FUNDAMENTALS AND DESIGN ASPECTS OF

EQUIPMENT IN CRUDE DISTILLATION UNITS

NAME SEAT NO

i. ABDULLAH AMIR B21108006002

ii. AHMED B21108006003
iii. AQSA MAJEED DAR B21108006004
iv. MISBAH UDDIN SIDDIQUI B21108006013

SUPERVISED BY:

DR. AHSAN

DEPARTMENT OF CHEMICAL
ENGINEERING

UNIVERSITY OF KARACHI

1
Table of Contents
1-INTRODCTION ......................................................................................................................3
2-EQUIPMENT DESIGN ...........................................................................................................4
2.1 Furnace (Heater) ................................................................................................................4
2.1.1 Design Basis ...............................................................................................................4
2.1.2 Design in Excel...........................................................................................................4
2.2 Distillation Column ...........................................................................................................6
2.2.1 Design Basis ...............................................................................................................6
2.2.2 Design in Excel...........................................................................................................6
2.3 Control Valve (Reflux Drum level control valve) ............................................................. 11
2.3.1 Design Basis ............................................................................................................. 11
2.3.2 Design in Excel......................................................................................................... 11
3-CRITICAL ANALYSIS ......................................................................................................... 15
3.1 Furnace ........................................................................................................................... 15
3.2 Distillation Column ......................................................................................................... 16
3.3 Control Valve .................................................................................................................. 17
4-EVIDENCE-BASED JUSTIFICATION ................................................................................. 18
4.1 Furnace ........................................................................................................................... 18
4.1 Distillation Column ......................................................................................................... 18
4.1 Control Valve ............................................................................................................. 19
5-EQUIPMENT DATASHEETS (SIZING, SKETCHES) .......................................................... 19
5.1 Furnace ........................................................................................................................... 19
5.1.1 Furnace Technical Data Sheet ................................................................................... 19
5.2 Distillation Column ......................................................................................................... 21
5.3 Control Valve .................................................................................................................. 23
References ................................................................................................................................ 26

2
1-INTRODCTION
This report outlines the detailed design and sizing of three critical equipment components for the
refining which are distillation column, a control valve, and a furnace. The design process was
conducted using Excel spreadsheets rather than commercial simulation software, emphasizing a
self-directed learning approach and resource optimization in alignment with PLO-12 (Lifelong
Learning). This methodology demonstrates the application of fundamental engineering principles
while enhancing problem-solving capabilities through practical implementation.
The designs comply with industry standards and best practices, ensuring operational reliability,
safety, and efficiency. Each component has been rigorously validated using academic and
technical references, reinforcing the credibility and accuracy of the engineering decisions. By
integrating theoretical knowledge with computational analysis, the project not only optimizes
system performance but also provides a deeper understanding of industrial design challenges. This
approach highlights a commitment to innovation, precision, and professionalism in addressing
complex engineering Problems[1].

3
2-EQUIPMENT DESIGN
2.1 Furnace (Heater)
2.1.1 Design Basis
Table 1:Design Basis for Furnace[2]

Data for Designing

Feed rate = 3566.16 BPH
T1 = 232.20 ⁰C
SG of Feed = 0.91
n = 1.00 row
α = 0.88
mfuel = 3975.12 kg
2
A = 158.14 m
G = 22.17
D = 0.10 m
C = 0.22 m
L = 12.00 m
Cp = 1.800867 KJ/kg.⁰C
NHV = 5.39E+04 KJ/kg

2.1.2 Design in Excel

We have Selected the Microsoft Excel Software for Designing of furnace. Calculations and Results
are shown below with tables:
Table 2:Calculations with formulas for Qcomb, Nt, Acp[3], [4]

For Qcomb

Qcomb = 2.14E+08 KJ/h

For NT

NT = 132.93

For Acp

2
Acp = 353.17 m

4
 Table 3:Calculations with formulas for %R, mstock [4], [5]

For αAcp
αAcp = 310.789 m2

For %R

R = 1 x 100
1 + 1.22

R = 45.13 %

For mstock
3
m = 3566.16 bbl 0.8524 1000 kg 1 m
3
h m 6.29 bbl

m = 483274.4 kg

Table 4:Values of constant S w.r.t Q in different units[3]

