Training Services

Crude Characterization

EDS 2004/CC-1
 Outline

„ Introduction
„ Background Topics
„ Crude Assay Review
„ Crude Breakup Objectives
„ Important Topics to Emphasize
„ Procedure - Sample Problem
„ Class Problem

EDS 2004/CC-2
 Introduction

„ What is a crude breakup procedure?

„ Procedure to calculate fraction yields and
properties for a given crude oil assay
„ A crude breakup can also be called a “crude
yield estimate” for a given crude oil assay

EDS 2004/CC-3

•In the past, many people in the industry have referred this procedure as performing
a “crude breakup”. This term is still used. I feel a better term might be “crude
yield estimate”. This is what we are doing - we are predicting the yields and
properties that the actual crude and vacuum unit will generate when processing the
crude represented by the crude assay. This gives the same meaning to the term
when “yield estimate” is applied to other (reaction) units in the refinery (such as
FCC, reforming, hydrotreating, etc.). However, with a crude unit, there is no
reaction, only separation occurring, so that is the major difference between a crude
“yield estimate” and other process unit yield estimates.
 Background

„ Understanding the terms and procedures used

is important to avoid misunderstandings
between ALL PARTIES -between and within
companies
„ Consistent procedure - all parties agree with
the results
„ Results represent a certain level of crude and
vacuum unit performance

EDS 2004/CC-4

•These points cannot be emphasized enough. I have spent countless hours (and
days) clearing up the misunderstanding/miscommunication involved in a new
refinery design. The misunderstandings often involve the word “cutpoint”. I
distinguish between “LP/Planning Cut Ranges for Yield” and “unit product
distillations”. These are the 2 kind of cutpoints I worry about.
•This is not rocket science (we’ve been boiling oil for 1000’s of years). However,
some people will refer to a 650°F diesel cutpoint - for one person, this is a LP cut
point for yield, for someone else this is an ASTM distillation endpoint (EP). Not
rocket science, but you can say the same word but mean (significantly) different
things!!!
•I will emphasize this more later.
Background for Using Crude Assay

„ Types of Laboratory Distillations

„ Physical Properties for Characterization

„ Specifications for Products

EDS 2004/CC-5
 Types of Laboratory Distillation

„ Engler D-86
„ Engler D-1160

- Run in a standard engler flask

- No packing
- No reflux
- Standardized
- Data not related to yield

CA-R00-01
EDS 2004/CC-6

•These are the basic laboratory distillations that are performed over the world.
They have been around a long time, and most everyone in the operating world is
familiar with them. Most laboratories have automated them to reduce costs and
increase sample processing capability.
 Types of Laboratory Distillation
(continued)

„ TBP Distillation

- Done in column with 15 to 100 stgs

- High reflux rate > 5 to 1
- Give accurate comp distribution

CA-R00-02
EDS 2004/CC-7

•This is the basis for a crude assay. Most crude assays are performed using a True
Boiling Point (TBP) procedure. There is an official ASTM test method (D-2892 -
official title “Distillation of Crude Petroleum (15-Theoretical Plate Column)”).
However, the tests are not necessarily standardized in terms of the number of
theoretical plates and the amount of reflux. However, this is normally not
significant.
•The key to a TBP distillation is the high number of fractionation stages and a high
level of reflux. This ensures a high level of fractionation between the cuts. Some
people even refer to this as “perfect” fractionation. Essentially we are getting a
very fine split between fractions with a TBP distillation (which does not occur in the
real crude/vacuum towers, and in the D-86/D-1160 distillations).
 Types of Laboratory Distillations
(continued)

„ D-2887 “Simulated Distillation” or Sim Dist

„ True Title “Boiling Range Distribution of
Petroleum Fractions by Gas Chromatography”
„ As stated in the title, this is a GC method
„ Results are different from the TBP (just like the
results for the D-86/D-1160 are different from the
TBP), but closer to the TBP than the D-86 or D-1160
„ All distillations have interconversions to relate the
laboratory method to a TBP distillation (this is how
the simulator handles all of these distillations - they
are converted to TBP distillations
EDS 2004/CC-8

•This is a relatively new type of distillation laboratory test. From a laboratory

handling viewpoint, it is easier to handle than the traditional D-86/D-1160
distillations. The results are different than either the D-86/D-1160 distillations or a
TBP distillation.
•Most process simulators (Hysys, Aspenplus, ProII) allow you to enter any type of
distillation data. In the simulator, the internal working curve that the simulator uses
is a TBP curve. All of your input data to a simulator is converted to a TBP curve,
usually using published API or ASTM conversion methods.
 Types of Laboratory Distillation
Difference between TBP and ASTM distillation of the same material

CA-R00-05
EDS 2004/CC-9

•This plot shows, that if the same material is taken to a laboratory and given a TBP
and ASTM test, the resulting distillation plot will not be the same, even though the
sample material is the same.
 Types of Laboratory Distillation
(continued)

„ EFV (Equilibrium Flash Vaporization)

Vapor
- Relates to commercial
flash
- Total vapor in
equilibrium with total
liquid
- Time consuming in
Liquid laboratory

