design considerations
Proper crude unit overhead system design is important when building a new unit or
revamping an existing one to process different crudes. Overhead condenser designs should
meet the specific processing objectives, such as distillate yield, run length and energy recovery
Tony Barletta and Steve White
Process Consulting Services
rocess
flow
schemes
and
equipment design play a major
role in atmospheric crude column
and condenser system corrosion and
fouling. There are two major types of
overhead systems single- and twodrum but there are many different
process flow schemes and several
exchanger
configurations.
Some
overhead systems experience severe
corrosion and fouling that increase the
atmospheric column operating pressure,
reduce the distillate yield or require
exchanger bundle changes at intervals
less than the normal four- to six-year
turnarounds. Some crude columns
have to be shut down to remove salts
deposited on the internals.
290
Raw
crude
250
155
C.W.
110
Single drum
Sour
water
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Wet gas
Naphtha
product
Temperature, F
PTQ Q3 2007 53
310
Raw
crude
155
250
C.W.
Wet gas
110
Product
(cold) drum
Reflux
(hot) drum
Sour
water
Naphtha
product
Temperature, F
Crude oil
out
Overhead
vapour in
Crude oil
in
t flange
Outlet
Temperature, F
54 PTQ Q3 2007
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Water
wash
155
Raw
crude
C.W.
Reflux
(hot) drum
Wet gas
110
Product
(cold) drum
Sour
water
Naphtha
product
Overhead vapour
to condensers
270
Reflux
110
Internal reflux
temperature
increases as it
flows down
tower
Localised
temperature
on top tray
below water
dewpoint
Salt lays down
once water vapourises
Temperature, F
Single-drum systems
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Water wash
Raw
crude
Forced water
condensation
Wet gas
C.W.
Single drum
Sour
water
Naphtha
product
PTQ Q3 2007 57
Temperature control of
hot drum bypass crude
Raw
crude
C.W.
TC
Wet gas
Reflux
(hot) drum
Product
(cold) drum
Sour
water
Naphtha
product
Exchanger design
Crude oil
out
Overhead
vapour in
t flange
Crude oil
in
Outlet
Two-drum systems
58 PTQ Q3 2007
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Column overhead
vapour
Crude out
Crude in
Conclusions
Temp. control of
hot drumbypass crude
Cold raw
crude
TC
C.W.
Wet gas
Sour
water
Naphtha
product
When required
Figure 10 Overhead system design: two-drum system for meeting specific requirements
PTQ Q3 2007 59