PRO/II Application Briefs

R4 - Vacuum Column
The problem involves preparing a base case simulation model for
an existing vacuum column by matching measured test run data.
This model will then be used for carrying out further studies on the
column performance as part of a revamp exercise.
The flowsheet for the column is illustrated in Figure R4-1.The
column is of two sections, each with a total draw and a pumparound
returning cooled liquid to the top of the section. The slop wax is
part of the heavy gas oil draw that is mixed with the feed before it
enters to the furnace.

Figure R4-1: Vacuum Column Flowsheet

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Process Data
Table R4-1 shows the analysis of the topped crude feed to the unit.
The steam feed is at 330 C and 8000 mm Hg.
Table R4-1: Feed Assay (ASTM D1160 at 2mmHg)

LV% Temp (C) LV% Temp (C)

0 93 40 252
5 145 50 295
10 190 60 326
20 206 70 375
30 236 75 409
Specific gravity = 0.9833
Temperature (C) = 330
Pressure (mmHg) = 8000

The product balance for the test run is shown in Table R4-2.
Table R4-2: Product Balance

Stream m3/hr Kg/hr

Topped Crude (dry) 99.37 97,509
Dissolved water - 318
Bottom Stream - 908
VOVHD - 1246
VLGO 7.10 6430
VHGO 41.34 38997
VResid 50.82 520

Measured temperatures and pressures for the column are listed in

Table R4-3.
Table R4-3: Column Data

Tray Pressure (mmHg) Temperature (C)

Top 74 66
LVGO draw - 136
HVGO draw - 282
Flash Zone 98 371
Bottom 115 366

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Methods and Data

The BK10 thermodynamic system is recommended for K-value,
enthalpy and density calculations for refinery vacuum units. The
PETRO option is selected to calculate thermal conductivity and
liquid viscosity. The API method generally gives the best prediction
of liquid viscosity for heavy hydrocarbon systems.
The ASTM D1160 distillation data at 2 mmHg are used directly by
specifying the measurement pressure on the D1160 statement. The
data are only available up to the 75% point on the curve. Measured
data rarely go beyond this and the program extrapolates to the 100%
point. The extrapolated portion of the curve makes up most of the
bottom product, and any inaccuracies will mainly affect the bottom
temperature.
This example uses the minimum assay data, which are the
distillation curve and average gravity. Results may be improved by
entering gravity and/or molecular weight curves if available.

Simulation Model
The column is modeled as a refinery column with 7 theoretical trays
as shown in Figure R4-1. Each packed section is assumed to be 2
theoretical trays. The number of trays may also be obtained from a
previous shortcut simulation. Tray 6 represents the furnace and
flash zone, where the slop wax and fresh feed are mixed and heated.
The furnace is included in the column model to calculate the duty
and ensure that a heat balance is obtained. The slop wax stream is
the liquid runback from the tray above the flash zone.
The temperature of the feed from the furnace will not be the same as
the flash zone temperature. It is calculated in a separate flash drum
by adding the furnace duty to the feed and the slop wax streams.
Thermal cracking usually occurs in the furnace, producing some
light gases. The only effect of these is on the temperature at the top
of the column, and it can be ignored unless this temperature is
important. For this simulation, we will match the top temperature
by adding a small quantity of ethane and propane to the feed to
represent the cracked gases (stream CRACK_GASES). For
subsequent simulations we may wish to adjust the cracked gases
stream to reflect the actual yield of vacuum overhead. To keep the
overall weight of feed constant, we can subtract the weight of
cracked gas from the topped crude, which is done automatically

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 PRO/II Application Briefs
using Calculator CA1. The reduced rate is then inserted into stream
"ADJD_TOP" which becomes the feed that is used in the column
simulation.
Trays 2 and 5 are total draws with all the liquid (except for the slop
wax from tray 5) going to the pumparounds and products. These are
modeled by specifying the liquid from tray 2 at a very small value
and that from tray 5 as the actual slop wax rate into the flash zone.
Note: When modeling an existing column, the most reliable
measured data should be used for the specifications. Less reliable
data can be compared with the calculated results.
The reliability of the measured pumparound rates is suspect, but the
return temperatures are assumed to be reasonably accurate.
Therefore, the pumparound return temperatures are entered and the
corresponding rates calculated.
The other specifications in this simulation are the volumetric rates
of the VHGO and VRESID and the top tray temperature. The
variables are the three duties and the side draw molar rates.

Input Data
Click Input/Unit of Measure.. or Click to view the Unit of
Measure (UOM) specified for this problem.
Figure R4-2: UOM Selection

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Click Input/Component Selection or to enter the
component slate data.

Figure R4-3: Component Selection

The TBP option is used to request printout of the distillation curves

for all the streams.

