Training Services

Vacuum Unit

Also called
“Vacuum Distillation Unit”
(VDU)

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 Outline

n Introduction
n Design Topics
n Design Examples
n Operating Tips
n Optimization, Revamps

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 Introduction

n Vacuum Unit - Why Do We Need One?

n What Is A Vacuum Unit?
n How Does It Work?
n How Is It Designed?

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 Crude Oil Mixture
Boiling Point
F C

< 30 <0 Gas & LPG

100-390 38-200 Gasoline & Naphtha

390-540 200-280 Kerosene & Jet Fuel

540-625 280-330 Diesel

625-700 330-370 Atmospheric Gas Oil

----------------------------------
700-1000 370-540 Vacuum Gas Oil

1000+ 540+ Resid

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 Why Do We Need a Vacuum Unit?

n As discussed in the Crude Breakup and Crude

Unit sessions, at atmospheric pressure
hydrocarbons begin to crack between 660-725°F.
n If the pressure is reduced, we can still vaporize
hydrocarbon compounds which can be separated
from an even heavier residue - we can separate
Vacuum Gas Oil (VGO) from Vacuum Residue
(VR) and process these 2 streams in separate
units and increase the revenue for the refinery.

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 What Is a Vacuum Unit?

n Fuels type
– Atmospheric Residue Charge
– Flash Zone
— 30-50 mmHg(a), 750ºF (400ºC)
– Products
— FLASHED gas oils
— Vacuum Residue (asphalt)
n Lubes type
– Requires significant fractionation between
cuts, much tighter fractionation control than a
Fuels type Vacuum Column
– We will not discuss lubes type further

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 Crude and Vacuum Unit

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 Vacuum Column

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 Operating Criterion

n Past
– No product thermal decomposition (lower flash
zone temperatures)
n Present
– Maximum gas oil yield (close to cracking) - but
maintain good quality gasoil
– Cracking Can
• Reduce vacuum (overload ejectors)
• Lead to coking problems

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 Cracking Depends On:

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 Operating Conditions

n Flash Zone Pressure

– 30 – 50 mmHg absolute

n Flash Zone Temperature

– Approximately 750ºF (400°C)

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 Vacuum Unit Design

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 Design Considerations

n Wet vs. Dry Design

n Level of Vacuum, Pressure Drop
n Number of Packed Beds
n Heater Transfer Line
n Flash Zone and Bottoms Section
n HVGO and Heat Removal Sections
n LVGO and Overhead Section

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 Design Considerations

n Wet vs. Dry Design

– Stripping Steam
– Heater Coil Steam
– With or without Precondenser
n Level of Vacuum
– 3 versus 4 Stage Ejectors
– With or without Precondenser
– Column pressure drop
n Number of Packed Beds
– Benefits of Intermediate Cut
– Fractionation between HVGO and LVGO

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 Wet vs Dry

n Major Design Decision - once set, cannot be

changed
n There really are 3 types - Dry, Wet with
Precondenser, and Wet without Precondenser
(which some call “Damp”)

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 Typical Vacuum Distillation Unit - No
Precondenser

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 Typical Vacuum Distillation Unit - With
Precondenser

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 Wet vs. Dry

n Dry Advantages: Much lower utility

consumption (no steam injected and less
motive steam for the ejectors)
n Dry Disadvantages:
– With no steam, distillate yield is limited by
absolute pressure
– With no steam in the heater, coking is more of
a concern
– Steam is often needed in the stripping section
to produce proper asphalt

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 Wet vs. Dry

n Wet Disadvantages:
– Much higher utility consumption (steam injection
and more ejector motive steam)
– Greater chance for water damage on startup
n Wet Advantages:
– With steam, distillate yield is greater because steam
lowers hydrocarbon partial pressure, thereby
enhancing vaporization and ultimate gas oil yield
– With steam in the heater, coking is less of a concern
– Steam is often needed in the stripping section to
produce proper asphalt

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 Precondenser vs. No Precondenser

n As the sketch shows, a precondenser will condense most

of the steam that was injected into the heater and/or
stripping section. However - this comes at a price.
n The condensed water in the precondenser exerts its own
vapor pressure (at condensing temperature) - this
means the overhead pressure cannot go lower than this
pressure.
n At 95°F (35°C) water exhibits 41 mmHg abs pressure -
to this must be added the inert gas pressure.
n Without a precondenser, overhead pressure can be any
value (although for a practical matter it is usually 20-25
mmHg at least).
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 Precondenser vs No Precondenser

n End Result - For maximum lift (deep cut) do

not use a precondenser.
n Precondensers will be more of a problem in
hot climates - if cold cooling water is available
most of the year, then the effect (while still
present) will be small.