CA-R00-03
EDS 2004/CC-10

•This is another type of laboratory test that is not practiced much anymore due to
the high cost. In order to extract any useful information from this test, a large
number of runs must be performed.
•In a simulator, this is the same as a “flash” calculation.
 Light Arabian Crude Assay

Table A - I
Crude and Residual Properties

Table A - II
Light Hydrocarbon Analyses
TBP Cut Points
IBP - 60°F
60 - 160°F

EDS 2004/CC-11

•Table 1 represents whole crude and residue properties. It shows how the
properties of the residue change as more distillate material is removed.
•Table 2 represents the light hydrocarbon analysis. In many recent assays, this
includes a complete GC breakdown up through C9 or C10 material (very valuable
information for doing catalytic reforming (Platforming) yield estimates).
 Light Arabian Crude Assay
(continued)

Table A - III
Gasolines and Naphthas
(60 - 200) (60 - 300) (60 - 400)
(200 - 300) (200 - 400) (300 - 400)

Table A - IV
Kerosenes and Gas Oils
(300 - 400) (300 - 500) (300 - 600)
(400 - 500) (400 - 600)
(500 - 600) (600 - 800) (800 - 1000)

EDS 2004/CC-12

•More data - representing the properties of interest for each cut.

 Light Arabian Crude Assay
(continued)

Table A - V
Vol-% Yield vs. TBP Temperature
800
700
600
Temp.

500
400 Vol-% Yield
300
200
100
0 10 20 30 40 50 60 70 80 90 100
EDS 2004/CC-13

•If there is any concept I want you to take away from this class, it is the power of
the TBP Yield Curve.
•This plot, for any crude assay, represents the yield compared to the temperature the
yield occurs at.
•It basically tells you how much naphtha, kerosene, diesel, gas oil, and residue you
will get from processing a particular crude in your refinery.
•This tells you how much of a particular cut you will get (hence it is called the Yield
Curve). The other information we need to determine the profitability of running a
particular crude in our refinery is the properties of the various cuts.
 Crude Breakup Objectives

„ Primary Objective - Predict commercial yields

and properties

„ Yields obtained from true boiling point (TBP)

distillation curve

„ Properties obtained from theoretical cuts

produced in the laboratory (tabulated in the
crude assay)

EDS 2004/CC-14

•Just repeating the purpose of doing a crude breakup (crude yield estimate)
 Yields

„ Theoretical yields are represented by the TBP

fractions prepared in the laboratory

„ Commercial yields do not match laboratory

(theoretical) yields - distillates are left in the
residue (a function of % overflash) and the
number of real trays and reflux is lower than
in the TBP distillation

EDS 2004/CC-15

•This is stating the obvious, that there is a difference between a TBP distillation
(lots of reflux and trays) and real world distillation in a real crude and vacuum unit.
 Objectives
“Predict”: Yields and Properties

CA-R00-08
EDS 2004/CC-16

•This shows the TBP Yield Curve, and how to use it to estimate yields.
 Objectives
“Predict”: Yields and Properties

CA-R00-09
EDS 2004/CC-17

•This shows how we will use the property information in the assay to determine
properties.
•More on this in the next few slides.
 Properties

„ Some properties required to characterize

hydrocarbon fractions (to perform engineering
calculations)

„ Others required to design a crude and vacuum unit

„ Others needed for design or operation of other units

in the refinery

EDS 2004/CC-18

•How many properties you are looking for will depend on the end use for doing a
crude breakup - whether for hydrocarbon characterization (computer simulation),
unit design, or for yield estimating in other units.
 Properties to Characterize Hydrocarbons

„ API or sp. gr.

„ Boiling point/distillation
„ UOP K
„ Molecular wt

EDS 2004/CC-19

•These are the properties that are required to characterize oil fractions for process
engineering calculations. You have had a session on Hydrocarbon Properties. In
that session you learned that in order to perform engineering calculations (such as
vapor liquid equilibrium, enthalpy calculations, etc.) you would need to know the
oils boiling point (either CABP, MeABP, or some other average boiling point) in
order to calculate the other data we need to know if order to perform engineering
calculations (in order to perform heat and material balance calculations).
•To do these calculations by hand, you need the boiling point, gravity, and UOP K,
and for some calculations, the mol wt. Then you need to look up the appropriate
data on the correct charts/data tables
•For a modern simulator, all that is really needed is a boiling point and gravity. For
the whole crude, this comes in the form of a TBP boiling point curve and a gravity
curve generated from the mid volume % point in the assay.
 Physical Properties for Characterization

UOP K (Characterization Factor)

API Gravity
CABP
or
API Gravity
Viscosity,cs
Mol Weight
API Gravity
Mean ABP

Reference
API Technical Data Book
UOP Charts

EDS 2004/CC-20

•To calculate UOP K, we need the gravity and boiling point (for distillate fractions)
and gravity and viscosity (for residue fractions), plus charts.
•To calculate Molecular Weight, we need the gravity and a Mean Average Boiling
Point, plus charts.
 Other Properties for Crude Unit Design

„ Sulfur
„ H2S
„ Salt
„ Acid Number
„ Viscosity
„ Pour Point

EDS 2004/CC-21

•For example, sulfur is used for metallurgy selection (as is H2S). Salt content is
used for desalter design. Acid number seriously affects metallurgy selection (it is
essentially a decision on whether the unit will be designed to process high acid
crudes). Viscosity affects exchanger design, piping design. High pour point
material requires heat tracing on process lines.
 Properties Required by Other Units

