only react within the limits imposed on it by
its creator.
4. FRACTIONATOR CONTROL
Some of the variables that can be used:
 Tower pressure.
 Feed flow rate.
 Feed composition.
 Feed temperature.
 Heat added (boil-up).
 Bottom product flow rate.
 Heat removed reflux.
 Distillate product flow rate.
4.1 Feed Section Control
Feed Composition
• it is necessary to make change elsewhere to the
operation of the column in order to compensate
for variations in feed composition.
4.1 Feed Section Control
Feed Rate Control
• Regardless of the process used to recover liquid,
both flow rate and composition will vary to the first
fractionator.
• The following Figures show several possible
arrangements.
4.1 Feed Section Control
• If the tank is large, method (A) could be used.
• The pump would be eliminated, if the tank is at a
high enough pressure.

(A)
4.1 Feed Section Control
• Method shown in Figure (B) would use the wide
band with or without the pump.
• A level indicator with level alarms would be
required on the tank to guard against low and
high levels.

(B)
4.1 Feed Section Control
• Method shown in Figure (C) is a further addition
that might be necessary when the pressure on
the accumulator is not constant.
• The LC resets the flow recording controller
(FRC).

(C)
4.1 Feed Section Control
• Figure (D) shows a steam pump layout.
• The level controller sets the control point for flow.
• The flow controller
actuate the valve on
the steam line.
4.1 Feed Section Control
Feed Temperature (Thermal Condition)
• For efficient separation; it is usually desirable to
have the feed at its bubble point when it enters
the tower, unless the feed comes directly from
some preceding distillation step.
• An outside source of heat is required.
4.1 Feed Section Control
• Steam may be used to heat the feed, any change
in feed temperature, a corrective adjustment to
the supply of steam into the exchanger.
• The use of a cascade loop can provide superior
temperature control.
4.1 Feed Section Control
• Constant temperature feed does not necessarily
mean constant feed composition (quality).
• If the feed composition varies, its bubble point
varies.
• It is common practice to set the temperature
control at a point which is equivalent to the
bubble point of the heaviest feed.
4.2 Top Section Control
Column Pressure Control
• Most distillation control systems are based upon
maintaining the column pressure at some
constant value.
• Any variation of the pressure will upset the control
system by changing the equilibrium conditions of
the material in the column.
4.2 Top Section Control
The set point for pressure is a compromise
between two extremes:
1. The pressure must be high enough to cause
condensation of the overhead vapor by heat
exchange with the cooling medium (usually
cooling water).
2. On the other head, the pressure must be low
enough to permit vaporization of the bottom
liquid by heat exchange with the heating
medium (usually steam or hot oil).
4.2 Top Section Control
• Column pressure can be controlled by
manipulating:
 The material balance
(rate of distillate product) or
 The condensing temperature
(bubble/dewpoint pressure of distillate).
4.2 Top Section Control
• The optimum pressure is determined by the cost.
• It is usually more economical to select the lowest
pressure which will allow satisfactory
condensation of the distillate product at cooling
water temperature.
• The type of pressure control to be used depends
on weather the overhead product is:
 Vapor,
 Liquid or
 Liquid and vapor.
4.2 Top Section Control
Vapor Distillate Product
Partial Condenser
• pressure-controlled by regulating the flow of
vapor from the reflux drum.
4.2 Top Section Control
Liquid and Vapor Distillate Products
Partially Flooded Condenser
• In this case the level controller regulates the flow
of liquid product.

• The reflux is on flow or

on temperature control.
4.2 Top Section Control
• A system shown for a total condenser is suitable
for a narrow boiling range product.
• The disadvantage is that a large control valve
must be placed in the overhead line.
4.2 Top Section Control
• When it is desired to operate the tower at a
pressure higher than the liquid vapor pressure,
gas of sufficiently high pressure should be
admitted to the reflux drum on pressure control.

