Patent Grant
10544372
The present invention relates to a distillation column for increasing the fraction oil yield and a method for increasing the fraction oil yield from a distillation column, more particular to a distillation column and a method for increasing the fraction oil yield for the heavy oil distillation in the petroleum refining industry.
The distillation column is a unit device widely used in the petroleum refining industry. For some fractionations of heavy oils, for example, fractionating light fraction oil from crude oil, wax oil and the like, the distillation column generally has a relative high bottom temperature, and the heat source for the reboiler has a high heat grade and is not easy to obtain. Since heavy oils tend to thermally crack at high temperatures, therefore, the distillation columns for crude oil or heavy oil generally don't provide with reboiler, and the heat required by distillation is almost provided by the feedstocks. After preheating feedstocks, the fraction oils are vaporized, the vaporized fraction oils are distilled off from the top and/or the sideline of the column, and non-vaporized streams are distilled off from the bottom of the column. The typical fractionation process for example comprises the atmospheric distillation and the vacuum distillation of crude oil.
The crude and vacuum distillation is the first step of the petroleum refining process, and provide with the starting materials for the subsequent processing units in the refinery, and directly with some final products. The fundamental procedure for the crude oil distillation (by example of fuel oil type) comprises heating the crude oil to about 220-260° C. and then sending it to a primary distillation column. Usually, only one top product, i.e. a reforming feedstock or a light gasoline fraction, is cut from the primary distillation column. In some primary distillation columns, besides the top product, a sideline product is cut off. The primary distillation column bottom oil is sent to the atmospheric column.
The conventional procedure for the atmospheric column is shown in
The conventional procedure for the vacuum distillation is shown in
The design and operation of the crude oil distillation unit will have a great effect on the product quality, the product yield and the economical benefit of the refinery. In the provision of the qualified product, increasing the distillation yield of the atmospheric distillation plant so that lighter components are distilled off in the atmospheric distillation column as much as possible and are not sent to the vacuum distillation any more, in one hand, can produce more lighter fractions, and in the other hand, can reduce the loads on the vacuum heating furnace and the vacuum distillation column; increasing the distillation yield of the vacuum distillation plant can increase the yield of fraction oils, and provide more feedstock for catalytic cracking and hydro-cracking so as to improve the economical benefit of the refinery.
The important factors which influence the yield of fraction oils of the atmospheric and vacuum distillation unit are the temperature and oil-vapor partial pressure of the vaporization section in the distillation column. The higher the temperature of the vaporization section is and the lower the oil vapor partial pressure is, the higher the vaporization ratio is, and therefore the higher the distillation yield of fraction oils is.
Currently, there are two methods for reducing the pressure of the vaporization section in the industry: one is to reduce the column top pressure of the distillation column. For the atmospheric distillation column, it is generally to reduce the pressure drops in the column top oil vapor pipeline and the condensing cooler. For the vacuum distillation column, a vacuum pumping equipment of high performance can effectively reduce the column top pressure. The other is to use packings, tower trays and column internals of high performances to effectively reduce the in-column resistance and so as to remarkably reduce the pressure of the vaporization section.
Another approach of increasing the fraction oil yield of the distillation column is to increase the temperature of the vaporization section. The temperature of the vaporization section is influenced by the outlet temperature of the heating furnace. The higher the outlet temperature of the heating furnace is, the higher the temperature of the vaporization section is. However, the temperature of the heating furnace cannot be too high, this is because it is possible for heavy oils to crack at a temperature higher than 360° C., and the coke produced by cracking the oils will badly influence the long and stable run of the plant. Therefore, a heating furnace with a furnace tube having a stepwise increased diameter and an oil transfer line with a large diameter are generally used industrially so as to reduce the outlet pressure of the heating furnace as much as possible, and therefore reduce the temperature of feedstock in the heating furnace with the proviso of ensuring the vaporization ratio of the feedstock.