„ Mercaptan Sulfur
„ PONA
„ Octane Number
„ Cetane Number
„ Smoke Point
„ Cloud Point
„ Viscosity
„ Many Others (see Section 4.2 of text)

EDS 2004/CC-22

•In most modern refineries, the products off the crude unit are processed in
downstream process units (although this is not always the case in some parts of the
world for diesel and fuel oil especially).
•Not every property is needed for every cut.
 Specifications for Products

Naphtha Diesel
Distillation Distillation
Kerosene Cetane Number
Distillation Pour point
Flash Point Fuel Oils
Freeze Point Sulfur
Viscosity

EDS 2004/CC-23

•These are some examples of properties needed for some crude/vacuum unit
products. When crude unit products are processed in downstream units, the
resulting products must ultimately meet final product specification.
•The specifications needed for products will vary, depending on the ultimate user of
the information. If the use is for a refinery LP, all of this information is needed,
plus a lot more. If the naphtha is going to a catalytic reformer (hopefully a UOP
Platforming Unit), then not only is the distillation required, but also the PNA
content. If the complex contains a vacuum unit, the amount of contaminants in the
gas oil (metals and con carbon) are required. Depending on the residue processing
scheme (coker, visbreaker, hydrotreating) the number of properties that must be
estimated will have to accommodate the process units in the refinery.
Topics Requiring Emphasis

„ General
„ Flash Zone Conditions
„ ASTM distillation
„ Degree of Fractionation
„ Typical Design Criteria

EDS 2004/CC-24
 General

„ Procedure is a set of guidelines - not hard

rules; changes can be made depending on
particular customer needs

„ Biggest problem usually is missing or

conflicting data within the assay

EDS 2004/CC-25

•I have performed this “manual” breakup several times, and have often modified
some of the data based on actual plant operating data (most often the estimate of
distillations has changed).
•As mentioned above, the biggest problem is usually missing or conflicting data
within the assay.
 Flash Zone Conditions

„ Predicted yields and cutpoints must be

compatible with realistic flash zone operating
conditions

„ This topic will be explored in detail in the

crude unit design talk

EDS 2004/CC-26

•There is a key point to be made here - the flash zone and furnace outlet have
definitive temperature limits. For crude columns, the furnace outlet temperature
typically must be limited between 660-725°F (more paraffinic crudes (higher UOP
K) have a lower temperature limit). The limit is caused by cracking. At some
point in the 660-725°F range, the crude will start to crack. This causes coking in
the heater (which then can cause a shutdown to clean the heater), can cause products
to go off specification do to color problems, and can overload the overhead system
with gas.
•When predicting yields with this breakup procedure, it is certainly possible to show
more distillate product produced in the crude and vacuum towers than is possible in
a real plant.
•In general, the crude tower lift (distillate product lift) and TBP cutpoint coincide
with the heater outlet (within 50°F). Actually operating experience with a crude is
the best data available for how far this can be pushed.
•For vacuum towers, somewhere between 1000 and 1050°F AEBP (Atmospheric
Equivalent Boiling Point, more on this later) is usually the limit.
 ASTM Distillation

„ Estimating ASTM distillation of fractions is not

always easy

„ Method of estimating ASTM distillation of

commercial cuts given in this procedure should
be used only if other methods or information is
not available

„ Note the difference between theoretical and

commercial distillation

EDS 2004/CC-27

•This is the inaccurate portion of a manual crude breakup. The best data is actual
data, match with a simulation. If actual data is not present, a simulation, coupled
with data/experience from similar units is the best estimate.
•The method shown in section 6.12 of the detailed procedure is very rough and
should only be used when the real or simulated data is not available (because it is
just a rule of thumb).
•Lastly, remember - the crude assay was done in a TBP apparatus, while the real
crude unit has fewer trays and much less reflux than a TBP apparatus (although a
real crude unit has more trays/reflux than a D-86/D-1160 test). The amount of
fractionation really does depend on the number of trays and the amount of reflux in
each section of the crude column. This is covered in more detail in the crude unit
design talk.
•It is a key point to remember that some of the properties we talked about can be
very seriously affected by fractionation performance. For example, in some
countries diesel pour/cloud/CFPP (these are cold flow properties) limit the amount
of heavy material that can be lifted into the diesel product in winter. And the
heaviest components have the most significant impact on these properties (in a
nonlinear manner). The “fractionation tail” can very seriously affect this, and is a
function of fractionation performance.
 Types of Laboratory Distillation
Difference between TBP and ASTM distillation of the same material

CA-R00-05
EDS 2004/CC-28

•This is the same slide that we saw before. It shows what happens when we use the
ASTM and TBP tests on the same sample.
 Types of Laboratory Distillation
Example - TBP Distilled Sample of 400-600°F TPB Range Material
(Same Liquid Volume % of Crude as the Next Slide)

Note: Values shown are for illustrative purposes only and are not meant to CA-R00-06
EDS 2004/CC-29
represent any commercial operation.

•Ok, this is where is gets a little tricky.