Table 5:Calculations with formulas for Qr, T2 [4] [5]

For Qr

Qr = 9.67E+07 KJ/h

For T2

T2 = 343.30 ⁰C

5
2.2 Distillation Column

2.2.1 Design Basis

Table 6:Design Basis for Distillation Unit [6],[7]

% Volume ⁰API BPD lb/h Mol. Wt Latent Heat

Off Gases 1.98 - 5.46E-04 4.66E-03 51.72 316.86

Waste Water - - 8.65E+02 1.26E+04 18.02 969.17
Naphtha 21.5 61.86 2.30E+04 2.46E+05 88.75 220.07
Kero 9.54 37.21 9.30E+03 1.14E+05 157.72 126.65
Diesel 19.1 31.96 1.92E+04 2.46E+05 216.07 200.53
AGO 4.56 23.47 4.50E+03 6.00E+04 296.67 243.25
Residue 43 15.1 4.40E+04 6.20E+05 436.36 381.00
Crude 100 29.25 1.00E+05 1.28E+06 206.22 -

2.2.2 Design in Excel

We have Selected the Microsoft Excel Software for Designing of Distillation Columns.
Calculations and Results are shown below with tables:
Table 7:Calculations and formulas for Calculating Sensible Heat of Products[3]

Sensible Heat

For Off gases For Atm Gas Oil

Q = 1.13 BTU/h Q = 4.42E+06 BTU/h

For Waste water For Residue

Q = 7.45E+06 BTU/h Q = 4.03E+06 BTU/h

For Naphtha For Steam

Q = 6.92E+07 BTU/h Q = 9.83E+05 BTU/h

For Kerosene Total Sensible = 1.33E+08 BTU/h

Q = 1.65E+07 BTU/h Heat

For Diesel
Q = 3.08E+07 BTU/h

6
 Table 8:Calculations and formulas for Calculating Latent Heat of Products[3]

Latent Heat

For Naphtha
Q = 5.41E+07 BTU/h

For Kerosene
Q = 1.44E+07 BTU/h

For Diesel
Q = 4.94E+07 BTU/h

For Atm Gas Oil

Q = 1.46E+07 BTU/h

Total Latent = 1.32E+08 BTU/h

Heat

Total Heat Removed = 2.66E+08 BTU/h

The total that needs to be removed to make the column thermally stable is found to be 2.66E+08
BTU/h.

Table 9:Calculations for hot Reflux [3], [8]

Hot Reflux
Lambda (Naphtha) = 220.07 BTU/lb
Lb of reflux = 1208067.02 lb/h
Moles hot reflux = 13612.08 moles
Moles Naphtha = 2769.21 moles
Moles of Vapor = 16381.29 moles
Moles of Steam = 416.32 moles
Total Moles at the top = 16797.62 moles
Total pressure at the = P1 = 1018.78 mm Hg
top of column

Partial pressure of gas = P2 = 993.53 mm Hg

7
From EFV curve,

Figure 1:ASTM Distillation and Flash Vaporization curve of the cuts[6].

The dew point temperature of Naphtha is found from curve as 375 ⁰F.

And General Gas Constant = R = 1.987 BTU/lb-mol ⁰R

The Antoine Equation is,

𝑃 𝑙𝑎 𝑏𝑑𝑎 𝑀. 𝑊
ln ( ) ( )
𝑃

Table 10:Calculation for top Temperature[9]

-0.025096883 = 9829.543083 x 0.001198 - 1

T
T = 832.95 ⁰R = 372.95 ⁰F
The actual temperature at the top is found to be as 372 ⁰F.