Currently, the vacuum column top pressure of the industrial plant has reached as low as 1 kPa (abs.), the pressure of the feeding section has reached as low as 3 kPa (abs.), and therefore it is hardly to further reduce the pressure. It is also more and more difficult to improve the performances of the packings and internals, and the cost is sharply increased. There are also some limitations for using the heating furnace with a furnace tube having a stepwise increased diameter and the oil transfer line with a large diameter. One limitation is that increasing the diameter of the furnace tube should be designed rationally according to the properties of the feedstock oil and the characteristics of the heating furnace, while it is very hard for a delicate furnace tube design due to a wide variety of feedstocks. Another limitation is that since a large quantity of feedstock is vaporized in the furnace tube, the density of the feedstock in the tube continuously decreases, especially sharply in a vacuum furnace tube, and therefore the heat-transfer coefficient of the medium in the furnace tube is sharply reduced, which results in the decrease of the overall heat-transfer coefficient in the furnace. In order to achieve the same heat-transfer intensity, a temperature difference should be increased, that is to say, the temperatures of furnace box and furnace tube should be increased. This will lead to a too high topical temperature on the furnace tube wall and influence the use life of the furnace tube.
According to the results of the simulation and calculation, in the furnace tube of the radiation section of the vacuum heating furnace and in the oil transfer line, the flow rate of the vapor phase entrapped with large liquid droplets are very high, the mass transfer area between the vapor and liquid phases is relative small, therefore lighter fractions cannot be completely vaporized and enwrapped in the non-vaporized heavy oils, which results in that the real vaporization ratio of the feedstock coming into the vaporization section of the distillation column is lower than the equilibrium vaporization ratio calculated by the theory. A part of lighter components are present in the column bottom residual oil, and therefore the distillation yield will be decreased. Now, as to the domestic atmospheric and vacuum distillation plants, the design cut point for the vacuum residue is generally set at 540° C. In many vacuum residues, the fraction below 500° C. has a content of greater than 8 wt %; the fraction below 538° C. has a content of greater than 10 wt %, even as high as greater than 30 wt % for some vacuum residues. By example of the atmospheric and vacuum distillation unit of SINOPEC Hainan Refinery, the equilibrium vaporization ratio of the atmospheric residue at the temperature and pressure of the vaporization section of the vacuum distillation column is 59.0 wt %, however, the industrial distillation yield is only 51.9 wt %. This shows that there is a certain gap between the industrial distillation yield and the equilibrium vaporization ratio. Therefore, the vacuum distillation still does not reach the equilibrium vaporization ratio, and there remains a great room for improving the distillation yield.
The object of the present invention is to provide a distillation column and a method for improving a fraction oil yield from petroleum hydrocarbons in the distillation column, especially for improving the fraction oil yield in the atmospheric and vacuum distillation column.
The present invention provides a method for improving a fraction oil yield from petroleum hydrocarbons in the distillation column, wherein said distillation column comprises a vaporization section and a fractionation stage, wherein said method comprises preheating a feedstock oil of petroleum hydrocarbons to be fractionated, sending it through a pressure-feeding system at a pressure of 100-1000 kPa, preferably 200-800 kPa, more preferably 200-600 kPa, and most preferably 200-400 kPa or 200-300 kPa higher than the vaporization section pressure of the distillation column into the vaporization section of the distillation column, atomizing and vaporizing in the vaporization section, and then distillation-separating in the fractionation stage; wherein the fraction oil is removed from column top and/or sideline, and a non-vaporized heavy oil is removed from the column bottom.
In one embodiment of the present invention, said distillation column for petroleum hydrocarbons refers to a distillation column, whose required heat is provided by feedstock and which is not provided with reboiler. It can be a flash column, a primary distillation column, an atmospheric distillation column, a vacuum distillation column or a hydrogenated oil distillation column. Said distillation column generally comprises a vaporization section, a fractionation stage, optional column top/bottom outlets, an optional middle section reflux, an optional sideline, an optional column top vacuum pumping system, an optional stripping stage, and an optional washing stage. Said distillation column can be an empty column, a plate column, or a packed column.