•What we’re saying here is, this is what we expect to see if we processed the crude
in a TBP apparatus. The 400-600°F cut from the TBP apparatus would have the
distillation shown above.
 Types of Laboratory Distillation
Example - Commercially Distilled Sample of 400-600°F TPB Range Material
(Same Liquid Volume % of Crude as Previous Slide)

Note: Values shown are for illustrative purposes only and are CA-R00-07
EDS 2004/CC-30
not meant to represent any commercial operation

•Ok, this is where we usually get really confused.

•A cut range can be related to yield. In the crude assay (which is a TBP
distillation), we can say that the 400°F- material represents the first 31.4 vol% of the
crude that boils over. At 600°F- this represents the first 51.6 vol%. So, when we
refer to the 400-600°F boiling range material, we are referring to crude that is in the
31.4-51.6 vol% yield pattern (20.2 vol% of the total crude).
•Now, when we yield this 20.2 vol% of the crude in the 31.4-51.6% range, in a TBP
column is has a 400-600°F distillation. However, in a real crude column, the
distillation is “sloppier” than this - in other words, we have material lighter than
400°F in the front end of the product, and material heavier than 600°F in the back
end of the product. So if we take this commercially distilled sample of the 31.4-
51.6% portion of the crude, it will have a distillation as shown above.
•If the same sample (material) is put into TBP and ASTM tests, they will always
have a graphical relationship as shown above.
•The confusing part comes in realizing that, for the same position in crude (31.4-
51.6 vol% of the crude) a TBP distilled sample (from a crude assay) and the
commercially distilled sample (from the crude unit) - these samples have different
distillations!!!
•And, they also can have different properties as well, especially cold properties,
such as cloud point, pour point, CFPP, freeze point - any property that does not
blend linearly.
 Degree of Fractionation

Degree of Fractionation for Mixtures - Define

„ Gap
– Difference between 5 vol-% of heavier cut and
95 vol-% of adjacent lighter cut
„ Overlap
– Negative gap
„ Typical for CDU Gap °F
Overhead -- Kerosene 20-30
Kerosene -- Diesel 10-20
Diesel -- Atm gas oil 0-10

EDS 2004/CC-31

•Once again, there is no rocket science here, everything is a matter of definition.

•Most refiners refer to gap as the ASTM 5% (heavier cut) - ASTM 95% (lighter
cut). This is the standard, worldwide definition. I have seen where some refiners
have used a 10%-90% gap. So when you say “gap”, also say what you’re definition
is so that everyone is clear on the definition.
•I prefer to use gap, and if it is negative (which is common), to simply use a
negative number. Many people in the industry use overlap when the gap becomes
negative.
•These are “typical” gaps for a 3 draw crude unit. 4 draw crude unit will have
lower gaps because the cuts are smaller (more on why this is the case during the
crude unit talk - see charts PD 170 and PD 171).
 Degree of Fractionation
Definitions: GAP (95% - 5%)

CA-R00-10
EDS 2004/CC-32
 Typical Design Criteria

Typical Design Values

6 - 10 Fractionating Trays between Cuts
3- 5 Vol-% Overflash
8 -10 Lbs/hr Stripping Steam/Bbl/h Stripped Liquid
> 0.20 Internal Reflux (L/V)

EDS 2004/CC-33

•As mentioned above, these are typical design criteria. However, many crude have
fewer trays between cuts, and some have quite a few more. It all depends on the
needs of the refiner.
•For stripping steam, the greatest need for stripping steam is in the lightest sidecut
(usually kerosene), and in the atmospheric residue (crude column bottoms). Many
units can operate with much lower levels of steam in the diesel/AGO cuts.
 Typical Design Criteria
Definitions: Overflash (3-5%)

CA-R00-11
EDS 2004/CC-34

•There are 2 overflash definitions. The one we will use is the one I have
encountered and consider to be the basic default definition. This says that the %
overflash is the flowrate of the liquid from the tray above the flash zone divided by
the total crude flow rate. For example, if the flow rate of the liquid from the tray
above the flash zone is 3000 BPSD and the total crude flow rate is 100,000 BPSD,
then the overflash rate will be 3%.
•UOP has used another definition as well. However, to avoid confusion, I do not
want to explain it here. We actually no longer use this definition. If someone
wants to know what the old internal UOP definition is, I will be happy to explain it
after class.
•Once again, the key point I want to emphasize is, that when you are taking to
someone and want to know what the overflash rate is, and they tell you “3%”, then
ask them how they define overflash, and have them draw a sketch showing you the
definition as well (if you are not certain).
 Procedure

„ Before beginning, it can be useful to sketch a

block flow diagram or a fractionation scheme -
helpful to illustrate slump

EDS 2004/CC-35

•It is always a good idea to have a picture in hand, whether it is a block flow
diagram or a process flow diagram.
•In the reference material, we have included a detailed, step by step procedure for a
manual crude breakup procedure. In this class, we will go through a sample
breakup using 2 methods - one using “perfect fractionation”, and the other (with the
same cutpoints) with “slump factors”.
•Then, tomorrow you will get a chance to work on a class problem using perfect
fractionation and slump factors.
 Block Flow Diagram
Obtain Product Yields
Enter Product Yields on Block Flow Diagram
Butanes and Minus
BPSD