8
 Table 11:Calculations for vapor density, Volume of vapor and Mass Velocity[3],[10]

For Density of Vapor

Moles Naphtha = 2769.21 moles
Moles Hot Reflux = 13612.08 moles
Moles Steam = 416.3217549 moles
Total Moles = 16797.62 moles
P1 = 1018.78 mm Hg
T1 = 106.6 ⁰F

Mass of Vapor = 1.46E+06 lb/h

Volume of Vapor = 5.17E+06 ft3

Density of Vapor = 0.28 lb/ft3

and K = 735 K

Assume
3
Density of Liquid = 42.7 lb/ft
For Mass Velocity
w/a = 2543.84 lb/ft2.h

For Mass Velocity

𝑤
𝑘√𝜌𝑣 𝜌𝐿 𝜌𝑣

For Area of Column

𝑀𝑎𝑠𝑠
𝑀𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

For Diameter of Column

4
𝐷 √
𝜋

For Volume of Vapors

𝑛
𝑉
𝑃
For Vapor Velocity
𝑉
𝑢

9
For Height of Column

𝐻 𝑁
The recommended tray spacing should be from 18 to 24 inches, with accessibility in mind
(Generally, for a tower diameter of 4 feet and above, the most common tray spacing is 24
inches[11].
Table 12:Calculations for Area, Diameter, Vapor velocity and Height of Column[12].

For Area of Column

2
A = 574.46 ft
For Diameter of Column
DC = 27.04 ft

For Vapor Velocity

u = 2.50 ft/s

Tray Spacing = 18.00 - 24.00 inches [1]

For Height of Column

H = N x TS [m] [N = 29]
= 29.00 x 0.61
H = 17.68 m = 58.00 ft

Figure 2:Typical Fractionator Parameter [7]

10
2.3 Control Valve (Reflux Drum level control valve)

2.3.1 Design Basis

Table 13:Design Basis for Control Valve[13]

LINE SIZE FOR C.V

Data
Q = 152.4 m3/hr
Qdesign = 167.64 m3/hr
L = 100 ft thenL= 50
viscoosity = 0.3635 cp 0.000244272 lb/ft.s
Density Mass Flow [kg/hr] = 111477.6854 Kg hr
hr 152.4 m3
= 731.4808755 kg/m3 = 45.66485928 lb/ft3

Cv = ?
2.3.2 Design in Excel
We have Selected the Microsoft Excel Software for Designing of Control Valve. Calculations and
Results are shown below with tables:

For Frictional Parameter

64
𝑓
𝑒

For Laminar flow

2.5 𝑒
2 log ( )
√𝑓 𝑒 √𝑥 3.7𝐷

For Turbulent flow

For Reynold’s Number

𝜌𝑉𝐷
𝑒
𝜇

For Pressure Drop per 100 ft

The Darcy’s equation is,

4𝑓𝐿𝑉 𝜌
∆𝑃
2𝑔 𝐷

11
 Table 14:Calculation for pressure loss due to friction in pipe[14]

SOLUTION
Pressure loss due to friction in pipe
Assume line size 8 inch
internal dia = 0.6651 ft = 7.981 in
Area = 0.3472 ft2

Qnor = 1.494982392 ft3/sec

Velocity = 4.305824861 ft/sec
Reynold no = 535367.1805
For Pressure drop per 100ft
f by colebrook eq
f = 0.015569
Pressure drop/100ft = 123.1951341 lbf 1 ft2
ft2 144 in2
= 0.855521765 psi
Pressure drop/50ft = 61.59756705 lbf 1 ft2
ft2 144 in2
= 0.427760882 psi

The result shows that the assumed line size is correct and 8’’ pipe can be used

For Head Loss

𝑘𝑉
ℎ𝐿
2𝑔

For Pressure Drop

∆𝑃 𝜌𝑔ℎ𝐿

12
 Table 15:Calculations for different Pressure losses[7], [15]

Pressure loss due to fittings

For 90° elbows K = 0.42 = 12x0.42 = 5.04
For gate valves k = 0.11 = 2x0.11 = 0.22
Overall Coefficient of resistance = 5.26
for Pressure drop fittings = 2226.643012 lb/ft.s2
= 3313.609846 Pa 1 psi
6895 pa
for Pressure drop fittings = 0.480581558
Pressure loss due to elevation
Elevation differnce between Reflux = 44.8766 - 58 = -13.1234 ft
drum and heater
Pressure loss due to elevation = -599.7624945 lbf/ft2
144
= -4.165017323 psi