In one embodiment of the present invention, the distillation column has a column top absolute pressure of 0.5-240 kPa, a vaporization section absolute pressure of 1-280 kPa, a vaporization section temperature of 150-430° C.; specifically, in the case of the atmospheric distillation, it has a column top absolute pressure of 110-180 kPa, a vaporization section absolute pressure of 130-200 kPa, a vaporization section temperature of 330-390° C.; and in the case of the vacuum distillation, it has a column top absolute pressure of 0.5-90 kPa, preferably 0.5-10 kPa or 0.5-3 kPa, a vaporization section absolute pressure of 1-98 kPa, preferably 1-5 kPa, a vaporization section temperature of 300-430° C., preferably 370-410° C.
The vaporization section of the distillation column as described herein locates between the upper fractionation stage and a feed inlet for the distillation column. The feedstock is introduced through said inlet into the distillation column, and vaporized in the vaporization section, either completely or partially. The vaporized vapor phase rises up into the upper fractionation stage to conduct heat-exchange and further fractionation. The temperature and pressure of said vaporization section is distributed in a gradient manner. The vaporization section temperature refers to the temperature range of the vaporization section. The vaporization section absolute pressure refers to the absolute pressure range of the vaporization section.
In one embodiment of the present invention, said preheating is conducted in a heating furnace (for example, an atmospheric heating furnace and a vacuum heating furnace). Said heating furnace has an outlet pressure of 100-1000 kPa, preferably 200-800 kPa, more preferably 200-600 kPa, most preferably 200-400 kPa or 200-300 kPa higher than the vaporization section absolute pressure, and an outlet temperature of 360-460° C., preferably 380-430° C.
In one embodiment of the present invention, in case of using a heating furnace, steam can optionally be ejected into the furnace tube of the heating furnace; preferably, steam is not ejected into the furnace tube.
In one embodiment of the present invention, in case of the vacuum distillation, steam can optionally be ejected into the vacuum distillation column; preferably, steam is not ejected into the vacuum distillation column.
In one embodiment of the present invention, said pressure-feeding system comprises a flow distribution system and one or more atomization devices. Said atomization device can be located in the vaporization section of the distillation column, or out of the distillation column, or both.
In one embodiment of the present invention, said flow distribution system will ensure that each atomization device can eject liquid and vapor in any event so as to achieve the atomization effect of the feedstock. Said flow distribution system can be a pipeline system composed of pipelines in one or more of in-line arrangement, staggered arrangement, parallel arrangement, vertical arrangement, loop arrangement, and tree-like arrangement in a symmetric or asymmetric mode. The function of said flow distribution system is to distribute the preheated feedstock to each atomization device, and all pipeline arrangement modes for achieving the above-mentioned function can be regarded as the flow distribution system.
In one embodiment of the present invention, said atomization device can be one or more nozzles or other devices capable of atomizing heavy oil, said one or more nozzles or other devices extends into the vaporization section of the distillation column and/or extends into an atomization vessel which is located out of the distillation column and fluid-communicated with the distillation column. Said atomization device such as nozzles (including but not limited to a rotary-flow type atomization nozzle, a centrifugal atomization nozzle, a variable area pressure-type atomization nozzle) can have one or more pores. The pore direction can be arbitrary. The atomization device can be optionally provided with auxiliary atomizing steam. Said auxiliary atomizing steam can be ejected together with or separately from the feedstock oil. The atomized fine droplets can have sizes sufficient to ensure a good vaporization effect and achieve the object of fractionating the feedstock oil effectively.
Said flow distribution system can be located out of the column and/or in the column. Said flow distribution system can be located out of the atomization vessel and/or in the atomization vessel. Said flow distribution system can be a flow distribution system having an automatic control, or a fully self-regulated flow distribution system having no automatic control. The flow distribution system having an automatic control is mainly composed of pipelines and auto-controlled valves. The flow distribution system having no automatic control distributes streams into atomization devices by a rational design of the resistances in branched pipelines.
In one embodiment of the present invention, said atomization vessel is a vessel have a sufficient space to atomize heavy oils. The example of the atomization vessel comprises an oil transfer line, a flash tank and a flash column. For reforming the existing plant, using the oil transfer line can accomplish utilization of old equipments. If setting the flash tank as atomization vessel, although the equipment capitals increases, the flash tank not only can provide more space and time for atomization and vaporization, but also is more advantageous for separating the vaporized oil vapor and the non-vaporized fine droplets.