Naphtha
Kerosine BPSD
BPSD

Crude Diesel Fuel

BPSD BPSD

Atmospheric Gas Oil

BPSD

Reduced Crude
CU-R00-02
BPSD EDS 2004/CC-36

•In any process design, one of the first tasks to be done is to determine the overall
process flow scheme. A block flow diagram is often used. Once the overall process
flow is known, an overall material balance should be prepared for the unit. In most
new unit designs, feed and product requirements are given as part of the design
basis.
•For a crude unit design, product yields are determined from the design basis crude
assay. Products can be defined either by product quality specifications such as API,
ASTM Distillation, etc., or as product yield specifications such as TBP cut points on
crude or combinations of both. In the first case, TBP cut points must be estimated
and the corresponding product properties determined. If the products do not meet
defined specifications, a new TBP cut point is selected and the entire process
repeated. When TBP cut points are specified, the expected or commercial volume
percent yield of each cut is read directly from the TBP distillation curve. In this
case, the properties of the cuts corresponding to this commercial yield must be
calculated to be consistent with the defined yield structure.
•This sounds confusing, but it is best illustrated by example.
 What is Slump?
Definitions: Slump

Commercial Yield

Slump is the fact that an Equilibrium

Flash Vaporization occurs in the flash
zone. In the stripping section below
the flash zone, not all of the materials
that boil lighter than the cutpoint in the
TBP distillation will be removed before
the commercial Atmospheric Residue
leaves the column.
Another way to think of it is that some
of the AGO, Diesel and Kerosene end
up in the Atmospheric Residue.
More on Slump later.
Crude {
Theoretical
Yield Slump CA-R00-13
EDS 2004/CC-37
 Procedure
Draw a simple Block Flow Diagram for a
Crude Distillation Unit

EDS 2004/CC-38
 Block Flow Diagram

Fuel Gas
ABSORBER

LPG

Kerosine Wild Naphtha DEBUTANIZER

CRUDE
DISTILLATION
COLUMN Light Naphtha
Diesel
NAPHTHA
SPLITTER

Heavy Gas Oil

Heavy Naphtha

Atmospheric Resid

CU-R00-02
EDS 2004/CC-39

•Note that the number of products produced depends on the complexity of the unit.
More sidedraws are possible as are more light end products. Many refiners choose
to split naphtha in the Crude Unit and strip lighter materials from the LPG.
•(Note that this is more of a process flow diagram than the block flow diagram
(although this picture is missing many of the elements of a traditional process flow
diagram). Some people prefer a picture that depicts process vessels as opposed to
squares. It is really more of a personal preference).
 Procedure

Draw a Fractionation Scheme for the CDU

EDS 2004/CC-40
 Procedure - Section 6

„ You have been provided with a detailed, step

by step manual crude breakup procedure.
This is in Section 6 of your reference material

„ The best way to show the details is to do a

sample problem. Most of the steps are
intuitive and basic and can be most easily
understood by doing an example.

EDS 2004/CC-41

•The purpose of the next slides is to provide an overview of the detailed procedure
that is provided in section 6 of your reference material.
• After a this quick overview of the procedure from these Powerpoint slides, we will
perform a sample problem.
•The reference material contains complete details if these are needed. However,
my experience has shown that we can capture most of the needed concepts by
quickly going over the procedure, and then performing a sample problem.
 Procedure - 6.1 Check BS&W

„ Check the bottoms sediment and water (BS&W)

content of the crude. If it is less than 0.5 vol-%,
make no adjustments.

„ If greater than 0.5 vol-%, adjust crude API to a

dry basis, and then continue

EDS 2004/CC-42

•I do not believe I have encountered any crude assays that have listed the BS&W
(which stands for Bottoms Sediment and Water - the test involves putting the crude
oil in a centrifuge and measuring the sediment and water that are centrifuged out of
the crude oil). Thus, I personally have not made this adjustment.
•The purpose of this step in the procedure is to ensure that excessive water is not
upsetting the results of the crude assay. If the BS&W is high, then you would
remove the BS&W quantity and renormalize the TBP distillation and gravity curve
without the BS&W quantity.
•From a commercial point of view, you measure BS&W to measure how much
water and dirt you are paying. Actually, the crude contract normally calls for
subtracting sediment and water from the crude shipment - why would you want to
pay oil price for water?
•Some refiners are moving toward more advanced methods of measuring BS&W,
such as Karl-Fisher for water determination and extraction for sedimentation
determination.
 Procedure - 6.2, 6.3

Make plots of following data

A. Temperature vs. vol-% yield
B. API gravity vs. Mid-vol-% distilled and vol-%
residual
C. Wt-% sulfur vs. mid-vol-% distilled and vol-%
residual
D. UOP K vs. mid-vol-% distilled and vol-% residual

What is “Mid-Volume Percent”?

What is “Volume percent Residual”?

