DESIGN AND FABRICATION OF CRUDE DISTILLATION UNIT COMPONENTS FOR A MINI PETROLEUM REFINERY

DESIGN AND FABRICATION OF CRUDE DISTILLATION UNIT COMPONENTS FOR A MINI PETROLEUM REFINERY

Abstract:

Nigeria is faced with high import of petroleum products, incessant shortage of the products and poor petroleum refining status. There is therefore the need to develop local technology in petroleum refining as a sustainable solution to these problems. This work contributes its own quota to this worthy course by designing and fabricating crude distillation unit components for a mini petroleum refinery to process 1 bbl/day of Escravos crude. The unit consists of atmospheric distillation unit and vacuum distillation unit. Components designed and fabricated are: an Atmospheric distillation column, a Vacuum distillation column, an ADU furnace, a VDU furnace, a Condenser, a Reflux drum, 3 Strippers, an AGO-Crude Heat exchanger, a Top Pump-around heat exchanger and a Bottom Pump-around heat exchanger. Design was done using both manual calculations and ASPEN Plus software. The ASPEN Plus simulation gave: Internal diameter of ADInternal diameter of AD Internal diameter of ADInternal diameter of AD Internal diameter of AD Internal diameter of AD Internal diameter of AD Internal diameter of AD Internal diameter of AD Internal diameter of ADInternal diameter of AD U, VDU and Stripper columns as U, VDU and Stripper columns as U, VDU and Stripper columns as U, VDU and Stripper columns asU, VDU and Stripper columns as U, VDU and Stripper columns asU, VDU and Stripper columns as U, VDU and Stripper columns as U, VDU and Stripper columns asU, VDU and Stripper columns as U, VDU and Stripper columns as U, VDU and Stripper columns asU, VDU and Stripper columns as 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively.7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively.7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively. 7.5cm, 9.9cm and 2cm respectively.7.5cm, 9.9cm and 2cm respectively.7.5cm, 9.9cm and 2cm respectively. Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for Required number of trays for ADU, VDU and ADU, VDU and ADU, VDU and ADU, VDU and ADU, VDU and ADU, VDU and ADU, VDU and Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively. ADU furnace Stripper columns was found to be 20, 9 and 4 trays respectively.

tubes in convection and 5 determined to be a double section box furnace with 12 tubes in convection and 5 tubes in radiati tubes in radiati tubes in radiati tubes in radiati on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace on section while VDU furnace had 4 had 4had 4had 4 tubes in radiation sect tubes in radiation sect tubes in radiation secttubes in radiation secttubes in radiation sect tubes in radiation sect tubes in radiation secttubes in radiation section only. All ion only. All ion only. All ion only. All ion only. All ion only. All tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU ttubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU t tubes are 0.4m long with diameter of 5mm. ADU top product condenser required was op product condenser required was op product condenser required was op product condenser required was op product condenser required wasop product condenser required was op product condenser required was op product condenser required was op product condenser required was op product condenser required was op product condenser required was op product condenser required was op product condenser required was a shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubesshell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubesshell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubesshell and tube heat exchanger with 3 tubesshell and tube heat exchanger with 3 tubesshell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes shell and tube heat exchanger with 3 tubes each of of which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and which had a length of 0.5m and diameter 5mm while crude diameter 5mm while crude diameter 5mm while crudediameter 5mm while crude diameter 5mm while crudediameter 5mm while crude diameter 5mm while crudediameter 5mm while crude -AGO, t AGO, t AGO, top pump around and bottom op pump around and bottom op pump around and bottomop pump around and bottomop pump around and bottom op pump around and bottomop pump around and bottom op pump around and bottom op pump around and bottom pump around heat pump around heat pump around heat pump around heat pump around heat pump around heat pump around heat pump around heat excexcexchangers were double pipe hangers were double pipe hangers were double pipe hangers were double pipe hangers were double pipehangers were double pipehangers were double pipehangers were double pipe hangers were double pipehangers were double pipe with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. with tube lengths 0.3m, 0.2m and respectively. Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm Reflux drum required is vertical separator of height x diameter; 32cm 5cm respectively. respectively. respectively. respectively. respectively.respectively.respectively. Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for Working drawing of each the designed components was prepared for ease of fabrication.ease of fabrication.ease of fabrication. ease of fabrication. ease of fabrication. ease of fabrication. ease of fabrication.ease of fabrication.ease of fabrication.ease of fabrication. ease of fabrication. All components were successfully fabricated and ready for

DESIGN AND FABRICATION OF CRUDE DISTILLATION UNIT COMPONENTS FOR A MINI PETROLEUM REFINERY