Clean diesel project

A process review, including the improvement of atmospheric and

vacuum distillation columns, for the reformulation of the diesel pool

Luigi Valagussa
Koch-Glitsch Italia

T
he reformulation of improvements can no longer be whether this diesel stream prop-
diesel oil fuel was intro- postponed in view of the erty can be achieved by mixing
duced by the European market regulation of diesel oil. the present straight-run diesel
Union in 2009. The aim of the from the CDU with an addi-
Fuel Directive is to reduce Study approach tional light stream to reach the
pollution from vehicle emis- The scope of this work was to maximum distillation point. The
sions. One feature of this analyse and compare different evaluation showed that if a
directive, discussed in this arti- ways to achieve the required D86T95=325°C blending stream
cle, is the specification that the diesel distillation end point is mixed with the present
maximum distillation final from the CDU/VDU as speci- straight-run diesel stream at
point of the diesel oil is set at fied by the shorter diesel oil cut D86T95=382°C, the light blend-
360°C for 95% of distilled (D86T95=360°C), while mini- ing should be about 1.7 times
volume measured according to mising the impact on the HDC (by volume) the total atmos-
the ASTM D86 analysis and HDT downstream units pheric diesel produced. This
(D86T95). Additionally, the and optimising the total diesel solution does not look very
Fuel Directive requires a reduc- production yield. attractive because it requires an
tion of sulphur content to a A refinery requested a licen- increase in treatment capacity,
maximum 10 ppm. Both the sor to conduct a feasibility which can affect the revamp of
specifications affect refinery study and to draw up a cost the existing HDT unit substan-
operations. More specifically, estimate for the revamp of the tially and the size of a new unit
catalytic processes such refinery’s HDT unit to achieve as well. It also omits any consid-
as hydrocracking (HDC) and the specified clean diesel oil eration of the availability of a
hydrotreating (HDT) are used requirements. light blending stream and the
to improve the diesel yield and No consideration was given total cost.
to limit the sulphur content and no modification was Two main points to consider
respectively. A more extensive proposed to produce in-specifi- from this example are:
analysis, which looks at the cation, straight-run diesel from • The clean diesel project must
atmospheric distillation unit the existing CDU. Therefore, the take the overall refinery proc-
(CDU) and vacuum distillation design basis for the HDT ess scheme and production
unit (VDU), may improve total revamp was a diesel stream capacity into account
diesel production and minimise with D86T95=360°C at the HDT • Alternatives are available to
the impact on existing units of battery limit. The HDT does not improve clean diesel produc-
the refinery. This analysis has significantly change the diesel tion and to limit the impact on
the benefit of lower capital cost distillation endpoint. The HDT the new/existing equipment
for the project; furthermore, the feasibility study investigated and facilities.

www.digitalrefining.com/article/1000423 PTQ Q1 2011 1

 LPG + Naphtha: (18.6)

Crude: 100 Kero: (13.3) (27.9)

D86T95=382°C
(15.8)
LDO
D86T95=324°C
(29)
HDO D86T95=391°C Cat. crack. Hydrotreater No spec. for
(12.1) HDC HDT
CDU clean diesel oil

Internal OVF: (6.33) (27.9 + 29Y)

AR (4.8) D86T95=375°C
(40.2) LVGO

SW recycle HVGO (24.2) (% vol on crude)

Y=HDC diesel vol yield
VDU
Heavy ends recycle: (6.7)
VR: (17.9)

Figure 1 Present scheme

Present scheme column, which is equipped specification of the diesel

The main features of the exist- with three beds of grid packing stream.
ing refinery (see Figure 1) are (old style). One bed at the top
listed below. The refinery is of the column for top pumpa- Alternative scheme to produce
presently producing non-clean round service produces a light clean diesel oil
diesel oil: vacuum gas oil (LVGO), a The first step was to evaluate
• The crude oil-handling capac- second bed at the middle of the whether the CDU and VDU
ity is 125 000 b/d. To increase column for mid pumparound columns can reach the target
the handling capacity, the service produces a heavy through enhanced perform-
atmospheric column was vacuum gas oil (HVGO), and a ance. It is clear from Figure 1
revamped some years ago by third bed at the bottom of the that the deep cut of HDO
Koch-Glitsch with Superfrac column is a wash bed. The two greatly affects the diesel qual-
trays and Flexipac HC struc- gas oils are mixed together and ity. In addition, no sensible
tured packing; it thus contains fed to the HDC unit benefit is achieved by modify-
the most advanced column • The diesel stream from the ing the internals of the existing
internals technology HDC unit is mixed with the atmospheric column to produce
• Light diesel oil (LDO) and HDT straight-run diesel and a in-specification, straight-run
heavy diesel oil (HDO) are final diesel stream with diesel oil and by minimising
produced in the atmospheric D86T95=375°C (value from the loss of HDO yield. The
column. These streams are refinery), which is above the main reasons are:
mixed together and fed to the distillation endpoint require- • There is a low margin for
HDT unit. The analysis of this ment for clean diesel oil, is improving the HDO final distil-
straight-run diesel oil is produced. lation points because the
D86T95=382°C, and this does The refinery has to consider present column internals are
not change significantly after two main modifications in already designed according to
HDT treatment. The present order to comply with the clean the most advanced and efficient
HDT unit is not able to reduce diesel specification: first, the technology
the sulphur content to the revamp of the HDT unit (to • Any attempt to maximise the
required level for clean diesel reduce sulphur content), which straight-run diesel oil,
oil will be approached and solved includingdifferent splitting of
• The atmospheric residue by a catalyst licensor; and, LDO/HDO, affects existing
(AR) is fed to the vacuum second, the distillation point equipment and operations (for