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 Pressure Drop, Level of Vacuum

n Pressure Drop
– From the column top to the flash zone, typical pressure
drop for a packed column ~10 mmHg
– Each accumulator tray ~1 mmHg
– Each packed bed ~1-2 mmHg
– Each tray 3-5 mmHg (that’s why new columns only have
packing - BIG pressure drop for old columns
n Level of Vacuum
– Pressures vary greatly
– Wet/No Precondenser UOP designs 35 mmHg flash zone
– Wet/Precondenser often 45-65 mmHg flash zone
– Dry often 20-30 mmHg in flash zone

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 LVGO Typical Vacuum
Section
Column
HVGO
Dimensions
Section

How do we determine
Wash
Section
column diameter?

Flash
Zone

Bottom
Boot

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 Vacuum Column Sizing
Glitsch Method

ρv
C = VS
ρl − ρv

ρl − ρv
VS = C
ρv

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 Vacuum Column Sizing
Glitsch

where: c = 0.35(1) ft/s

VS = superficial vapor velocity, ft/s
ρv = vapor density, lb/ft3
ρl = liquid density, lb/ft3

Note: (1) For new designs using grid and

limited by re-entrainment, not flooding.

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 Vacuum Column Sizing
Old UOP Method

760
PV = 2.9
P
where: PV = permissible vapor velocity, ft/s
P = pressure at a given point in
column, mmHga

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 n Heater Transfer Line

n Flash Zone

n Bottoms

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 Heater Transfer Line

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 Heater Transfer Line

n To Size Line
– Use 70% of sonic velocity at column inlet conditions
– Maximum 350 ft/s
n Transfer line pressure drop will impact flash zone
temperature and distillate recovery (temperature
will drop from heater outlet to flash zone inlet).
We want to minimize the pressure drop
n Recommend “telescope” expanding diameter design
for deep cut designs

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 Heater Transfer Line

C p  T 
Vs = 223   
C v M 

where: V s = sonic velocity, ft/s

Cp/Cv = ratio of specific heats (use 1.0)
T = vapor temperature, ºR
M = vapor mol weight

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 Feed Distribution

n The Vapor-Liquid Separation is not an

Equilibrium-Flash separation in reality - with
the vapor velocity at 50-100% of sonic
n There is a large amount of entrainment
n Many different designs have been used in
order to minimize entrainment
– Tangential
– Box
– Many others

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 Vacuum Column
Tangential Feed Distributor

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 Vacuum
Column
Box Feed
Distributor

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 Wash Section

n Wash Section is to De-entrain resid material.

Any fractionation is incidental.
n Column Diameter set by Glitsch C-Factor
limit for packing 0.3 to 0.35 ft/s
n Overflash or slop wax rate to be controlled by
minimum packing wetting rate.

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 Grid Bed

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 Grid De-entrainment Efficiencies

Entrainment Removal
Grid Depth, ft-in Efficiency, Percent
2–0 90.0
2–6 95.0
3–0 98.0
3–6 99.0
4–0 99.5
5–0 99.9
6–0 99.99

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 Accumulator Tray Details

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 Wash Section

n Critical Performance parameter TRUE Wash

Oil Rate in slop wax = minimum of 0.2 gpm/ft2.
n Valuable to determine % entrainment in slop
wax (by performing a concarbon or metals
balance)

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 n Heavy Vacuum Gas Oil Section

n Heat removal Sections

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 Heavy Gas Oil Section

n Primary function is a a condensing/heat removal

section.
n Note that all withdrawals from the column (slop
wax, HVGO, LVGO) come from Total Trap
Trays - once vapor comes up through the
chimney tray, it can’t go back down the column
(except for wash oil, which is pumped from the
HVGO draw to the slop oil section).