Figure 3:Table for valve sizing w.r.t Cv [13]

13
For Specific Gravity
𝝆𝒓
𝑺. 𝑮
𝝆𝑾

For Cv

𝑺. 𝑮
𝒗 √
∆

Table 16:Calculation for Cv [7], [15]

for total Pressure loss across line

total Pressure loss across line = -3.256674882

Pressure drop across Control Valve

Pressure drop across Control Valve = 4.756674882

For flow Coefficient of Valve

we have to find S.G
Density of water = 62.4 lb/ft3
S.G = 0.731808642
Cv = 65.75437966
and more linear range.
So, select a 3" valve for optimal
performance and control.

14
3-CRITICAL ANALYSIS
3.1 Furnace
Table 17:Comparative Evaluation of Heating Systems[16],[7]

Advantages (Performance &

Option Limitations (Economic & Environmental)
Integration)

- High thermal efficiency (over

- Significant CO₂ and NOₓ emissions
85%)
- Requires dedicated safety systems (burner
Direct-Fired - Compact design suitable for
management, stack monitoring)
Furnace high-temperature service
- Limited turndown ratio compared to electric
- Lower fuel cost when natural
systems
gas is used

- High operational cost due to electricity

- No on-site emissions; ideal for
tariffs
zero-carbon goals
Electric - Inefficient for high thermal demand (>5
- Precise temperature control
Heater MW)
- Modular and easily scalable
- Can require expensive power infrastructure
for lower duty applications
in remote areas

 Design Justification

A direct-fired furnace was selected based on its superior thermal output, economic fuel sourcing,
and proven field integration in large-scale applications like crude fractionation and re-boiling
duties. The flexibility in handling large flowrates and temperature differentials aligns with FEED
sensitivity analyses on flow, temperature rise, and thermal efficiency. Spreadsheet models (e.g.,
Excel) enable rapid iteration on design parameters such as flue gas temperature, excess air levels,
and exchanger coil configuration.

15
3.2 Distillation Column
Table 18:Alternative Designs for Distillation Columns[16], [7]

Design
Operational Strengths Operational Challenges
Option

- Superior for fouling-prone services

- Higher pressure drop across the column.
due to ease of mechanical cleaning.
- Larger footprint and potentially higher
Tray - Effective in handling high liquid
CAPEX.
Column loads and broad flow ranges.
- Mechanical complexity may require more
- Allows visual inspection and
maintenance.
maintenance access.

- Lower pressure drop, advantageous in - Susceptible to fouling from particulates

vacuum or energy-sensitive operations. or viscous feeds.
Packed - Smaller column diameter reduces - Maldistribution can affect efficiency
Column material cost. without proper liquid/gas distribution.
- Higher surface area promotes efficient - Foam formation risks with high liquid
mass transfer at low pressure. viscosity or surfactant presence.

 Design Justification

The tray column is preferred for applications involving dirty or fouling-prone process streams. Its
mechanical robustness and ability to be cleaned and inspected internally make it suitable for
operations requiring high reliability and accessibility. Excel-based modeling was used to estimate
theoretical stage numbers and column diameter, confirming the design feasibility without resorting
to third-party simulation platforms.

16
3.3 Control Valve
Table 19:Control Valve Comparison Table[17], [18]

Option Performance Characteristics Limitations & Suitability

- Precise throttling due to linear flow

- Higher pressure drop due to tortuous
path control
flow path
- Easy to automate using diaphragm
Globe Valve - Not ideal for full open/close on-off
actuators
applications
- Suitable for high-pressure drops and
- More expensive and larger footprint
accurate flow regulation

- Poor throttling performance at partial

openings
- Low pressure drop when fully open
- Prone to erosion if used frequently for
Ball Valve - Compact, simple design
flow control
- Cost-effective for on/off isolation duties
- Typically limited to isolation, not
modulation

 Design Justification

The globe valve offers superior control accuracy, crucial for regulating flow into heat exchangers.
Its linear flow characteristics and suitability for automation make it ideal for fine-tuning process
conditions. According to Surface Production Operations Volume 2, globe valves are the standard
choice for automatic throttling applications due to their modulating capabilities and robust actuator
compatibility.