2 PTQ Q1 2011 www.digitalrefining.com/article/1000423

instance, pumparound and heat tionation service. This is HDO partially + LVGO). This
recovery). The total diesel oil necessary to produce the in- stream can be sent to HDT for
yield must be reduced and the specification LVGO product. the final treatment
heavy ends that are not recov- Currently, this arrangement • As discussed already, the
erable into the HDO stream is one of our recommended vacuum column is revamped
must be left in the atmospheric options, because there is exten- from the existing three beds to
residue fed to the vacuum sive experience that it provides four beds. The produced LVGO
column. An increase in atmos- a stream suitable for a diesel oil is suitable for the diesel oil
pheric residue could affect the pool without further process- pool, and the HVGO is sent to
existing vacuum heater ing. In our study, we the HDC together with the
performance, which is already determined that the recoverable excess HDO stream. Even if the
limiting the present operations. LVGO with the revamped vacuum column revamp
On the other hand, a total vacuum column is about 2 reduces the total vacuum gas
revamp of the vacuum column vol% on a crude feed basis. oil (VGO) to HDC, the total
internals (from the old grid On the basis of the above feed to HDC must account for
packing to new structured considerations, an alternative the extra feed coming from the
packing beds) can produce the scheme, the HDO splitting and HDO stream not conveyed to
LVGO stream in specification vacuum revamp scheme (HDO HDT.
for clean diesel oil and there- splitting scheme), to produce Comparing the HDO split-
fore be suitable for blending clean diesel oil without reduc- ting scheme to the present
with the atmospheric straight- ing the HDO yield, can be scheme, it can be seen that the
run diesel oil. This avoids utilised (see Figure 2): total feed to HDT decreases
additional processing of this • The HDO from the atmos- from 27.9 vol% based on crude
stream through HDC. The pheric column is split into a to 20.7 vol%; however, the
vacuum column revamp calls stream that can be mixed with HDC feed increases from 29
for four new structured pack- the LDO stream and then with vol% based on crude to 36.1
ing beds, instead of the three the LVGO stream produced by vol%, resulting in a capacity
existing beds, with the addi- the vacuum column in a ratio increase of 24.5% for HDC. The
tional bed located below the suitable to obtain D86T95=360°C increased HDC capacity
top pumparound bed for frac- in the resulting stream (LDO + requires a deeper investigation

LPG + Naphtha: (18.6)

Crude: 100 Kero: (13.3)

(15.8)
D86T95= LDO
324°C
HDO Cat. crack. Hydrotreater
(3) HDC HDT
CDU
D86T95= Clean
391°C Internal OVF: (6.33) diesel oil
AR (36.1)
(18.8) (1.9)
(40.2) D86T95=365°C LVGO
(27) (20.7 + 36.1Y)
HVGO D86T95=360°C
SW recycle

VDU
Heavy ends
recycle: (6.7)
VR: (17.9) (9.1) (% vol on crude)
(9.1) Y=HDC diesel vol yield
(20.7)