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 Heat Removal Sections

Q = U “A” (LMTD)

where: “A” = volume of packing

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 Heat Removal Sections

U = h o = 421 C 0.8
(gpm A t)
0.58

where: C = capacity factor at bottom of

bed, ft/s
gpm = liquid leaving bed, gal/min
A t = column cross sectional area, ft2

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 GRC Bed - Grid/Ring Combination Bed

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 GRC Bed

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 Grid Layer

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 Grid Bed

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 Liquid Distribution

n As with any packed bed, liquid distribution is

critical to packed bed performance.
n There are 2 main types - spray nozzles and
gravity fed distributors.
n Spray nozzles have been the primary device.
n Gravity fed distributors are gaining more
acceptance with new designs.

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 Spray Nozzle
Assembly
Layout

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 Vacuum Column Spray Nozzles
HVGO

(37 Spray Nozzles)

CU-R00-31
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 Spray Nozzles

Spray
Distributor
Nozzle

Packing
Holddown
Grid

CU-R00-32
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 Liquid Distribution

n Improper liquid distribution leads to all sorts

of problems.
n Plugged spray nozzles lead to dry sections of
the packed bed, which (especially in the wash
zone) leads to a coked bed and a shutdown.
n Normally a filter is installed near the spray
nozzle inlet, and the line after the filter is made
out of stainless steel to prevent rust from
clogging spray nozzles.

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 n Light Vacuum Gas Oil Section

n Overhead System

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 LVGO Process Flow

Vacuum
Column
Ejector
s

PR FR
C

LC

T
I

FRC

LVGO to Blending

CU-R00-30
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 Vacuum Column Overhead

n Consists of multi sets of ejectors, condensers,

and ejector overhead receiver

n Provides the vacuum atmosphere necessary for

the proper operation of the vacuum column

n Provides for separation of the non-condensible

gases, liquid hydrocarbon, and water

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 Typical Vacuum Distillation Unit

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 Vacuum Producing Equipment

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Diagram of a Jet Ejector

A E
Steam C

B
Compressed
Vapors
Suction

IRP-R01-67
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 Ejector Condensate Drum

Liquid from
Condensers
Non Cond. Gas to
Vapor Heater

Oil to Water
Slops Outlet

CU-R00-33
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 Non-condensables

n Air leakage
n Gases produced in the heater and vacuum
column due to thermal cracking
n Dissolved non-condensable in the feed
n Water of saturation in the feed

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 Non-condensable in Vacuum Columns

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 Ejector Design
Figure 1: Ejector Performance Curve
1.2
1000
1.1

Correction Factor
1

0.9
Single Stage
Ejector Inlet Pressure (mmHg)

0.8

0.7

100
0.6
0 50 100 150 200 250 300 350 400
Steam Pressure (psig)

2 Stage, Condensing

10
3 Stage, Condensing

4 Stage, Condensing

1
1 10 100
Add 2 % to Steam Consumption for Every
1.0 PSI Increase over 0.5 psig discharge
Steam Ratio (# Steam / # DAE)
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 Vacuum Unit Design
Examples

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 Vacuum Unit Design Examples

n Column Sizing at the Flash Zone

n Column Sizing at the HVGO Draw
n HVGO Circulation Rate
n Column Sizing at the LVGO Draw and LVGO
Circulation Rate
n Bottom Boot Sizing - Stripping Steam Rate
n Ejector Sizing

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 Material Balance

ºAPI UOP Mol (106 scfd) Volume Weight

Gravity K Weight bpsd Lb/h Lb -mol/h Percent Percent

Reduced 22.4 12.0 474 39,370 532,602 1124 100.00 100.00

Crude

Estimated Yields

Gas – – 36 (0.381) 1,589 41.9 - 0.3%

Vac Naph 51.7 11.9 131 13 151 1.1 0.03% 0.03%

LVGO 33.5 12.0 289 5,397 67,894 234.8 13.7% 12.8%

HVGO 24.9 12.1 436 20,158 267,087 612.4 51.2% 50.2%

Slop Wax 17.7 12.2 630 1,197 16,631 26.4 3.0% 3.1%

Resid 14.3 12.2 761 12,497 179,405 235.5 31.7% 33.7%

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 Design
Temperatures

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 Column Size at Flash Zone

750ºF at 40 mmHga (0.774 psia)

Vapors Rising Lb/h Mol/h

Gas 465 15.5
Steam 667 37.0
LVGO 17355 61.3
HVGO 68575 149.1
Slop Wax 4890 8.9
Total 91952 271.8

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 Column Size at Flash Zone

– Molecular weight (mol wt) of vapors rising:

91952 lb  h 
 h 271.8 mol  = 338. 3
  

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 Column Size at Flash Zone

– The equation for c-factor in this service is:

ρl − ρv
VS = C
ρv

where: c = 0.35 ft/s

VS = superficial vapor velocity, ft/s
ρv = vapor density, lb/ft3
ρl = liquid density, lb/ft3

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 Column Size at Flash Zone

– Vapor density (ρv):

( mol wt )( psia )
ρv = = lb ft 3
(10.73)( R )
o

where:

( psia )( ft 3 )
10.73 = Gas Constant ( R ) =
( lb mol)( o R )

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 Column Size at Flash Zone

– Therefore, ρv at this point in the column is:

338.3 lb 

0.774 psia  lb mol - o R 
 3
ρv =    = 0.0202 lb ft
 lb mol ( 750 + 460 )o 
R 
10.73 psia - ft 3



– The cubic feet per second (CFS) of vapors rising is:

91952 lb  h  ft 
3
CFS =     = 1267
 h 3600 s 
0.0202 lb 


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 Column Size at Flash Zone

– Therefore, Vs at this point in the column is:

(46.8 - 0.0202)
Vs = 0 . 35 = 16.9 ft s
0.0202

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 Column Size at Flash Zone

– The required column cross sectional area (CSA) is:

1267 ft 3  s 
CSA =    = 75 .0 ft 2

 s 16.9 ft 

– This results in a column diameter (ID) of:

4 
ID = 75.0 ft 2   = 9.80 ft (2990 mm )
π 

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 Size at
HVGO Draw

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 Column Size at HVGO Draw
665ºF at 37 mmHga (0.716 psia):
ºF lb/h Btu/lb 106 Btu/h
Heat In
Feed to Column 750 138975 459 63.74
Stripping Steam 413 667 1174* 0.78
HVGO Reflux 545 W 271 271(W)

139642 + W 64.52 + (271W)

Heat Out
Resid from Column 710 47690 364 17.35
Net Slop Wax 725 4890 377 1.84
Vapors Rising to HVGO Draw
Steam 665 667 1340* 0.89
Gas 665 465 511 0.24
Net LVGO 665 17355 448 7.78
Net HVGO 665 68575 438 30.04
HVGO Reflux 665 W 438 438(W)

139642 + W 58.14 + (438W)

*Corrected to liquid at 60ºF

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 Column Size at HVGO Draw

IN OUT

64.52 ⋅10 6 Btu 271 Btu W lb  58.14 ⋅10 6 Btu 438 Btu W lb 
+   h  = +   
h  lb   h  lb  h 

W = 38204 lb h

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 Column Size at HVGO Draw

Vapors Rising lb/h Mol/h

Gas 465 15.5
Steam 667 37.0
Net LVGO 17355 61.3
Net HVGO 68575 149.1
HVGO Reflux 38204 83.1
Total 125266 346.0

– Molecular weight of vapors rising:

125266 lb  h 
   = 362.0
 h 346.0 mol 
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 Column Size at HVGO Draw

– Vs at this point in the column is:

45 .74 − 0.0215
Vs = 0.35 = 16.43 ft s
0.0215

– ρv at this point in the column is:

362.0 lb 

0.716 psia  lb mol - o R 
 3
ρv =    = 0.0215 lb ft
 lb mol ( ) 
o  3
665 + 460 R 10.73 psia - ft 


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 Column Size at HVGO Draw

– The CFS of vapors rising is:

125266 lb  h  ft 
3
CFS =     = 1621
 h 3600 s 
0.0215 lb 

– The required column cross sectional area (CSA) is:

1621 ft 3  s 
CSA =    = 98 .7 ft 2

 s 16.43 ft 
– This results in a column diameter (ID) of:

4 
ID = 98.7 ft   = 11.2 ft (3410 mm ) 2

π 

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 HVGO
Circulation

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 HVGO Heat Removal Section

n Using the previous calculated vacuum column

diameter and other necessary data, calculate
the amount and type of packing required for
the HVGO heat removal section

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 HVGO Heat Removal Section

– 11 feet, 6 inch ID = 103.9 ft2 column cross sectional

area (CSA)