17
4-EVIDENCE-BASED JUSTIFICATION
4.1 Furnace
 Books

 Steven AA. Treese, P.R.P., David S.J. Jones, Handbook of Petroleum Processing 2ed. 2015.
981.
 Nelson, W.L., Petroleum refinery engineering. 2018: McGraw-Hill.
 Mujumdar, A., Process Heat Transfer. Drying Technology, 1996. 14(7-8): p. 1907-1908.
 Other References

 API Standards 560.STANDARD, A., Fired Heaters for General Refinery Service. 2016.

4.1 Distillation Column

 Books

 Nelson, W.L., Petroleum refinery engineering. 2018: McGraw-Hill.

 Gary, J.H., et al., Petroleum refining: technology and economics. 2007: CRC press.
 Association, G.P.S., GPSA engineering data book. Section, 2004. 20: p. 20-2.
 Lamm, M.H. and L.R. Jarboe, Chemical Engineering Separations: A Handbook for
Students. 2020, Iowa State University Digital Press.
 Himmelblau, D.M. and J.B. Riggs, Basic principles and calculations in chemical
engineering. 2012: FT press.
 Kister, H.Z., Practical distillation technology. 1983, McGraw Hill, New York.
 Fahim, M.A., T.A. Al-Sahhaf, and A. Elkilani, Fundamentals of petroleum refining. 2009:
Elsevier.
 Other References

 Hoon, C.Y., A.L. Ling, and A. Jaya. Distillation Column selection and sizing. 2011;
Available from: https://oilproduction.net/files/12-
ENGINEERING%20DESIGN%20GUIDELINES%20-%20distillation%20column%20-
%20Rev%2003%20web.pdf.

18
4.1 Control Valve
 Books
 Association, G.P.S., GPSA engineering data book. Section, 2004. 20: p. 20-2.

 Edition, F., Control Valve Handbook. 1965.

 Other References

 Bhatia, A., Control Valve Basics: Sizing and Selection. Continuing Education and
Development, Inc, 2014. 9.
 15. Control valve sizing guidelines2016 Available from:
https://enggcyclopedia.com/2016/10/control-valve-sizing-guidelines/.

5-EQUIPMENT DATASHEETS (SIZING, SKETCHES)

5.1 Furnace

Figure 4:Final sketch of Furnace

5.1.1 Furnace Technical Data Sheet

 Material of Construction (MOC) Justification

Materials of Construction (MOC) are selected based on operating temperature, chemical

compatibility, and mechanical strength requirements. For this furnace application:

 **SS316** is used for zones exposed to high temperatures and potential corrosion.

19
  **Carbon Steel (CS) with Refractory Lining** is selected for structural components
exposed to high heat but not aggressive media.
 **N/A** is used where MOC is not applicable, such as calculated values.

 Technical Data Sheet

Parameter Value Unit MOC Remarks

Feed Rate 3566.16 BPH To be confirmed Feed flowrate

Feed Specific 0.91 - To be confirmed Specific gravity

gravity
T1 232.2 °C SS316 Inlet
temperature
Cp (specific 1.800867 kJ/kg.°C N/A Of feed material
heat)
NHV (Net 53900.0 kJ/kg N/A Lower heating
Heating Value) value
Mass of fuel 3975.12 kg To be confirmed Fuel required
(mfuel)
Mass of stock 483274.4 kg To be confirmed Calculated from
(m) feed
 Design Parameters and Calculations

Parameter Value Unit MOC Remarks

n 1.0 - To be confirmed Number of rows

α 0.88 - To be confirmed Factor to

convert actual
exposed surface
to cold surface

A 158.14 m² CS with Area

refractory lining

G 22.17 - To be confirmed Air-Fuel Ratio

D 0.1 m SS316 Diameter

C 0.22 m SS316 Clearance or
spacing
L 12.0 m CS with Length
refractory lining

20
 Qcomb 214000000.0 kJ/h N/A Combustion
heat duty
Qr 96700000.0 kJ/h N/A Radiation heat
NT 132.93 - To be confirmed Number of
tubes
Acp 353.17 m² CS with Area of wall
refractory lining