In one embodiment of the present invention, said atomization device comprises one or more nozzles or other devices capable of atomizing heavy oil which extend into an atomization vessel which is located out of the distillation column and fluid-communicated with the distillation column, wherein a vapor-phase stream generated in the atomization vessel comes into the vaporization section of the distillation column, and a liquid-phase stream generated in the atomization vessel comes directly into the bottom of the distillation column and mixes with the bottom residual oil, or the vapor-phase stream and the liquid-phase stream generated in the atomization vessel comes into the vaporization section of the distillation column through a same pipeline.
In one embodiment of the present invention, said atomization device comprises one or more nozzles or other devices capable of atomizing heavy oil which extends into the vaporization section of the distillation column, wherein a feedstock oil of petroleum hydrocarbons to be fractionated is preheated, atomized and partially or totally vaporized through a pressure-feeding system at a pressure of 100-1000 kPa, preferably 200-800 kPa, more preferably 200-600 kPa, and most preferably 200-400 kPa or 200-300 kPa higher than the vaporization section pressure of the distillation column, and comes into the vaporization section; wherein the fraction oil is removed from column top and/or sideline, and a heavy oil is removed from the column bottom.
In one embodiment of the present invention, in said distillation column, a foam removal element 9 can be disposed above the vaporization section, and/or a liquid collection element 10 can be disposed below the vaporization section. Said foam removal element can be a demister pad or a vapor-liquid filtration net whose function is to reduce or eliminate the entrainment and avoid liquid to be entrapped by vapor and come into the fractionation stage. Said liquid collection element 10 can be a one- or multiple-layer liquid collection tray, which collects large liquid droplets that are formed from the continuous agglomeration of fine droplets due to their collision with each other. Said collected liquid droplets fall down to the column bottom, and are removed as residual oil. Both the foam removal element 9 and the liquid collection element 10 can be disposed for increasing the fractionation efficiency of the distillation column.
In another aspect, the present invention provides a distillation column for improving a fraction oil yield from petroleum hydrocarbons, wherein said distillation column comprises a vaporization section, wherein said distillation column comprises a pressure-feeding system, through which a feedstock oil of petroleum hydrocarbons to be fractionated is fed at a pressure of 100-1000 kPa higher than the vaporization section pressure of the distillation column.
In one embodiment of the present invention, said distillation column can be a distillation column which is not provided with reboiler, and preferably comprises a flash column, a primary distillation column, an atmospheric distillation column, a vacuum distillation column or a hydrogenated oil distillation column.
In one embodiment of the present invention, in said distillation column, a liquid collection element can be disposed below an inlet for ejecting the feedstock oil and/or a foam removal element can be disposed above the inlet for ejecting the feedstock oil.
In one embodiment of the present invention, said pressure-feeding system comprises a flow distribution system and one or more atomization devices. Said atomization device can be located in the vaporization section of the distillation column, or out of the distillation column, or both.
In one embodiment of the present invention, said atomization device can be one or more nozzles or other devices capable of atomizing heavy oil, said one or more nozzles or other devices extends into the vaporization section of the distillation column and/or extends into an atomization vessel which is located out of the distillation column and fluid-communicated with the distillation column.
In one embodiment of the present invention, said flow distribution system can be located in the column and/or out of the atomization vessel and/or in the atomization vessel.
In one embodiment of the present invention, said atomization vessel comprises an oil transfer line, a flash tank and a flash column.
According to the method and the distillation column of the present invention, the following advantages can be achieved:
(1) The feedstock oil to be fractionated is preheated, and then sent through the pressure-feeding system at a certain pressure into the distillation column. The vaporization of the feedstock oil in the vaporization section is accelerated by the atomization provided by the atomization device. Therefore, the real vaporization ratio of the feedstock oil in the vaporization section is more close to the equilibrium vaporization ratio, and the lighter fraction oils in the feedstock oil are vaporized into the vapor phase as much as possible. In addition, after the atomization into fine droplets, due to a sharp surface-area increase, the vaporization rate will be also increased greatly, which is in favor of increasing the fraction oil yield.