– Calculate the capacity factor (C) below the packing

1621 ft 3   0.0215
C =  2 
= 0.339 ft s
 s 103.87 ft  45.74 − 0.0215

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 HVGO Heat Removal Section

– Calculate the capacity factor (C) above the packing

444 ft 3   0 .01157
C =  2 
= 0.064 ft s
 s 122.72 ft  51 .23 − 0 .01157

– Based on the above capacity factor calculations, a

Grid/Ring Combination (GRC) bed is required in
the HVGO section of the column

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 HVGO Heat Removal Section

– Calculate the overall heat transfer coefficient (U) using

Glitsch’s equation:

0.58
0.8  704 
U = ho = 421(0.286 )   = 469 Btu h − ο F − ft 3
103.87 

– Use 400 Btu/h - ºF-ft3 as a maximum practical U for

design.

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 HVGO Heat Removal Section

– LMTD is:

665 ⇒ 375

545 ⇐ 325

120 50

80ºF

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 HVGO Heat Removal Section

– Calculate heat removed (Q) in the HVGO section

of the column

151151 lb ( 271 − 132) Btu  6

Q=   = 21.01 ⋅10 Btu h
 h  lb 

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 HVGO Heat Removal Section

– Calculate volume of packing:

21.01 ⋅106 Btu  h − o F − ft 3 

    = 656.6 ft 3
 80 F 
 
h o
  400 Btu 

 3 ft
656.6 ft   = 6.32 ft re quired bed depth
103.87 ft 
3

– Use 6 feet, 6 inch actual bed depth.

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 Bed Composition

Bed Composition

0.4
0.35
C factor, ft/sec

0.3
0.25
0.2 C factor, ft/sec
0.15
0.1
0.05
0
0 1 2 3 4 5 6 7
Bed Height, ft

3 feet, 6 inch grid plus 3 feet, 0 inch rings if operation at turndown is not a prime concern.
3 foot, 0 inch grid plus 3 feet, 6 inch rings if operation at turndown is a prime concern.

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 HVGO Circulation Rate

ºF lb/h Btu/lb 106 Btu/h

Heat In
Feed to Column 750 138975 459 63.74
Stripping Steam 413 667 1174* 0.78
HVGO Circulation 325 W 132 132(W)

139642 + W 64.52 + (132W)

Heat Out
Resid from Column 710 47690 364 17.35
Net Slop Wax 725 4890 377 1.84
Net HVGO 545 68575 271 18.58
HVGO Circulation 545 W 271 271(W)
Vapors Rising to LVGO Draw
Steam 375 667 1202* 0.80
Gas 375 465 315 0.15
Net LVGO 375 17355 276 4.79

139642 + W 43.51 + (271W)

*Corrected to liquid at 60ºF

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 HVGO Circulation Rate

IN OUT
64.52 ⋅10 6 Btu 132 Btu W lb  43.51 ⋅10 6 Btu 271 Btu W lb 
+    = +   
h  lb  h  h  lb  h 

W = 151151 lb h

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 LVGO
Circulation

Size at LVGO
Draw

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 LVGO Circulation Rate
375ºF at 33 mmHga (0.638 psia):
ºF lb/h Btu/lb 106 Btu/h
Heat In
Vapors Rising to LVGO Draw
Steam 375 667 1202* 0.80
Gas 375 465 315 0.15
Net LVGO 375 17355 276 4.79
LVGO Circulation 110 W 23 23(W)

18487 + W 5.74 + (23W)

Heat Out
Net LVGO 200 17355 70 1.21
LVGO Circulation 200 W 70 70(W)
Vapors to Ejectors
Steam 115 667 1084* 0.72
Gas 115 465 175 0.08

18487 + W 2.01 + (70W)

*Corrected to liquid at 60ºF

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 LVGO Circulation Rate

IN OUT
5.74 ⋅10 6 Btu 23 Btu W lb  2.01 ⋅10 6 Btu 70 Btu W lb 
+    = +   
h  lb  h  h  lb  h 

W = 79360 lb h

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 Column Size Above LVGO Draw

Vapors Rising lb/h Mol/h

Gas 465 15.5
Steam 667 37.0
Net LVGO 17355 61.3
Total 18487 113.8

– Molecular weight of vapors rising:

18487 lb  h 
 h 113.8 mol  = 162.5
  

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 Column Size Above LVGO Draw

– Vs at this point in the column is:

51 .2 − 0.0116
Vs = 0 .35 = 23 .25 ft s
0.0116

– ρv at this point in the column is:

162.5 lb 

0.638 psia  lb mol - ο R 
 3
ρv =    = 0.01157 lb ft
ο 
 lb mol ( )  3
375 + 460 R 10.73 psia - ft 


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 Column Size Above LVGO Draw

– The CFS of vapors rising is:

18487 lb  h  ft 
3
CFS =  3600 s 0.01157 lb  = 444
 h  
 


– The required column cross sectional area (CSA) is:

444 ft 3  s 
CSA =    = 19 . 1 ft 2

 s 23.25 ft 
– This results in a column diameter (ID) of:

4 
ID = 19.1 ft 2   = 4.93 ft (1940 mm )
π 

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Bottom Boot Size

n Diameter is selected to give a liquid velocity

of approximately 2 feet/minute based on total
flow (net bottom plus quench)
n Typical DP cell length used is 60 inches
n Gives 2.5-5 minutes residence time based on
net product

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 Bottom Boot Size

– For this example:

139* gal  ft 3 min 
    = 9.29 ft 2
required

 min    2 ft 
7.48 gal 

– This results in a boot diameter of:

2 4 
ID = 9.29 ft   = 3.44 ft ( 1050 mm )
π
– The final boot diameter can be set at 3 feet 6 inches ID
(1070 mm).

* Refer to Heat and Weight Balance sheets included in reference material.

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Bottom Boot Size

– Bottom Stripping Section utilizes large hole sieve decks

– Boot Diameter based on requirements for sieve tray
design
– Check the residence time across the 60 inch DP cell
based on net resid (e.g.):

9.62 ft 3 5 ft  min 7.48 gal 

   *   = 2.93 min
3
 ft 
    ft
123 gal  

* Refer to Heat and Weight Balance sheets included in reference material.

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Stripping Steam Rate

3,203 bbl Resid 5 lb Steam

   = 667 lb/h Steam = 37 mol/h
 24 h  bbl Resid 

n For a deep cut design, this level of steam stripping

will result in oversized ejectors and large motive
steam requirements
n Benefits of bottoms stripping will be reduced by
coil steam injection
n For deep cut, recommend 2 lb Stm/bbl Resid

3203 bbl Resid 2 lb Steam 

  = 267 lb/h Steam = 15 mol/h
 24 h 
 bbl Resid 


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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Sizing Example
Non-condensable

n Air Rate
– At 37,000 BPD, Air Rate is 72 lb/hr
– Note this calculation is independent of pressure
n Cracked Gas Rate
– At 37,000 BPD and 750oF, base rate is 720 lb/hr
– Correction for 11.9 UOP K is 1.25
– Net Rate is 900 lb/hr
– Cracked gas Molecular Weight is 36

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Performance

n Ejector steam
– Large portion of unit operating costs
– A function of gas rate and desired pressure
corrected for the following:
— Offgas MW
— Offgas Temperature
— Steam pressure
— Offgas % Non-condensable
n Curves are based on Dry Air Equivalents,
which must be calculated from charts
n Method presented is independent of condenser
cooling water temperature
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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Design
Figure 1: Ejector Performance Curve
1.2
1000
1.1

Correction Factor
1

0.9
Single Stage
Ejector Inlet Pressure (mmHg)

0.8

0.7

100
0.6
0 50 100 150 200 250 300 350 400
Steam Pressure (psig)

2 Stage, Condensing

10
3 Stage, Condensing

4 Stage, Condensing

1
1 10 100
Add 2 % to Steam Consumption for Every
1.0 PSI Increase over 0.5 psig discharge
Steam Ratio (# Steam / # DAE)
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 Ejector Design
Figure 2: MW Entrainment Ratio Figure 3: Temp Entrainment Ratio
1.8 1

1.6
0.95
1.4 Air
0.9
Entraiment Ratio

Entraiment Ratio
1.2

1 0.85
Steam
0.8 0.8

0.6
0.75
0.4 Weight of gas
Entrainment Ratio =
Weight of air 0.7 Weight @ Temp
0.2 Entrainment Ratio =
Weight @ 70
0 0.65
0 20 40 60 80 100 120 140 0 100 200 300 400 500 600 700 800 900 1000
Molecular Weight Gas Inlet Temperature (Deg F)

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nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Design
Figure 4: % Condensable Correction
1.8

