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BE OILS!
Question
Time matters
• In the origin of oil found in oil pit/marsh, and the utilization is just for combustion, so
it was not needed to distill the oil
• After the invention of Internal Combustion Engine by James Watt (1781 M), it became
the major influence in the rise in the importance of petroleum
– Thus we need to distill it
– Thus we have better engine performance & reliability with distillated oil
– Thus we may earn some money
– Thus we may expand to new markets
– Last but not least,
…we have only 1 (one) EARTH to care
One Advice
Low Low
Return, Return,
Low High
Revenue Revenue
The problem • Face your problem, don’t go Facebook!
is not the • How come you face your problem if the problem is
to the
problem is
the problem.
The • The power of center
• The power of small
Crime
The Power of Lead / Pb
IV A Elements • Nuclear Reactor Wall
Tin / Sn
• Ligth and Strong
Germanium
• The pioneer of semiconductor
Silicon / Si
• The true army of modern computer
Carbon / C
• Where there is life, there is C involved
The Derivatives
n-paraffin
Paraffinic
Aliphatic iso-paraffin
Cyclic
Hydrocarbon
Benzoid
Aromatic
Polycyclic
The • CRUDE OILS may be characterized by its PONA
• PONA is Paraffinic, Olephinic, Naphthenic, and
Derivatives Aromatics
• It indicates the major composition of Crude Oil
in Refinery • Can be represented with UOP-Watson K factor
kebo gupak
Main
Contaminant
Sulphur Nitrogen
Secondary
Mercaptan Sulfide Bisulfide Primary Amine Tertiary Amine
Amine
RSH RSR RSSR/RSRSR RNH2/RNHR RN
RNH/RNR
The • Major contaminants to countermeasure are Sulphur,
and Nitrogen
Contaminants • All acidic contaminants can be analyzed as Total Acid
in Refinery Number (TAN)
Process Side
Petrol Gasoline
Campus Refinery
Campus Refinery
m3/hour barrel/day
Overhead
Receiver
Crude
Column Sidecut Debutanizer
Stripper
Steam
Kerosene
Crude Distillation Unit Sidecut
Stripper
Steam
Diesel
Desalter
Steam
Reduced
Crude
CDU
Operation
• Driving Force
– Internal
• Relative volatility of each
component to another
components
• High RV goes up, lower RV
down
• Good RV is Good for
separation performance
– External
• The delta pressure between
top and bottom column
CDU
Operation
• Draw Off Temperature
– Regulates T 50% of cuts
• Cold Reflux / Pump-around
– Regulates IBP & T 5% of cuts
• Hot Reflux / Wash-oil
– Regulates EP & T 95% of cuts
CDU
Operational
Concept
• Why do we use pump around?
• Why do we draw side stream?
• Why do we need stripping steam?
• Why do tray/plate column is more
applied than packed column?
• Why do we use heater-type reboiler?
• Why do we use preheating train?
Crude Distillation
Electrodes
Preheat Exchangers
Try
Crude Brine Water Cocks
27
Study Case
•Permasalahan:
‒CDU mengolah 125.000 barrel per hari crude oil
‒Kandungan air di crude 0.8 % vol
‒Efisiensi furnace 85 %
‒Panas penguapan air 500 kcal/kg air
‒Harga fuel adalah 36.75 USD/BSRF (1 BSRF = 1.570.335 kcal)
‒Gross margin kilang adalah 4 USD/bbl crude diolah
29
Dasar-Dasar Crude Unit Distillation
30
Dasar-Dasar Crude Unit Distillation
• Komposisi Feed
‒ Variability dalam komposisi crude tercermin dalam TBP curves.
TBP cut ranges merupakan acuan commerical yields BUKAN ASTM
distillation
‒ Crude units sering kali mengolah slop oil yang juga
mempengaruhi kualitas dan yield produk.
‒ Crudes yang diterima oleh Kilang sering kali tidak sesuai benar
dengan crude assay data crude yang bersangkutan.
‒ Umumnya feed ke CDU merupakan campuran dari beberapa
jenis crude dan jarang sekali merupakan satu jenis crude saja.
31
Dasar-Dasar Crude Unit Distillation
• Reflux
‒ Liquid dingin kontak secara
countercurrent dengan vapor panas
‒ Semakin tinggi reflux, semakin baik
separasi serta recovery dengan
spesifikasi produk yang tertentu.
‒ Semakin besar reflux rate, semakin
besar pula diameter kolom tower
yang besar.
‒ Profil reflux untuk kolom CDU
dipengaruhi oleh profil panas yang
dihilangkan melaui pump around.
Semakin tinggi panas yang
dihilangkan di top, semakin tinggi
internal reflux.