Figure 2 HDO splitting and vacuum revamp

www.digitalrefining.com/article/1000423 PTQ Q1 2011 3

 into the suitability of running less than the present capacity the HDO yield from the CDU
the existing unit under the new and it is actually about 5.7% has been reduced to produce a
conditions, and the expected less than the capacity of the HDO stream that can be mixed
conclusion is that the HDC unit present scheme. The existing with LDO (same yield as the
itself has to be revamped. HDT could need some modifi- present scheme and the HDO
Additionally, we have to note cations due to the ultra-low splitting scheme) and with
that diesel production from sulphur level required by the LVGO from the VDU to
HDC depends on the conver- clean fuel regulation. On the produce a straight-run, in-
sion yield, and this may result contrary, the decreased feed specification diesel oil
in a decrease in overall diesel rate can provide additional (D86T95=360°C) that is fed to
production. benefit by allowing improved HDT. This stream results in
performances with the same 26.3 vol% based on crude,
New scheme for maximising arrangement or with minor which is lower than the not-in-
clean diesel oil modifications compared with specification present feed, but
The main feature of the new the HDO splitting scheme definitely higher than the feed
scheme proposal involves the • The new scheme saves on computed for the HDO split-
atmospheric over-flash (OVF). vacuum heater duty demand, ting scheme. The crude heater
As Figure 3 shows, this stream which generally is a bottleneck duty is the same for all the
is drawn off from the atmos- in revamping projects. schemes and, because of the
pheric column, bypasses the The new scheme is unusual in reduced yield of HDO in the
vacuum heater and is fed to the existing plants where the atmos- new scheme, the extra distillate
VDU above the wash section. In pheric over-flash is typically is recovered in the over-flash
this case, the vacuum column is combined with the atmospheric stream, which increases to 10.3
also revamped with four beds. residue. Recent atmospheric vol% based on crude, compared
The benefit of the new column revamps have mostly with 6.33 vol% in the earlier
scheme can be quantified by been carried out to increase not schemes. Different rates for the
comparing the values reported only capacity but also the distil- over-flash stream or splitting
in Figure 1 (present scheme), lates yield (including diesel oil thereof (partially drawn off and
Figure 2 (HDO splitting and yields), therefore reducing gas partially conveyed into atmos-
vacuum revamp scheme) and oil losses in the atmospheric pheric residue) can be
Figure 3 (new scheme). The residue. This approach was investigated more deeply
benefits are: acceptable because a longer according to needs and
• The new scheme gives better diesel oil cut was allowed, constraints, while taking the
overall clean diesel oil recovery enabling the atmospheric resi- recoverable yield of HDO and
compared to the HDO splitting due to dry up. Practically all of the impact on crude and
solution the straight-run diesel product vacuum heater duties into
• In the new scheme, the feed was recovered in the atmos- account.
to HDC decreases by approxi- pheric column, and the vacuum In the new scheme, we used
mately 14.7% compared to the column was arranged to all of the crude heater duty
HDO splitting scheme and produce a long gas oil cut from available from the present
therefore the required treat- the mixing of LVGO and HVGO scheme. Since the over-flash
ment capacity of HDC results (see Figure 1) containing heavy stream is totally conveyed to
in an approximate increase of ends to be converted into lighter the vacuum column rather than
only 6.2% in comparison to the products in HDC. being sent to atmospheric resi-
present arrangement. We can The new scheme (see Figure due as in the other schemes,
expect no, or only minor, modi- 3) shows how a review of the resulting atmospheric resi-
fications to the existing HDC conditions in the CDU and due product decreases to 34.7
unit VDU allows for major benefits vol% based on crude, compared
• In the new scheme, the feed with minor impact. with 40.2 vol% in the earlier
to HDT increases approximately schemes. In this specific case, a
27% compared to the HDO CDU operations few mechanical modifications
splitting scheme; however, it is In Figure 3, it can be seen that to the existing unit are needed

4 PTQ Q1 2011 www.digitalrefining.com/article/1000423

 LPG + Naphtha: (18.6)

Crude: 100 Kero: (13.3)

(15.8)
LDO
D86T95=324°C
(7.3) HDO Cat. crack. Hydrotreater
D86T95=372°C HDC HDT
CDU
Internal OVF: (10.3)

AR
(3.2) LVGO
D86T95=365°C Clean diesel oil
SW recycle HVGO (30.8)

VDU
Heavy ends (26.3)
(34.7)
recycle: (6.7)
VR: (17.9) (% vol on crude)
Y=HDC diesel vol yield
(26.3)
D86T95=360°C