1.6

1.4
CORRECTION FACTOR

1.2

0.8

0.6

0.4

0.2

0
0 20 40 60 80 100
% NON CONDSENSABLE

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nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Design - Example
Calculate Motive Steam Requirements for the vacuum overhead system.
Given:
Non condensible Rate - 2652 lb/hr MW - 31.3
Condensible Rate - 18 lb/hr MW - 140
Steam Rate - 8336 MW - 18
Vacuum - 25 mmHg Discharge - 1.5 psig
Temp - 120ºF Steam Pressure - 150 psig
Equivalent Air
Non-Cond + Cond MW - 32.8
MW ER (Fig 2) - 1.06 Temp ER (Fig 3) - 0.985
Steam
MW ER (Fig 2) - 0.81 Temp ER (Fig 3) - 0.982
(2652 + 18) 8336
Eq. Air Mass Flow = +
(1.06)(0.985) (0.81)(0.982)
= 13037 lb/hr of Equivalent Air
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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Ejector Design - Example
Motive Steam Requirements
Two Stage Three Stage
Base Ratio (Fig 1) 6.8 4.5
Steam Pressure Corr* 0.89 0.89
Discharge Modifier 1.02 1.02
Non Cond Corr - 24% (Fig 4) 0.65 0.72
Two Stage Ratio = 6.8*0.89*1.02*0.65 = 4.01 lb steam/lb air
Steam Rate = 4.01*13037 lb air/hr = 52,310 lb/hr of steam
Three Stage Ratio = 4.5*0.89*1.02*0.72 = 2.94 lb steam/lb air
Steam Rate = 2.94*13037 lb air/hr= 38,345 lb/hr of steam
Installing a third stage will save 13,965 lb/hr of steam or $1039 / day

* Based on 140 psig - 10 psi Control valve drop

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 Typical
Vacuum
Column
Dimensions

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 Vacuum Unit
Operating Tips

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 Operating Tips

n Flash Zone Pressure

n Flash Zone Temperature
n Circulating HVGO and LVGO
n Slop Wax Draw
n Steam

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 Pressure

n Must Maintain Steady Pressure

n Effect on Gas Oil Yield
n Effect on Capacity

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 Temperature

n Increases Gas Oil Yield

n Sign of Cracking if Temperature Increase
Reduces Vacuum
n Controlled at Heater Outlet
n Bottoms to be Quenched to <690°F

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 Circulating Gas Oil

n Find Optimum HVGO Circulation for

Maximum Crude Preheat

n Find Optimum LVGO Circulation for

Minimum Overhead Temperature

n Rule of Thumb:
LVGO to HVGO ratio is 1:3 to 1:4

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 Slop Wax Draw

n Increase if HVGO Metals and Carbon High

n Watch Spray Pressure
n Send to Heater or Bottoms?
n Recommend external measured draw
n Actual Wash = Total Wash -
Entrainment -
Leakage and Condensate

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 Slop Wax Draw

n An example of entrainment calculation based

on ramscarbon material balance:
HVGO at 0.4 wt% ramscarbon
Vac Resid at 22.7 wt% ramscarbon
Slop Wax at 9.3 wt% ramscarbon

n By algebraic calculation, x = wt frac of resid

into slop wax
9.3 = (x)(22.7) + (1-x)(0.4)

n Inferred entrainment x = 0.399

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 Effect of Slop Wax on Yields - Need to Make Wash Oil

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 Steam

n Bottom Stripping

n Steam to Heater?

n Optimize steam injection against ejector size,

operating costs, and lift

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 Operation Design Considerations

n Bottoms Rundown (fuel oil production)

– Quench draw to 650oF-690oF
– Inject hot cutter stock to improve resid heat
transfer coefficient
– Blend cold cutters to improve rundown viscosity
– Make allowances for asphalt production
– Avoid finned fans. Use tempered water cooling

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 Operation Design Considerations

n Non-condensible Off Gas

– Arrange for disposal (typically to crude furnace)
– Preferable to amine treat
– Heat trace offgas line

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 Operation Design Considerations

n Packed Sections
– Ensure good vapor and liquid distribution

– Provide filters for reflux lines

– Use stainless steel downstream of filters to

avoid scaling
– Mount pressure points at reflux inlets to
monitor spray pressure drop
n Overhead pressure control
– Often installed, seldom used