EDS 2004/CC-43

•My mentor, who worked for UOP for over 40 years, constantly emphasized the
need to plot the data in order to see the data trends graphically. With modern
computers, we can get a tremendous amount of data in tables. However, unless this
data is plotted, you can often miss many of the discontinuities and trends in the data.
•There are 2 other concepts which are being introduced here which are very
important - Mid-Volume Percent and Volume Percent Residual.
 Procedure - 6.3 Mid-Volume Percent

„ Mid-volume percent is defined as half the

volume percent of a specific distillate cut plus
the total volume percent of all preceding
distillate cuts

„ Plotting the data is important - Tabular data

does not always make all trends clear

EDS 2004/CC-44

•For example, if we have a 300-400°F TBP cut that represents the 20-30% fraction
of the crude (and if the cut properties are linear), then the mid-volume% point is
25%.
•Similarly, if we had a much narrower 340-360°F TBP cut that represents the 24-
26% fraction of the crude, the mid volume percent of the cut would still be 25%.
•Thus, the Mid-Volume Percent is the midpoint of the cut.
 Procedure
Definitions: Mid-Volume Percent

CA-R00-12
EDS 2004/CC-45

•In mathematical terms, we take the volume of crude that has already been distilled
over, and half of the volume of the cut in question. Add them together, and you
have the mid volume%.
•Mid volume% is what we use to determine all DISTILLATE properties. We
match the mid volume percent with the appropriate chart/table for the distillate cut
in question.
•So what do we do for residue (either atmospheric or vacuum)? We have a
different concept, called volume percent residual.
•For this, examine Figure V-A-3 in the reference material.
•For the whole crude, look at the 100% point on the x-axis. As distillate (light)
material is removed, we move to the left on the x-axis, representing how the
“residue” property is affected by the removal of the lighter material. The x-axis
represents “volume percent remaining in residue from the original crude”.
 Procedure - 6.4 TBP Cut Point Basis

„ TBP cut ranges can be of two types

„ Normally, TBP cut ranges refer to commercial

yield

„ This procedure also defines TBP cut ranges

with respect to product properties

EDS 2004/CC-46

•For the purposes of this class, when we see TBP Cut Ranges quoted ( 300-400°F )
we will assume this refers to the commercial yield as referenced to the TBP yield
curve from the crude assay.
•As part of the detail of the procedure, we will also define a TBP cut range for
product properties. However, when we do this we will clearly state that this cut
range is for product properties.
•Once again, this is simply another area for definition. When you are dealing with
someone else and quoting TBP cut ranges, make sure you know whether this is
referring to yield or properties.
 Procedure - 6.4 TBP Cut Point Basis
(continued)

„ IT IS VERY IMPORTANT TO KNOW

IF THE CUT RANGES QUOTED ARE:
– TBP cut ranges for commercial yield
– ASTM IBP-EP for product properties
– TBP cut ranges for product properties

EDS 2004/CC-47

•As you have noticed, I can’t emphasize this enough.

 Procedure - 6.4 TBP Cut Point Basis
(continued)

THIS IS OFTEN THE MOST CONFUSING

PART OF ANY COMMUNICATION BETWEEN
(OR WITHIN) COMPANIES - one person says
“385-525°F kerosene and they are referring to
TBP cut point for commercial yield. The other
person hears “385-525°F” and believes it is an
ASTM distillation range.

MAKE SURE YOU ARE CLEAR!

EDS 2004/CC-48

•Just in case you didn’t get the message...

 Procedure - 6.5

Prepare work table with following headings

1. TBP Cut Point
2. Cumulative Volume Percent
3. Nominal TBP Range, °F
4. Cut Volume Percent
5. Correction Factor
6. Volume Percent for
Properties
7. Cumulative Volume Percent
8. Mid-Volume Percent
9. API Gravity
10. Corrected TBP Cut Point,
°F
11. Corrected TBP Range, °F
12. Est ASTM Initial Boiling
Point, °F
13. Est ASTM End Point, °F
14. Estimated ASTM 50
Percent Point, °F
15. UOP Characterization
Factor
16. Molecular Weight
17. Weight Percent Sulfur

EDS 2004/CC-49

•We have provided the work table for you in the spreadsheet. Before computers,
this was all done on paper.
 Procedure
Definitions: Slump

Commercial Yield

Slump is the fact that an Equilibrium Flash

Vaporization occurs in the flash zone. In
the stripping section below the flash zone,
not all of the materials that boil lighter than
the cutpoint in the TBP distillation will be
removed before the commercial Atmospheric
Residue leaves the column.
Another way to think of it is that some of the
AGO, Diesel and Kerosene end up in the
Atmospheric Residue.
More on Slump later.

Crude {
Theoretical
Yield Slump CA-R00-13
EDS 2004/CC-50

We’ve seen this slide before. It provides a pictorial view of slump that I find
makes it easier to visualize what is happening when we talk about slump.
 Residue Slump

Note: Light material which remains in the bottoms

liquid leaving the crude column is called the SLUMP.

The theoretical or laboratory yields must be corrected

for the SLUMP. The corrections are as follows:
C 5- 1.00
Naphtha 0.99
Kerosene 0.97
Diesel 0.94
Gas Oil 0.94
Does one multiple or divide the theoretical yields in (4)
to obtain the yields for the commercial properties????
EDS 2004/CC-51

•These are the typical correction factors that UOP has traditionally used. I have
found the need to adjust them from time to time.
•These are guidelines only - you need to use your engineering judgement and
experience in order to determine if these values fit your operation.
•These represent typical crude column performance. If you have a bottlenecked
column, you may need to increase some of these slump factors. If you have a lot of
overflash or bottoms steam, you may need to move these numbers toward 1.00 (that
is, reduce the slump factor).
 Residue Slump

Another way to think of slump - since some of the lighter

distillate products (diesel, kerosene, etc.) are left in the
residue, we actually lift some heavier distillates into the
lighter products in order to make the desired product
rates (commercial yield).