32
Dasar-Dasar Crude Unit Distillation
33
Crude Unit Distillation Basics
• Jumlah Stage
‒ Semakin banyak jumlah stage, atau ketinggian kolom packing, semakin
baik separasi.
‒ Overall Overall column efficiency tergantung kepada jumlah stage serta
reflux rate.
‒ Jumlah stage kolom atmospheric distillation umumnya sedikitnya 15 trays
atau sebanyak-banyaknya 50 trays.
‒ Distilasi vakum biasanya menggunakan packing dibagian bottom section
dan trays or packing di bagian top kolom – Penghilangan heat di kolom
vakuum umumnya lebih penting dibanding dengan separasi.
‒ # of stages < # of trays.
34
Steam Stripping
Overhead
Crude Receiver
Column Sidecut Debutanizer
Stripper
Steam
Kerosene
Sidecut
Stripper
Steam
Diesel
Desalter
Steam
Reduced
Crude
35
Crude Distillation – Heat Balance
• Distilasi Atmospheric
• Heat Inputs
‒ Heater
‒ Steam
• Heat Outputs
‒ Bottom Product
‒ Side Draws
‒ Overhead Draws
‒ Condenser Duty
‒ Pumparound Duties
36
Process Variables
37
Reliability Issues
38
Charge Heater Issues
• Pengendapan Asphaltene
‒ Opportunity crudes Local Hot Spot akibat coking
‒ Crude blending incompatibility
• Pengendapan Salt
‒ Proses desalting yang tidak sempurna
‒ Injeksi caustic
• Oil Film Temperature yang tinggi
‒ High heat flux/low mass velocity design
‒ Outlet temperatures tinggi
• Pengaturan nyala api yang buruk
‒ Perawatan burner jelek
‒ Jaga kandungan O2 levels cukup tinggi untuk
39
mempertahankan agar nyala api jauh dari tube
Overhead Corrosion Issues
Fe 2 HCl FeCl 2 2 H
FeCl 2 H 2 S FeS 2 HCl
40
Overhead Corrosion Control
42
Crude Distillation – Corrosion
43
Crude Column Metallurgy
pH Control
Inhibitor
Water Wash
Gas
Naphtha
Sour Water
Steam Carbon Steel
o
< 500 F
Kerosene
> 500oF Carbon Steel
or Monel
Steam
Light Gas Oil 317 SS
Steam Steam
Heavy Gas Oil
Reduced Crude
44
Issue Fouling pada Exchanger
% by Weight
Iron sulfides, oxides 10-30
Asphaltic material (soluble in benzene) 2-26
Asphaltic material (insoluble in benzene) 41-63
Inorganic salts (CO3=, SO4=, Cl–) 0.5-20
45
Exchanger Fouling – Primary Causes
46
Solusi Mengatasi Exchanger Fouling
• Desalting
‒ Residence time yang cukup
‒ Optimasi pemakaian chemical
‒ Optimasi mix valve pressure drop
• Polimerisasi
‒ Minimize oxigen di wash water
• Crude Blending
‒ Identifikasi permasalahan crude dan operasi dalam limit berdasarkan
assay atau unit testing.
• Exchanger Cleaning
‒ Fouling adalah suatu yang tidak dapat dihindari, oleh karena itu
perlu dimonitor dan dioptimisi. Sparing/isolation exchangers
dibutuhkan untuk online cleaning manual. Spring-type inserts
(seperti Spirelf®) bisa juga digunakan.
47
How to • Specify the degree of separation:- Set product
specification.
design •
•
Select the operating conditions:- Operating pressure.
Crude
Determine the stage and reflux requirement:- The
number of equilibrium stages.
Column? •
•
Select type of contacting device:- Plates or packing.
Size the column:- Diameter, number of real stages.
• Design the column internals:-
Plates,Distributors,Packing Supports etc.
• Mechanical design:- Vessel and Internal fittings.
The • On its own unit, CDU is economically-unsustain.
• It will be very sensitive to market price of crude oils and
not just • When the crude price falls, CDU gets some margin.
• When the crude price rises, CDU loses a grand of cash.
single CDU
plant only. • Then, we need bottom conversion and its complete
packages to be
– More sustain economically
– More resistant to market price
– More cash to gain and return
Typical • CDU – Vacuum Distillation – Hydrocracker & Delayed
Coker
Configuration • CDU – ARHDM & Residue Catalytic Cracker
• CDU – Vacuum Distillation – Fluid Catalytic Cracker
Coker
convert from low valuable heavy fraction hydrocarbon
to technically better lighter fraction hydrocarbon
Ngayogjakarto Hadiningrat
Setu Pon,
5 Jumadilakir 1950 Tahun Je
• Why we need to learn about crude oils?
Why – CRUDE OILS I’D SO CRUEL I DO CRUELS