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 Operation Design Considerations

n Water Damage
– Water at 40 mmHg explodes to 25,000 times its
volume inside a vacuum column
– Only use superheated steam with traps

– Thoroughly check vessel and piping for low

points where water might collect
– Install hold down grids to keep packing in place

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 Vacuum Unit
Monitoring, Optimization,
Troubleshooting,
Revamps and Control

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 VDU Monitoring

n Heater
– Monitor Flux

– Calculate velocity profile / optimize steam

injection
– Monitor draft

– Monitor transfer line velocity

– Monitor wetgas make / composition

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 VDU Monitoring

n Column

– Monitor column pressure profile

– Calculate c-Factors for each bed

– Monitor section heat removal

– Monitor wash rate / slop wax rate

– Monitor spray header pressure drops

– Monitor flash zone entrainment and wash

zone effectiveness (HVGO product quality)
– Monitor top temperature

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 VDU Monitoring

n Ejectors
– Monitor ejector/condenser performance
– Monitor skim oil / wet gas make
– Monitor steam consumption

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 VDU Unit Optimization

n Optimize Stripping Steam Injection

– Measure ejector performance / determine
optimal injection rate
n Maximize coil outlet temperature.
– Monitor heater flux / offgas make

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 VDU Unit Optimization

n Increase CDU stripping steam

– Reduces VDU skim oil, improves vacuum

n Optimize LVGO / HVGO recovery

– Increasing HVGO draw will limit load on
LVGO section allowing lower top temp & lower
pressure drop
– Increasing LVGO draw will increase draw
temperatures / heat recovery

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distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
 VDU Troubleshooting
Problem Symptoms Possible Cause
Loss of Distillate High flash zone a) High column pressure drop
Yield pressure b) Poor Ejector performance (see
Poor Overhead Vacuum)
c) Wash section coking
High overflash rate a) Leaking draw tray
b) Control failure on wash oil
Low Flash Zone a) Poor furnace performance
Temperature b) Open vent/steam out valve

Loss of Section High PA return temp a) Exchanger fouling

recovery b) Open bypass
c) Control problems
Low PA flow a) Hydraulic problems
b) Control problems
Low product flow a) Leaking draw tray
b) Poor liquid/vapor distribution
c) Section flooding

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 VDU Troubleshooting
Problem Symptoms Possible Cause
Poor overhead High overhead
a) High LVGO return temp, poor
vacuum temperature / High
exhanger performance
skim oil rate
b) Poor LVGO or HVGO section
vapor/ liquid distribution
c) Loss of CDU stripping
Low Ejector a) Fouled condensers
compression b) Blocked or undersized ejector
throats
c) Poor steam quality / low flow
d) Increased gas / stripping steam
rates
High Seal Drum a) Blockage in offgas line
Pressure b) High pressure drop due to high
flow or equipment problems
HVGO quality High metals * / a) Entrainment due to high flow
problems concarbon rates or equipment damage
b) Insufficient wash rate
c) Coking in wash section
* Note that some organo-metallic components may be present
in the HVGO boiling range
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 VDU - Revamp Opportunities
Increased Capacity - $$$

n High performance (structured) packing

– Increased heat transfer
– Allows for higher pumparound rates
n Add Furnace Capacity
– Additional Transfer Line ?
n Increase CDU Distillate recovery
– Remove more diesel
– Increase AGO draw

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 VDU - Revamp Opportunities
Improved Yields - $$

n Increase Vacuum
– Add/Rearrange Ejectors
– Allows for higher pumparound rates
n Increase Temperature
– Consider run length/cracked gas
– Calculate Flux
n Decrease pressure drop
n Reduce entrainment
– Improve wash section
– Upgrade feed separation device

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 VDU - Revamp Opportunities
Reduce Energy Costs - $

n Change from HP to MP Steam

n Replace ejector with Vacuum Pump
n Recover vacuum naphtha as diesel product
– May require some fractionation
n Increase number of draws

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 VDU Process Control

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 Control Issues

n HVGO PA Rate
– Control duty, not Rate
– Use Vap Temp above bed to reset duty
– Set LVGO/HVGO cutpoint
n LVGO Reflux (fractionation bed)
– Use Vapor Temp above bed to reset flow
– Sets LVGO End Point

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 Control Issues

n Column top temp

– Try to minimize
– Control by LVGO pumparound duty
n Top pressure control
– Limits top vacuum
– Often kept closed

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