(2) Since the pressure in the furnace tubes of the heating furnace increases, the density of the oils in the furnace tubes increases, and the heat-transfer coefficient and therefore the overall heat-transfer coefficient increase. Thus, at the same heat transfer intensity or the same outlet temperature of the heating furnace, the temperature in furnace box of the heating furnace will be decreased, and therefore the surface temperature of the furnace tube and the cracking of the feedstock oil can be decreased.
(3) Because of a high pressure in the furnace tubes, the oils are substantially not vaporized. Therefore, the multiple enlargements of the diameter of the furnace tube are not necessary. Thus, the structure of the heating furnace is simplified and the diameter of the oil transfer line can be substantially reduced.
(4) In case of applying the present invention to the vacuum distillation, the distillation yield for the vacuum distillation column can be increased, and the diameter for the oil transfer line can be also remarkably decreased; in case of the atmospheric distillation, the distillation yield for the atmospheric distillation column can be increased, and the loads for the vacuum heating furnace and the vacuum column can be decreased; and in case of the atmospheric and vacuum distillation, the overall distillation yield for the atmospheric and vacuum distillation column can be increased, and the operation cost can be decreased.
In the following context, the method for improving a fraction oil yield from petroleum hydrocarbons and the relevant apparatus of the present invention will be illustrated with reference to the accompanying drawings, but the scope of the present invention is not limited thereto.
Referring below to
Referring below to
Referring below to
Referring below to
Comparative Example 1 illustrates the effect of the fractionation of a mixed crude oil by an atmospheric distillation method of the prior art.
The mixed crude oil to be fractionated has properties as shown in Table 1.
Example 1 illustrates the effect of the atmospheric distillation of crude oil according to the method of the present invention.
It can be seen from Table 2 that when the method of the present invention is used in the atmospheric distillation, relative to the atmospheric distillation with a conventional feeding manner, the outlet pressure of the atmospheric heating furnace is increased by 166.4 kPa, and the outlet temperature of the atmospheric heating furnace is increased by 4.0° C. Under the substantially same vaporization section pressure and temperature, the distillation yield of the present distillation column reaches 33.2% and increases by 3% relative to the conventional feeding manner. The present method, if used in the atmospheric distillation column, can increase the distillation yield of the atmospheric distillation column.
Comparative Example 2 illustrates the effect of the vacuum fractionation of an atmospheric residue according to the prior art.
The feedstock oil to be fractionated is an atmospheric residue and has properties as shown in Table 3.
Example 2 illustrates the effect of the vacuum distillation according to the method of the present invention.
It can be seen from Table 4 that when the method of the present invention is used in the vacuum distillation, relative to the vacuum distillation with a conventional feeding manner of Comparative Example 2, under the same vaporization section pressure and temperature, the distillation yield of the present vacuum distillation column reaches 60.2% and increases by 2.6% relative to the conventional feeding manner. The outlet temperature of the vacuum heating furnace increases by 18° C. The surface temperature of the furnace tube decreases by 33° C. The non-condensable gas content in the vacuum distillation column top product decreases from 0.3% to 0.2%. In the conventional feeding manner, the vacuum heating furnace has a furnace tube with a stepwise increased diameter and it is complex. According to the present invention, the diameters for the furnace tube and the oil transfer line are both Φ152 mm, which simplifies the structures of the furnace tube and the oil transfer line. In addition, in comparison with Comparative Example 2, the final boiling point for the vacuum wax oil increases by 25° C. All of density, viscosity, heavy metal contents and residual carbon content increase, but still meet the subsequent feedstock requirements by the downstream units. In the vacuum residue, the content for the fractions below 500° C. decreases from 4.3% to 1.3%, while the content for the fractions above 600° C. increases from 65.1% to 75.9%. The density, viscosity and residual carbon content of the residual oil increase remarkably.