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Click Input/Thermodynamic Data.. or click to view the
Thermodynamic Data - Modification dialog box. Select BK10 as
indicated in Figure R4-4 below. Use the Modify Data button to
open the Modification DEW and override the enthalpy methods.

Figure R4-4: Thermodynamic Data - Modification

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The default component flowrate output is suppressed, as the oil
does not have defined components. Laboratory assay curves are
used to represent the streams with pseudocomponents (boiling point
cuts) for which the necessary thermophysical properties can be
estimated.

Figure R4-5: Assay Stream Data

The feed temperature calculation is separate from the column model

and is calculated after the column has converged. In order to feed
the slop wax to the flash calculation, the TFLOW statement is used
to create the stream SLOP, which is identical to the liquid from tray
5. The flash unit simply adds the flash zone duty to the feed and
slop wax streams, and the resultant temperature is the furnace outlet
temperature.

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Figure R4-6: Feed & Products

The damping parameter value DAMP=0.9 is recommended for

vacuum columns, as it assists the convergence.

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Figure R4-7: Column - Convergence & Specification

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The column specifications and variables can be adjusted using the
Column - Specification and Variable dialog box.

Figure R4-8: Column - Specification & Variables

Keyword Input File

TITLE PROJECT=R4R, PROBLEM=APPBRIEFS, USER=SIMSCI, DATE=JUL07
DESC - USES REFERENCE STREAM
DESC - MODIFIED 12/22/94 TO CHANGE DAMPING FACTOR TO .9
PRINT STREAM=SUMMARY, TBP
DIMENSION METRIC, PRES=MMHG
SEQUENCE SIMSCI
COMPONENT DATA
LIBID 1,H2O/2,C2/3,C3, BANK=SIMSCI,PROCESS
ASSAY CONVERSION=API94, CURVEFIT=CURRENT, KVRECONCILE=TAILS
THERMODYNAMIC DATA
METHOD SYSTEM=BK10, VISCOSITY(L)=API, VISCOSITY(V)=PETR, &
CONDUCTIVITY(L)=PETR, CONDUCTIVITY(V)=PETR, SET=BK1001
STREAM DATA
PROPERTY STREAM=R1A, TEMPERATURE=330, PRESSURE=8000, PHASE=M, &
RATE(LV)=99.3701, ASSAY=LV
D1160 STREAM=R1A, DATA=0,93/5,145/10,190/20,206/30,236/40,252/ &
50,295/60,326/70,375/75,409, TEMP=C, PRES(MMHG)=1.99999
SPGR STREAM=R1A, AVERAGE=0.9833
PROPERTY STREAM=R1B, TEMPERATURE=330, PRESSURE=8000, PHASE=M, &
RATE(LV)=3, COMPOSITION(M)=2,75/3,25
PROPERTY STREAM=R1C, TEMPERATURE=330, PRESSURE=8000, PHASE=M, &
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RATE(WT)=318, COMPOSITION(M)=1,100
PROPERTY STREAM=W1, TEMPERATURE=355, PRESSURE=8500, PHASE=M, &
RATE(WT)=907.999, COMPOSITION(M)=1,100
PROPERTY STREAM=R1REF, REFSTREAM=R1
NAME R1A,TOPPED CRUDE/R1B,LIGHT ENDS/R1C,DIS. STM/R1,VAC FEED/ &
R2,FURNACE PROD/V1,OVERHEAD/V2,LVGO/V3,HVGO/ &
V4,VAC RESI NORMALIZE
UNIT OPERATIONS
MIXER UID=M1, NAME=FEED MIX
FEED R1A,R1B,R1C
PRODUCT M=R1
COLUMN UID=C1, NAME=VAC COLUMN
PARAMETER TRAY=7,IO DAMPING=0.9
FEED R1,6/W1,7
PRODUCT OVHD(M)=V1, LDRAW(M)=V2,2,25, LDRAW(M)=V3,4,120, &
WATER=WD_C1,1, BTMS(M)=V4,79.9999, SUPERSEDE=ON
DUTY 1,6,,SIDEHC1
DUTY 2,1,,PAROHC1
DUTY 3,3,,PAROHC2
PA NAME=1, FROM=2, TO=1, PHASE=L, DNAME=PAROHC1, TEMP=49
PA NAME=2, FROM=4, TO=3, PHASE=L, DNAME=PAROHC2, TEMP=166
PRINT PROPTABLE=PART
ESTIMATE MODEL=REFINING, RRATIO=3
PRESSURE 1,73.9998/6,98.0001/7,114.999
SPEC ID=COL1SPEC1, STREAM=V3, RATE(LV,M3/H),TOTAL,DRY, &
VALUE=41.34
SPEC ID=COL1SPEC2, STREAM=V4, RATE(LV,M3/H),TOTAL,DRY, &
VALUE=50.88
SPEC ID=COL1SPEC3, TRAY=5, RATE(LV,M3/H), PHASE=L,WET, &
VALUE=3.5
SPEC ID=COL1SPEC4, TRAY=2, RATE(KGM/H), PHASE=L,WET, VALUE=0.1
SPEC ID=COL1SPEC5, TRAY=1, TEMPERATURE(C), VALUE=67
VARY DNAME=SIDEHC1,PAROHC1,PAROHC2
VARY DRAW=V2,V3
TFLOW NET(L)=SLOP,5
FLASH UID=FL1, NAME=FEED TEMP
FEED R1REF,SLOP
PRODUCT M=R2
ADIABATIC
DEFINE PRES(MMHG) AS COLUMN=C1, TRAY=6, PRESSURE(MMHG), &
PHASE=L
DEFINE DUTY(KC/H) AS COLUMN=C1, DNAME(KC/H)=SIDEHC1
END

