Main fractionator water wash systems

When properly designed and operated, main fractionator wash water systems
can remove salt with little upset

Christopher F Dean Saudi Aramco

Scott W Golden Process Consulting Services Inc

M
ain (fractionator) column water wash temperature can lead to ammonium chloride
systems are sometimes needed when deposits on the trays or in the packing. These
producing heavy naphtha product to salts must periodically be removed; otherwise,
ensure the FCC feed rate and gasoline quality can FCC capacity will be reduced.
be met throughout the run. Heavy naphtha prod-
uct draws are used to segregate the high sulphur Heavy naphtha product draws
portion of the gasoline or to reduce the liquid and pumparounds
load through the gas plant. This is becoming Figures 1 and 2 show two heavy naphtha product
more prevalent due to the production of propyl- draw systems. The product in Figure 1 is with-
ene for petrochemical feedstocks. Consequences drawn from the same location as the
include a lower main column overhead tempera- pumparound, which is the most common
ture, higher wet gas rate and reduced gas plant arrangement. Pumparound temperature is set by
propylene recovery. Lowering the overhead the heavy naphtha product rate. As the overhead

Condenser Condenser

Reflux Reflux

Heavy naphtha
product
Heavy naphtha Heavy
PA return naphtha PA

Heavy naphtha Heavy naphtha

pumparound & pumparound
product

Figure 1 Typical heavy naphtha draw Figure 2 Alternative flow scheme

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  215
/VERHEADVAPOUR

 90
 
2EFLUX


 200
Oil and trace
water

Temperature, °F

4EMPERATUREo&

Figure 3 Localised temperatures Figure 4 Low overhead temperature

product naphtha rate decreases and the heavy concentrations, and water dewpoint all contrib-
naphtha product draw increases, the draw ute to salt formation. Ammonium chloride salts
temperature drops. When cold-feed preheat or are deposited after condensed water has
gas plant C3/C4 splitter and stripper reboiler absorbed the ammonia and HCl, and subse-
services use the heavy naphtha pumparound quently the water vapourises. Water forms when
heat, a reduction in the draw temperature can localised temperatures are below the water
create problems in each of these systems. dewpoint, which depends on the quantity of
Existing exchanger surface areas or pump capac- water present in the column overhead vapour
ity are often insufficient to meet the required and operating pressure. High concentrations of
duties. It is common during revamps to have to water reduce the dewpoint temperature. Water
add pump capacity and increase the exchanger content of the overhead vapour depends on the
surface area due to higher product draw rates. feed nozzle atomising steam, reactor stripping
However, in many cases, modifying the flow steam and main column steam, with rates vary-
scheme eliminates or minimises the pumparound ing dramatically between units.
system investment. Heavy naphtha product can Column overhead vapour HCl and ammonia
be withdrawn above the pumparound (Figure 2), concentrations play a central role. FCC feeds
allowing existing equipment to be reused without containing high chlorides are mainly unhydrot-
modifications. This permits a higher product reated atmospheric and vacuum residue
draw rate without lowering the pumparound containing residual inorganic salts (MgCl, CaCl
draw temperature. The internal liquid rate above and NaCl) from the crude unit desalters, and
the pumparound is sometimes less than the purchased gas oil contaminated with seawater.
targeted heavy naphtha product yield. In these As overhead vapour HCl and ammonia concen-
instances, it is necessary to use a dual draw trations increase, salt forms at higher
system, with the majority of product yielded temperatures. Severely hydrotreated feeds
above the pumparound and a smaller amount contain small amounts of nitrogen compounds
from the pumparound draw tray. This maximises and almost no chlorides. Therefore, overhead
the pumparound temperature. vapour ammonia and HCl concentrations are
low. High chloride feeds generate large amounts
Salt formation of HCl, so the column overhead temperature
Localised temperatures, HCl and ammonia may need to be as high as 265°F to avoid salt

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formation, whereas low chloride feeds can oper- down the tower. This is difficult to remove when
ate as low as 235°F without rapid salt formation. it deposits below the water draw tray.
Reflux temperature and rate influence the rate
of salt deposition because they set localised Normal operations
temperatures. Reflux temperatures vary from 75– During normal operation, the targeted heavy
120°F, depending on ambient conditions and the naphtha product rate is set by controlling the
condenser system design. Reflux rate depends on overhead temperature. Lowering the overhead
column heat balance. Overhead vapour tempera- temperature produces more heavy naphtha prod-
ture may be 240–300°F, yet the liquid uct with localised temperatures low enough to
temperature leaving the top tray may be only 150- condense water even during normal operation.
180°F. High rates and cold reflux reduce the local Ideally, this water is withdrawn continuously to
temperature. Recognising the difference between minimise the amount of salt deposited. When
localised liquid temperatures on the top trays and the column is designed with a proper water draw
measured vapour temperatures is essential to one or two trays below the top tray, it is possible
understanding the mechanism of salt formation. to continuously remove free water.
Heat is exchanged when cold reflux and hot Operating with a continuous draw is quite
vapour mix on the tray. Figure 3 depicts the simple. Draw rate is set high enough to ensure
change in liquid temperature across a one-pass hydrocarbon is always present. This is done by
tray. In this case, reflux enters at 90°F, heat (and sampling the draw stream and visually checking
mass) is exchanged between the vapour and for hydrocarbons. Since there is little water
liquid, and liquid leaves at 160°F. A portion of present, this stream will be more than 90%
the vapour entering the top tray is condensed. hydrocarbon. This ensures water is removed
Localised temperatures below the water dewpoint without having to install an interface detector on
contribute to salt formation because the water the main column. Even though the draw stream
absorbs HCl and ammonia from the vapour. contains 90% hydrocarbon or more, it will be
Water eventually vapourises because tempera- less than 10 gallons per minute for most units.
tures increase as liquid flows down the column, This stream can be cooled and routed to the
and salt is deposited. main column overhead receiver, where the oil
and water are separated. The rate is so low that
Column overhead temperature
Column overhead temperature is set by operat-
ing pressure, the amount of water and overhead
naphtha product endpoint. A question often
asked is “What is the maximum percentage of
FCC gasoline that can be withdrawn as heavy
naphtha?” The answer depends on the rate of
salt deposition that is tolerable. If the rate of salt
laydown is high, there needs to be an effective
way to remove it; otherwise, the tray will plug,
eventually causing flooding.
Product
Refiners yielding 20% or more of the gasoline
as heavy naphtha will likely have high rates of salt Sour
water
deposition unless the feed has no chlorides. Those
main columns that have operated problem-free
FC
for years at 215°F or lower have well-designed
water draw trays and good operating procedures.
One refiner has been operating at below 190°F for
several years (Figure 4), but continuously with- FC