Comparative Example 3 illustrates the effect of the vacuum distillation of an atmospheric residue according to the prior art.
A mixed crude oil to be fractionated was introduced into an atmospheric distillation column, and fractionated into straight run gasoline, kerosene, and diesel fractions. The distillation yield for the atmospheric distillation column was 32 wt %. Similarly to
Example 3 illustrates the effect of the vacuum distillation of crude oil according to the method of the present invention.
The used atmospheric distillation column system and the mixed crude oil to be fractionated were same as those used in Comparative Example 3. The distillation yield of the atmospheric distillation column was 32 wt %. As shown in
From the results of Table 6, it can be seen that by disposing a nozzle on the oil transfer line, under the same pressure of the vaporization section of the vacuum distillation column as that of Comparative Example 3, the outlet pressure of the vacuum heating furnace reaches 280.0 kPa, and the furnace wall temperature reaches 556° C., which is 5° C. lower than that of Comparative Example 3. The outlet temperature of the vacuum heating furnace reaches 418° C., which is 22° C. higher than that of Comparative Example 3. Fine droplets ejected into the oil transfer line are flashed and vaporized in the oil transfer line, and sent into the vaporization section of the vacuum distillation column, still remaining at the substantially same temperature as Comparative Example 3. Under the same vaporization section pressure as Comparative Example 3, the distillation yield after the feedstock passing through the vacuum distillation of Example 3 reaches 33.7 wt %, which is 3.9% higher than that of Comparative Example 3. The vacuum residue density and viscosity increase. In the vacuum residue, the mass content for the fractions below 500° C. decreases from 10% (Comparative Example 3) to 5.8%.
Example 4 illustrates the effect of the vacuum distillation of crude oil according to the method of the present invention.
The used atmospheric distillation column system and the mixed crude oil to be fractionated were same as those used in Comparative Example 3. The distillation yield of the atmospheric distillation column was 32 wt %. As shown in
It can been seen from Table 6 that by disposing the atomization nozzle and the flash tank at the outlet of the vacuum heating furnace in Example 4, the distillation yield of the vacuum fraction oil in the atmospheric residue reaches 34.5 wt %, which is 4.7% higher than that of Comparative Example 3.
Example 5 illustrates the effect of the vacuum distillation of crude oil according to the method of the present invention.
The used atmospheric distillation column system and the mixed crude oil to be fractionated were same as those used in Comparative Example 3. The distillation yield of the atmospheric distillation column was 32 wt %. The used vacuum distillation column according to Example 5 was structurally same as that of Example 4. The used vacuum heating furnace was structurally same as that of Example 4. The used flash tank was same as that of Example 4. As shown in
It can been seen from Table 6 that, in Example 5, by disposing an atomization-type pressure-feeding system and the flash tank at the outlet of the vacuum heating furnace, the distillation yield of the vacuum fraction oil in the atmospheric residue reaches 35.1 wt %, which is 5.3% higher than that of Comparative Example 3.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010 1 0519177 | Oct 2010 | CN | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CN2011/000665 | 4/15/2011 | WO | 00 | 5/14/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/055145 | 5/3/2012 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 1394488 | French | Oct 1921 | A |
| 2740753 | Schmalenbach | Apr 1956 | A |
| 4234391 | Seader | Nov 1980 | A |
| Number | Date | Country |
|---|---|---|
| 101376068 | Mar 2009 | CN |
| 101717658 | Jun 2010 | CN |
| 102079984 | Jun 2011 | CN |
| 2 174 697 | Apr 2010 | EP |
| 324376 | Jan 1930 | GB |
| 51-5001 | Feb 1976 | JP |
| S55-123684 | Sep 1980 | JP |
| S63-006086 | Jan 1988 | JP |
| 2001-129301 | May 2001 | JP |
| 0142393 | Jun 2001 | WO |
| Entry |
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| International Search Report dated Jul. 28, 2011, issued in corresponding International Application No. PCT/CN2011/000665. |
| Number | Date | Country | |
|---|---|---|---|
| 20130220889 A1 | Aug 2013 | US |