• The controller should

be a split range type.
4.2 Top Section Control
Liquid Distillate Product
Total Condenser
• When the overhead vapor is totally condensed in
the condenser, the pressure in the reflux drums is
equal to the liquid vapor pressure.
• The pressure is then a function of the condenser
outlet temperature.
4.2 Top Section Control
4.2 Top Section Control
• The temperature of the condensed product in the
accumulator can also be controlled by controlling
the cooling medium.
4.2 Top Section Control
• This method is not recommended if the cooling
medium is cooling water as it induces fouling and
scaling in the condenser.
• If the cooling medium is air, louvers or variable
pitch for blades can be used to control air flow.
• Induced draft coolers are preferred because the
tube bundle is not exposed to precipitation.
4.2 Top Section Control
• The Figure shows a flooded condenser system
for a total condenser.
• In this system the accumulator runs completely
full of liquid and pressure is controlled by
manipulating
• This method is commonly
used in NGL fractionators.
4.2 Top Section Control
Reflux Controls
• The rate of reflux would be controlled by a flow
control set
manually or
representing
a ratio to
distillate
stream.
•
4.2 Top Section Control
• Measuring temperature in a column usually
requires that the sensing device be in the liquid
on the tray.
• Heat transfer from a liquid medium to the sensing
device is much greater than the heat transfer
from a gas medium.
4.3 Bottom Section Control
Reboiler Control
• Boil-up rate is controlled by setting the flow of
heat to the reboiler.
• A flow controller
is placed in the
line carrying
the heating
medium to the
reboiler.
4.3 Bottom Section Control
• Other types include thermosyphon reboilers and
forced-circulation reboilers.
• For them, the bottom product is withdrawn from
the column.
6. TROUBLESHOOTING
6. TROUBLESHOOTING
6.1 Flooding
6.2 Dry Trays
6.3 Damaged Trays
6.4 Water in Hydrocarbon Column
6.5 Foaming
6.6 Condenser Fogging
6.1 Flooding
6.1 Flooding
Design
• Flooding is a common operating problem.
• Companies naturally wish to obtain maximum
capacity out of fractionation equipment and thus
often run routinely close to flooding conditions.
• New columns are typically designed for around
80% of flood.
• Clearly, the column needs some flexibility for
varying operating conditions.
6.1 Flooding
• The designer, therefore, shouldn't expect to
design for 100% of flood and be able to
accommodate variations In operating conditions.
• Designers recommend a percentage of flood of
not more than:
 77% for vacuum towers.
 82% for other services.
 65-75% for columns under 36" diameter.
6.1 Flooding
How to Identify Type & Location of
Flooding
 Increase in pressure drop and a decrease in
temperature difference.
 Pressure fluctuation.
 Possible capacity increase.
 Temperature profile.
6.1 Flooding
Increase in pressure drop and a decrease
in temperature difference:
• Product quality is also impaired.
• When a column floods, the levels in the
accumulator and bottom often change.
• It can occur that:
 The accumulator fills with liquid carried
over while,
 The reboiler runs dry.
6.1 Flooding
Pressure fluctuation:
• Also, in a flooded column, the pressure will
often tend to fluctuate.
• This may help to differentiate between:
 Flooding, and
 High column bottom level.
• The high bottom level will give higher than
normal pressure drop but often not the
magnitude of pressure fluctuations associated
with flooding.
6.1 Flooding
Possible capacity increase:
• Here is a tip for possible capacity increase for
towers with sloped downcomers.
• Usually, the tray vendor doesn't use the dead
area next to the bottom part of the sloped
downcomer as active area if the trays are
multipass.
• This area could be used for additional vapor
capacity in an existing column.
6.1 Flooding
Temperature profile:
• In fractionating columns the temperature of any
given plate is dependent on:
 The pressure, and
 Composition of the material on the tray.
• When both top and bottom product are very
narrow boiling range products only one steep
column temperature gradient will be located near
the feed inlet.
6.1 Flooding
• When wide boiling range products are
manufactured to flattening down of the
temperature profile will occur over the trays near
the product outlets.
• Comparison of the known profile for normal
operation with that when operation is poor may
help to locate the source of the trouble.
6.1 Flooding
Operating Difficulties Causing
Flooding
 Fouling.
 Operation near Critical Conditions.
 High Loads in Rectifying Section.
 Way of Introducing Feed.
 Downcomer Backup Flood.
6.1 Flooding
Fouling:
• Sometimes upsets in operation are caused in
sections of a column due, for example, to local
fouling.
• Differential pressure measurements are helpful in
locating the sections that are causing the
difficulties.
• Careful and repeated tests have to be made to
determine the sections at which the increased
pressure drop first occurs.
6.1 Flooding
Operation near Critical Conditions:
• When a column is operated under conditions of
temperature and pressure which are very near to