The purpose of the slump calculations is to reflect the

fact that the crude assay was done with a TBP distillation
(near perfect fractionation) while in a real crude/vacuum
unit we have commercial distillation (no where near
perfect fractionation, a lot of overlap between product
draws).
EDS 2004/CC-52

•That pretty much says it all.

 Procedure - 6.7, 6.8
Volume Calculations

„ Find the cumulative and mid volume percents

for the various cuts

EDS 2004/CC-53

•Simple algebra, as you can see in the spreadsheets and reference material.
 Procedure - 6.9
Gravity (API) vs. Mid-Volume %

„ Find the API gravity of each cut from the

plots of gravity vs. mid volume-% or %
residual

EDS 2004/CC-54
 Procedure - 6.10, 6.11
TBP Cut Range for Properties

„ Find TBP cut range for properties by reading

the % yield from column 7

EDS 2004/CC-55
 Procedure - 6.12, 6.13
Estimated ASTM Distillation

„ Use the following procedure only if better

methods are not available (computer
simulations)

EDS 2004/CC-56

•We have provided a rule of thumb that is very rough for estimating ASTM
distillations from the TBP cut ranges. THIS SHOULD ONLY BE USED IF
MORE ACCURATE DATA IS NOT AVAILABLE (real plant data or data from a
process simulator will be more accurate than the rules of thumbs presented here).
 Crude Breakup
Relationship of TBP Cut Points to ASTM IBP
and ASTM EP

Estimated ASTM IBP

If TBP less than 300°F

ASTM IBP = TBP Cut Point
If TBP > 300 up to 650°F
ASTM IBP = TBP - 15°F
If TBP > 650°F
ASTM IBP = TBP - 50°F

EDS 2004/CC-57
 Crude Breakup
Relationship of TBP Cut Points to ASTM IBP
and ASTM EP

Estimated ASTM EP

If TBP less than 350°F

ASTM EP = TBP Cut Point
If TBP greater than 750°F
ASTM EP = TBP + 50°F
If TBP between 350 & 750 Interpolate

EDS 2004/CC-58

•For the EndPoint plot, see Figure A-7 in the reference material.
 1000

Sample
900

800

700
Problem
600
Probability
500
Chart
400

350

°F 300

250

200

150

100

50

IBP 5 10 20 30 40 50 60 70 80 90 95 EP

pct Over CA-R00-04

EDS 2004/CC-59

•This chart is used to connect the estimated IBP and EP from the rule of thumb
estimate. The other points on the distillation can then be estimated.
•This chart came about from data gathered in the 1950’s from “well run” US crude
units. The original purpose was to assist crude unit operators with identifying
properly operating columns. Plotting your distillations on the chart should yield a
straight line. Significant deviations from a straight line would indicate a problem
with the operation of the unit.
•We use it for estimating distillations when no other data is available.
 Procedure - 6.14
Plot UOP K Values from Assay

„ Do this if UOP K has not been previously

plotted vs. mid-volume percent

„ Calculate UOP K for distillate and residual

cuts from the data given in the assay - use
either the fundamental definition to find CABP
or viscosity and °API for residual cuts

EDS 2004/CC-60
 Procedure - 6.15
Record UOP K Values for Cuts

„ Find UOP K of cuts using UOP K vs. mid-

volume % plot

EDS 2004/CC-61

•This is the basic way we determine properties for a cut - by using the mid-volume
percent (for distillate cuts) or volume percent residual (for residue cuts) to find out
the value of a particular property.
 Procedure - 6.16
Double Check UOP K, Calculate Mol Wt.

„ Use ASTM 50% point to double check UOP K

vs. R.E. charts B2 and B3. Make sure it is in
agreement: +- 0.05. Adjust ASTM 50% point
if necessary

„ Use ASTM 50% point to find MeABP, then use

R.E. charts B2 and B3 to find mol wt.

EDS 2004/CC-62

•You can double check the UOP K by using the estimated 50% point and the gravity
to see if the value matches up with the value from the mid-volume% plot. Doing
this would ensure that the data is consistent and valid.
•To find the molecular weight, use the charts that were shown to you in the
Hydrocarbon Property session.
 Procedure - 6.17
Find Sulfur in Cuts

„ Using mid-volume percent of the cuts, find

percent sulfur in each cut from the plot of mid-
volume-% vs. sulfur for the assay

„ Use residual crude % vs. sulfur for the residue

„ Useful to check sulfur balance between whole

crude and sum of the cuts

EDS 2004/CC-63
 Procedure - 6.18 to 6.21
Other Properties, Calculations

„ Other needed properties can be found by

plotting assay values vs. mid-volume-%\ (or
residual crude).

„ Methods for estimating flash zone conditions

and overhead receiver gas also given. Possible
today to use computer calculations as well.