Figure 3 New scheme

to be able to apply the new below the LVGO pumparound scheme. Furthermore, the
processing scheme: bed, is made available in speci- recovery of HVGO (with a
• A new draw-off nozzle is fication for mixing with the slightly higher endpoint
installed in the atmospheric atmospheric diesel oil and compared with the previous
column vessel for over-flash avoiding further processing in cases) is 30.8 vol% based on
service HDC, as in the present scheme. crude, compared with 24.2
• A new circuit complete with The arrangement shown is not vol% according to the present
pumps, piping, control and necessarily required to realise scheme and 27 vol% according
instrumentation is installed to the clean diesel project, but it to the HDO splitting scheme.
feed the over-flash product to has been applied in many The new scheme (with the
the vacuum column. projects (practically since the atmospheric over-flash fed to
introduction of structured the vacuum column) enables
VDU operations packing in the market) to better recovery of in-specifica-
The existing vacuum column is improve the performance of tion LVGO and also increases
still arranged with an old-style vacuum columns worldwide the HVGO yield, resulting in a
design consisting of three beds with significant results. It is maximisation of the total
with low-efficiency grid pack- clear that the clean diesel regu- distillates yield (LVGO +
ing. We propose a total revamp lation pushes heavily towards HVGO) compared with the
of the column internals, provid- any investment that can other schemes. In conclusion,
ing four beds equipped with improve the recovery of diesel this looks to be the most effi-
new structured packing from oil while limiting the penalty of cient way to improve gas oil
Koch-Glitsch. paying for the production of recovery.
The additional bed is located the required shorter cut. In the reported comparisons,
between the HVGO and LVGO Figure 3 shows that the the slop wax (SW) recycle to
pumparound beds, providing a recovery of in-specification the vacuum heater, the external
fractionation section for the LVGO is 3.2 vol% based on feed (heavy ends recycle) and
LVGO product. In this way, the crude, compared with 1.9 vol% the yield of vacuum residue
LVGO product, drawn off according to the HDO splitting (VR) product have been set at

www.digitalrefining.com/article/1000423 PTQ Q1 2011 5

 the same values for all of the stream entering the vacuum (150°C) and moving the feed
schemes. column. In the new scheme, the location to above the bottom
Since the over-flash is drawn atmospheric over-flash is fed pumparound bed. The results
off totally from the atmospheric above the wash bed of the are in line with the new scheme
column, rather than being vacuum column at the draw-off in terms of recovery, product
conveyed into the atmospheric conditions from the atmos- characteristics and heater duty,
residue according to the new pheric column. This means that but the bottom pumparound
scheme, the atmospheric resi- this stream is fed at about duty decreases substantially
due feed decreases to 34.7 vol% 363°C, a very high temperature, (approximately half that of the
based on crude, compared with into a column under vacuum. new scheme). However, flash-
40.2 vol% for the other schemes; This will cause high flashing ing of the over-flash stream is
as a result, the vacuum heater rates at the inlet of the vacuum practically nil, and this solves
will be affected. column or, more specifically, the space problems described
For the same vacuum resi- downstream of the valve earlier.
due, the vapourisation rate to controlling the over-flash flow On the other side, feeding the
the furnace according to the rate. This condition requires a over-flash between the bottom
new scheme is thus less than relatively large nozzle. In the pumparound bed and the
that required for the other LVGO fractionation bed
schemes, both as quantity of increases the risk of contamina-
vapour flow and as percentage The diesel oil pool tion with unwanted material
of total feed to the heater. As a that can be entrained into the
result, the heater duty demand
is now subject distillates products. The risk is
in the new scheme is 12.7
MMKcal/h with a vapourisa-
to more stringent higher than in the case where
the over-flash is fed above the
tion of 22 wt% of total feed, specifications wash bed. This matter should
compared with 14.8 MMKcal/h be evaluated in more detail,
and a vapourisation of 24.8 according to the while taking the quality and
wt% in the other schemes. characteristics of the over-flash
These figures are very attrac- EU’s Fuel Directive stream into account.
tive when evaluating the The simplified process flow
performance of an existing case of a revamp, the necessary diagram shown in Figure 4
furnace at the new conditions, room has to be evaluated care- indicates the new over-flash
even with the increased fully to provide sufficient room circuit and the new beds of the
temperature at the heater for the nozzle, the disengage- vacuum column.
outlet. In fact, this temperature ment space above the wash bed
increases in the new scheme by and a feed inlet device. Summary and conclusion
approximately 6°C compared Cooling of the over-flash The diesel oil pool is now
with the previous schemes stream, before feeding it to the subject to more stringent speci-
because a heavier cut of atmos- wash section of the vacuum fications according to the EU’s
pheric residue is fed to the column, reduces the flashing Fuel Directive for the utilisa-
heater. This point should be rate but increases the heater tion of clean diesel oil. The
evaluated more deeply during duty demand. In this case, a reformulation of the diesel oil
the engineering phase, as well critical piece of equipment, pool can be achieved by a
as the fact that the lower such as the vacuum heater, can review of operations and
vapour rate will cause a reduc- cause a bottleneck because of improvement of the perform-
tion in the pressure drop along the increase in the vapourisa- ances of the atmospheric and
the transfer line, which results tion rate and the heater outlet vacuum distillation columns.
in a lower heater outlet temperature. A new processing scheme,
temperature. An alternative was evaluated; applied to an existing refinery,
Some final consideration namely, cooling down the over- has been presented and the
must be given to the conditions flash stream to the temperature attainable benefits have been
and location of the over-flash of the bottom pumparound discussed. These benefits