the critical values of the hydrocarbons to be
processed, fractionation can be poor owing to the
fact that a column section contains only one
phase and is consequently flooded.
6.1 Flooding
High Loads in Rectifying Section:
• Sometimes this tray is flooding and further
increases in reflux are ineffective because it
merely goes overhead as liquid.
• A heat balance around the overhead condenser
shows, if much liquid is entrained, which is an
indication of overloading of at least the top part of
the column.
6.1 Flooding
Way of Introducing Feed:
• As the vapour or liquid entering may upset the
flows in that part of the column.
• Further more attention must be given to the
velocity of the vapour and liquid feed in the inlet.
• Too high a vapour velocity may cause atomization
of the liquid feed resulting in considerable
entrainment.
6.1 Flooding
Downcomer Backup Flood:
• If the downcomer backup for valve trays exceeds:
 40% of tray spacing for high vapor
density systems (3.0 lbs/ft3),
 50% for medium vapor densities, and
 60% for vapor densities under 1.0 Ibs/ft3.
• Flooding may occur.
6.1 Flooding
• Another good rule of thumb is that the
downcomers area should not be less than 10% of
the column area, except at unusually low liquid
rates.
• Note that:
 High vapor rates as well as
 High liquid rates
• Can cause down comer backup flooding.
6.2 Dry Trays
• No fractionation occurs in the dry section, so the
temperature difference decreases.
• However, unlike flooding the pressure drop
Decreases
• The problem is caused by either:
 Insufficient liquid entering the section, or
 Too much liquid boiling away.
6.2 Dry Trays
• Insufficient liquid entering a section caused by:
 Too little reflux, or
 Too much sidestream withdrawal.
• Excessive liquid boiloff caused by:
 Too hot a feed, or
 Too much reboilling.
6.3 Damaged Trays
• Trays can become damaged by several ways:
 A pressure surge can cause damage.
 A slug of water entering a heavy
hydrocarbon fractionator will produce
copious amounts of vapor.
 Bottom liquid level is reached the reboiler
outlet line, the wave action can damage
some bottom trays.
 Steam/Water Operations.
 Depressuring.
6.3 Damaged Trays
• Effects of damaged trays
 Poorer fractionation,
 A decrease in temperature difference
because of the poorer fractionation.
 An increase in pressure difference.
6.3 Damaged Trays
Steam/Water Operations
• Steam/water operations during shutdown have
high potential for tray damage if not handled
correctly.
• If a high level of water is built up in the tower and
then quickly drained, as by pulling off a bottom
manway, extensive tray damage can result,
similar to pumping out hydrocarbons too fast
during operation.
6.3 Damaged Trays
• Steam and water added together to a tower can
be a risky operation.
• If the water is added first at the top, for instance,
and is raining down from the trays when steam is
introduced, the steam can condense and impose
a downward acting differential pressure, this can
result in considerable damage.
6.3 Damaged Trays
• If steam and water must be added together:
 Start the steam first.
 Then slowly add water, not to the point of
condensing all the steam.
 When finished, the water is removed first.
6.4 Water in Hydrocarbon Column
• Here small amounts of water are meant rather
than large slugs which could damage the trays.
• Often the water will boil overhead and be drawn
off in the overhead accumulator bootleg.
• However, if the column top temperature is too
low, the water is prevented from coming
overhead.
• The water can often make the tower appear to be
in flood.
6.4 Water in Hydrocarbon Column
• Many columns have water removal trays
designed into the column.
• Top or bottom temperatures may have to be
changed to expel the water if the column isn't
provided with water removal trays.
• In some instances, the water can be expelled by
venting the column through the safety relief
system.
6.5 Foaming
6.5 Foaming
• The mechanism of foaming is little understood.
During the design phase, foaming is provided for
in both the tray downcomer and active areas.
 The higher the pressure, the more foaming
tendency, since the heavy oil will contain more
dissolved gases at higher pressures.
 Liquids with low surface tension foam easily.
 Suspended solids will stabilize foam.
6.5 Foaming
Solving Foaming Problem
 Adding antifoam,
 Providing adequate tray spacing,
 Providing adequate column downcomer area,
and sometimes
 Filling the downcomer with Raschig rings to
provide coalescing area.
6.6 Condenser Fogging
• Fog, like smoke, is a colloid.
• Fogging occurs in a condenser when:
 The mass transfer doesn't keep up with the
heat transfer.
 A higher temperature differential (ΔT) with
noncondensibles present, or
 A wide range of molecular weights can
produce a fog.
6.6 Condenser Fogging
• Once a fog is formed, it is very difficult to knock
down.
• It will go right through:
 Packed columns,
 Mist eliminators, or
 Other such devices.
Special devices are required to overcome a fog,
such as an electric precipitator with charged
plates.
7. CASE STUDY
 Presented by
Ahmed Yehia Mohamed

Process engineer,
Suez Oil Processing Company (SOPC)

+20 100 890 7 390

[email protected]