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Results
The calculated results should be compared with all the available
measured data. If the match is not considered good enough, then it
may be necessary to try different specifications or alter the number
of theoretical trays. Only when the base case is satisfactory should
it be used to investigate changes in the column operation.
In this example, the calculated tray temperatures show good
agreement with the measured values shown in Table R4-3.

Output
The result of the feed temperature calculation is shown on the flash
output in Figure R4-9. The temperature of the feed stream is
370.109 C compared with the flash zone temperature of 368.8 C
shown on the column summary.

Figure R4-9: Flash Data

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A number of charts and tables can be obtained in excel spreadsheet
for streams and Equipments used in the PFD by clicking the Tools/
Spreadsheet.

Figure R4-10: Spread Sheet

The extract from the stream summary output shows the properties
for the product streams.

Figure R4-11: Stream Property Details

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Column Summary
UNIT 2, 'C1', 'VAC COLUMN'
TOTAL NUMBER OF ITERATIONS

IN/OUT METHOD 13

COLUMN SUMMARY
---------- NET FLOW RATES ----------- HEATER
TRAY TEMP PRESSURE LIQUID VAPOR FEED PRODUCT DUTIES
DEG C MM HG KG-MOL/HR M*KCAL/HR
------ ------- -------- -------- -------- --------- --------- ------------
1 67.0 74.00 87.2 82.8P 103.2V -0.8991
0.0W
2 134.6 78.80 0.1 107.6 82.8P
25.2L
3 223.2 83.60 305.8 128.5 217.1P -5.2885
4 277.2 88.40 27.5 217.1 217.1P
107.6L
5 345.2 93.20 7.4 263.6
6 368.8 98.00 90.8 243.4 264.7M 4.8314
7 363.1 115.00 62.1 50.4V 79.1L

FEED AND PRODUCT STREAMS

TYPE STREAM PHASE FROM TO LIQUID FLOW RATES HEAT RATES

TRAY TRAY FRAC KG-MOL/HR M*KCAL/HR
----- ------------ ------ ---- ---- ------ ------------ ------------
FEED R1 MIXED 6 0.5642 264.69 17.8119
FEED W1 VAPOR 7 0.0000 50.40 0.6863
PROD V1 VAPOR 1 103.20 0.9096
PROD WD_C1 WATER 1 0.0000
PROD V2 LIQUID 2 25.19 0.4103
PROD V3 LIQUID 4 107.64 5.7035
PROD V4 LIQUID 7 79.06 10.1186

PSEUDO PRODUCT STREAMS

TYPE STREAM PHASE FROM TO LIQUID FLOW RATES HEAT RATES

TRAY TRAY FRAC KG-MOL/HR M*KCAL/HR
----- ------------ ------ ---- ---- ------ ------------ ------------
NET SLOP LIQUID 5 7.37 0.6446

OVERALL MOLE BALANCE, (FEEDS - PRODUCTS) 6.2450E-14

OVERALL HEAT BALANCE, (H(IN) - H(OUT) ) -3.9589E-06

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A range of other tray properties is available. The tray temperature
profile is illustrated below.

Figure R4-12: Temperature Profile

The flowrate details are shown below.

Figure R4-13: Flowrate Profile

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The thermal conductivity details are illustrated below.

Figure R4-14: Vapor Thermal Conductivity

To view other available plots, select Output/Generate Plot to view

the Generate Plot dialog box. Select the appropriate options and
click Plot to generate and view the graph.
Distillation curves can be viewed by clicking Tools/Distillation
Curve to view the Stream Distillation Curve dialog box. Select the
appropriate stream and distillation curve options to generate the
plot.

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