EDS 2004/CC-64

•While using a process simulator will be the method used today, it is valuable to
double check simulation results using the process charts that have been presented to
you (or real operating data if you have it, that is the best source). This gives
greater confidence and validity to your simulation result.
 Procedure - 6.22
Construct a Material Balance

„ Prepare a table for the desired cuts with columns

for °API, UOP K, mol wt., BPSD, lb/h, mol/h, and
vol-%

„ This will represent the unit material balance

EDS 2004/CC-65
 Sample Problem
Work Table
Find Assay Data with TBP Distillation Data
1 2 3 4
TBP Cut Pt, °F Cum vol-% Nom TBP Range Cut vol-%
C5 IBP – C5
200 C6 – 200
375 200 – 375
525 375 – 525
600 525 – 600
675 600 – 675
725 675 – 725
1,000 675 – 1,000
Vacuum Residue 1,000 plus
Note: Entries in 2 and 4 represent commercial yields to be produced in the CDU.

Lab yields not equivalent to commercial yields.

The crude breakup can be based upon:

A. Yields for TBP cuts
B. Product quality
EDS 2004/CC-66

•The UOP Crude Breakup Procedure uses 2 working calculations tools - a “Work
Table” and a “Material Balance Table”.
•Both of these are now put into an Excel spreadsheet, and we will do the sample
problem as a demonstration of the procedure in class.
•You will then do a class problem utilizing the spreadsheet as well.
 Sample Problem
Work Table

Find Assay Data with API Gravity Information

1 5 6 7 8 10 11
Mid 9
TBP Cut Corr vol-% Cum vol-% API Corr Corr
Pt, F Factor for prop vol-% Distil Grav TBP Cut TBP Range
C5 1.00
200 1.00
375 0.99
525 0.97
600 0.94
675 0.94
725 (DIFF)
1,000 1.00
Vac. Resid 1.00

EDS 2004/CC-67

•The Work Table consists of at least 16 columns.

 Sample Problem
Work Table

Use Empirical Method to Obtain ASTM Distillation?

1 9 10 11 12 13 14
Est Est Est
TBP Cut API Corr Corr TBP ASTM ASTM ASTM
Pt, °F Grav TBP Cut Range IBP EP Midpt
C5 IBP-C5
200
375
525
600
675
725
1,000
Vac. Resid

EDS 2004/CC-68
 Sample Problem
Work Table

How can one get the “UOP K” and the Mol Wt?
1 12 13 14 15 16 17
Est Est Est
TBP Cut ASTM ASTM ASTM Mol wt-%
Pt, °F IBP EP Midpt UOP K Wt Sulfur
C5
200
375
525
600
675
725
1,000
Vac. Resid

EDS 2004/CC-69
 Sample Problem
Material Balance

In = Out
Crude = Products
Basis: Volume-Percent

Check the Weight-Percent In & Out

Make Necessary Changes

EDS 2004/CC-70

•Basis: You can choose to perform your crude breakup as either volume based or
weight based. UOP has traditionally chosen a volume basis.
•However, as the sample problem will show, the crude will then not exactly weight
balance. UOP in the past has forced a weight and volume balance by adjusting
product gravities to achieve a weight balance.
•Does this represent reality? NO! In real life, weight must balance, but the
volume will most likely not add up to 100%. This is because, in order to have a
100% volume balance, the products separated from the crude would have to exhibit
ideal mixing properties. This does not happen exactly, because we are separating
light fractions (more paraffinic) from heavier fractions (more aromatic).
•However, my experience has been that the volume difference is usually less than
1% away from ideal.
 Sample Problem
Material Balance

API UOP Mol BPSD Lb/H Mol/H Vol-%

Grav K Wt
C3
iC4
nC4
iC5
nC5
LtNaph
HvyNaph
Kerosene
Diesel
Gas Oil
Light Vac.
Gas Oil
Heavy Vac.
Gas Oil
Vacuum Residue

EDS 2004/CC-71

•This table is also included in the Crude Breakup Spreadsheet. It is a simple

material balance table.
•Before the advent of computerized process simulators, the data shown in the above
material balance was needed to perform process calculations uses the manual
process charts (specifically, you needed UOP K and molecular weight for these
charts).
•With a modern process simulator, all you really need for your simulation input is a
distillation curve and a gravity curve. For crude units, you can get this 2 ways:
•For an operating unit, you will most likely take product flowrates, gravities, and
product distillations and enter those into the simulators oil characterization tool.
You can then blend the whole crude as the sum of the net products.
•If you are starting with a crude assay (either for designing a new crude unit or for
simulating how a new crude will behave in an existing unit) it is easier just to input
the whole crude TBP curve and whole crude gravity curve.
 Sample Problem
Material Balance - LVGO Properties

API UOP Mol BPSD Lb/H Mol/H Vol-%

Grav K Wt
Lt. Naph

Hvy. Naph

Kerosene

Diesel

Gas Oil

“True” Vac.
Gas Oil

Yielded Vac. Gas

Oil

EDS 2004/CC-72

•For the LVGO, we need to add up the slumped material in order to calculate the
Yielded LVGO properties. In the Work Table, the LVGO shown there is the
perfectly fractionated TBP cut. For the material balance, we want to know the
properties of the commercially yielded LVGO, which will contain a lot of slump
material.
•Thus, we need to arithmetically add these properties together. This has been done
in the spreadsheet.