draws water during normal operation. Hence,

salts never build up on the trays. Yet, it is essen-
tial that all free water be withdrawn; otherwise,
water containing HCl and ammonia will flow Figure 5 Water wash system

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 175
#ONDENSER

75
2EFLUX

7ATER
INTERMITTENT 185
USE
/IL Oil and
continuous
water
/ILANDWATERTO
OVERHEAD
CONDENSERS
INTERMITTENT Temperature, °F

Figure 6 Continuous water draw Figure 7 Water draw

it does not materially change the sulphur content • Correct water draw tray location
in the main column overhead product stream. • Proper routing of oil and water
• Proper water draw tray design
Water washing: abnormal operations • Good operating procedures.
Water washing will cause significant upsets if the In one instance, the overhead temperature ran
system is poorly designed, process routing is continuously at 175°F, which was below the
incorrect or the procedure is not done properly. water dewpoint. Yet, the water draw tray was
During the water washing procedure, water and located only two trays below the top. Reflux was
oil will be withdrawn from the column at 150– just 75°F during the winter; therefore, its
190°F. If this stream is routed directly to the temperature increased to only 185°F on the
main column overhead receiver without cooling, water draw tray (Figure 6). At times, operating
it will flash, generating a higher wet gas compres- temperatures below the water draw were below
sor load. During water washing, this stream the water dewpoint. In this instance, the water
needs to be piped upstream of the overhead draw tray should have been located at least three
condensers (Figure 5). trays below the top of the column to ensure the
Proper operating procedures are essential, tray below the water draw operated above the
because water washing forces an abnormal oper- water dew point. The water draw tray should
ation on the main column. First, the column typically be located one to two trays below the
overhead temperature must be reduced, and top of the column, but in a few cases, as noted in
then sufficient water added to the reflux so water this article, it needs to be lower. In all cases, it
is present on the water draw tray. Water draw must be seal-welded to ensure all the water is
tray temperatures need to be low enough so that removed.
sufficient water is present to remove the salt. The water draw tray design needs to provide
When the water draw tray product is routed to sufficient residence time to separate the oil and
the main column condensers, the main column water. The downcomers from the tray above the
overhead receiver temperature and overhead water draw and those feeding the tray below
product naphtha remain relatively constant, need to be oriented correctly (Figure 7). Low
minimising gas plant upsets. residence time or improper downcomer orienta-
tions will allow free water to flow below the
Water wash system design water draw. In some cases, it is necessary to
Four main features of a functional water wash make the trays and water draw from a dual alloy
system are: stainless to avoid corrosion.

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 Operating procedures are important. During and high concentrations of chlorides and ammo-
normal operation, there is only a small amount nia will need a very high temperature. Often, this
of water and mostly oil. When water washing, high temperature means producing little or no
the flow increases significantly, so the piping heavy naphtha.
system must be large enough to handle the full
flow rate. Christopher F Dean is a process engineer with Saudi Aramco at the
Ras Tanura refinery in Saudi Arabia. Dean’s current responsibilities
Conclusions include FCC operations, crude unit and other key refinery units,
while also providing strategic planning support.
What is the maximum heavy naphtha draw and
Scott Golden is a chemical engineer with Process Consulting
minimum main column overhead temperature?
Services in Houston, Texas, USA. His responsibilities include
Truly, there is no minimum temperature as long
FCC, crude unit, hydrotreating and associated product recovery
as the unit has facilities to remove the salts, systems. Email: sgolden@revamps.com
metallurgy to deal with potential corrosion and
is run with proper operating procedures. Since
most main columns have no water draw, few Links
engineers have experience of them, so they are
often viewed as unnecessary. Yet, without an More articles from: Process Consulting Services
effective water wash system, the overhead
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temperature must be high so that the rate of
Revamps, Shutdowns and Turnarounds
ammonium chloride deposition is very low. A FCC
main column with a high reflux rate, cold reflux

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