6 PTQ Q1 2011 www.digitalrefining.com/article/1000423

 New vacuum
column internals Naphtha – gas Kerosene Diesel oil Gas HVGO

New circuit for OVF

by-pass to VDU LVGO

Atmospheric
distillation unit
Vacuum
distillation unit

KERO

LDO
Steam

HDO Heavy ends

recycle
Steam

Steam Steam
Vacuum
residue

Crude
oil Steam
Heating

Figure 4 New process flow diagram

include increased overall clean specification LVGO for the proposed: first, the installation
diesel recovery with minor diesel pool (3.2 vol% based on of the latest generation of struc-
impact on the existing down- crude) and partially as HVGO tured packing; and second, the
stream HDC and HDT units. feedstock to HDC, resulting in introduction of a new LVGO
The new scheme is compared an increase in total gas oil fractionation bed below the top
with the present scheme (repro- recovery (LVGO + HVGO) of pumparound (not shown in the
ducing the actual operations/ about 17 vol% in comparison to present arrangement). These
arrangement) and with the the present operations. Under modifications will improve the
HDO splitting scheme. The the stated conditions, the product quality and yields as
new scheme, representing an vacuum heater duty demand described.
alternative for clean diesel decreases by approximately Important issues to resolve
production based on a tradi- 14% in comparison to the while developing a revamp
tional route, is shown and present operations. This adds a project according to the new
discussed. solid benefit because the scheme are the increased
A new process route where vacuum heater, a critical item, temperature at the vacuum
the atmospheric over-flash is is often a bottleneck in revamp heater outlet and the feed loca-
fed to the vacuum column projects. The vacuum column tion of the atmospheric
bypassing the vacuum heater internals play an especially over-flash stream to the
has been suggested. With this important role in improving vacuum column. In the
scheme, the recovery of gas oil products separation and gas oil reported new scheme, the over-
in the vacuum column can be recovery. Two main modifica- flash has been fed hot above
enhanced, partially as in- tions to the vacuum column are the wash section, but an

www.digitalrefining.com/article/1000423 PTQ Q1 2011 7

 Total clean diesel production summary with the HDO splitting scheme,
for all the assumed conversion
yields in HDC. We conclude
vol% on crude (% difference vs present) that the new scheme can
Case Present scheme HDO splitting scheme New scheme
LDO to HDT (hydrotreating) 15.80 15.80 15.80
achieve the recovery of clean
HDO to HDT 12.10 3.00 7.30 diesel while minimising the
LVGO to HDT 0.00 1.90 3.20 penalty in clean diesel produc-
Total to HDT 27.90 20.70 26.30 tion, which is an expected
LVGO to HDC (hydrocracking) 4.80 0.00 0.00
HVGO to HDC 24.20 27.00 30.80
result of the stricter specifica-
HDO to HDC 0.00 9.10 0.00 tion for market diesel oil.
Total to HDC 29.00 36.10 30.80
Total diesel D86 95%v, °C 375 360 360 FLEXIPAC, HC and SUPERFRAC are marks
HDC diesel conversion yield %v 30 36.60 31.53 (-5.07) 35.54 (-1.06) of Koch-Glitsch, LP.
50 42.40 38.75 (-3.65) 41.70 (-0.70)
70 48.20 45.97 (-2.23) 47.86 (-0.34)
Luigi Valagussa is Refining Process
90 54.00 53.19 (-0.81) 54.02 (0.00)
Manager with Koch-Glitsch in Italy. He
has more than 30 years’ experience
Table 1 in oil refining and process design, and
graduated in chemical engineering from
alternative with a cold feed at various values of conversion Politecnico of Milan, Italy.
above the bottom pumparound yield. The new scheme, in Email: [email protected]
bed could be considered. comparison with the alternative
In Table 1, the production HDO splitting scheme, enables Links
rates referred to are reported in better splitting of the treatment
terms of vol% based on crude capacity between HDT and More articles from the following
feed. Total diesel production HDC, which is closer to the categories:
depends on the conversion existing capacities. Total clean Alternative Fuels
yield of the HDC unit; there- diesel production is better in Crude Vacuum Units
fore, we reported several cases the new scheme, in comparison

8 PTQ Q1 2011 www.digitalrefining.com/article/1000423