αAcp 310.789 m² CS with Cold plane area

refractory lining

R (% recovery) 45.13 % N/A % Radiation

heat
T2 343.3 °C SS316 Outlet
temperature

5.2 Distillation Column

Figure 5:Final sketch of Distillation Column

21
  Data Sheet
Temperature [F]:623.56
Pressure [psia]: 65

Mass Flow [lb/hr]:1284969.84

Parameter Value Unit Source/Remarks

Column Type Tray Distillation - Assumed (e.g., Sieve Tray)

Operation Condition (OC) Atmospheric Pressure - -

Material of Construction Carbon Steel/SS304 - Dependent on service

Diameter (DCDC) 27.04 ft Calculated from area

Height (HH) 58.00 (17.68 m) ft (m) -

Tray Spacing 18.00 - 24.00 inches Typical range

Number of Trays 29 - Based on separation

Mass Velocity (w/aw/a) 2543.84 lb/ft²·hr -

Vapor Velocity (uu) 2.50 ft/s -

Downcomer Area 10-15% of Active Area ft² Typical for stability

Weir Height 2.0 - 4.0 inches Adjustable for liquid holdup

Hole Diameter (Sieve Tray) 0.25 - 0.50 inches Standard design

22
5.3 Control Valve

Figure 6:Final Sketch of Control Valve

23
  Data Sheet
Q:152.4 m3/hr
Q design:167.6 4 m3/hr

Pressure Drop: 4.75psi

Parameter Value Remarks

Model N/A Unique identifier for ordering

Type Globe Select based on piping layout

Size (DN) 3 inches Nominal pipe size

Pressure Rating PN16, ANSI 150# Max allowable pressure

Connection Type Flanged / Threaded / Welded Flanged for easy maintenance

Body: CF8M (SS316), Trim:

Material Corrosion-resistant for harsh media
SS304/SS316

Temperature
-20°C to +200°C (Standard) Extended range available
Range

Flow Coefficient
66 Higher Cv = higher flow capacity
(Cv)

Overcapacity (OC) ~20-30% (Typical) Ensures valve can handle surges

Avoid operation below 10% for

% Lift 10% to 90% (Recommended)
precise control

Rangeability 50:1 (High-performance) Suitable for wide flow variations

24
Parameter Value Remarks

Leakage Class ANSI Class IV / V Class V for tight shutoff

Flow
Equal % Equal % for better control
Characteristic

Actuator Type Pneumatic (Diaphragm) Most common for automation

Fail-Safe Action Air-to-Open / Air-to-Close Choose based on safety needs

Air Supply 3-15 psi / 0.2-1.0 bar Standard signal range

Positioner Smart Improves accuracy & response

Response Time < 2 sec (for 90% stroke) Critical for fast processes

25
References

1. Felder, R.M., R.W. Rousseau, and L.G. Bullard, Elementary principles of chemical
processes. 2020: John Wiley & Sons.
2. Steven AA. Treese, P.R.P., David S.J. Jones, Handbook of Petroleum Processing 2ed. 2015.
981.
3. Nelson, W.L., Petroleum refinery engineering. 2018: McGraw-Hill.
4. STANDARD, A., Fired Heaters for General Refinery Service. 2016.
5. Mujumdar, A., Process Heat Transfer. Drying Technology, 1996. 14(7-8): p. 1907-1908.
6. Gary, J.H., et al., Petroleum refining: technology and economics. 2007: CRC press.
7. Association, G.P.S., GPSA engineering data book. Section, 2004. 20: p. 20-2.
8. Lamm, M.H. and L.R. Jarboe, Chemical Engineering Separations: A Handbook for
Students. 2020, Iowa State University Digital Press.
9. Himmelblau, D.M. and J.B. Riggs, Basic principles and calculations in chemical
engineering. 2012: FT press.
10. Kister, H.Z., Practical distillation technology. 1983, McGraw Hill, New York.
11. Hoon, C.Y., A.L. Ling, and A. Jaya. Distillation Column selection and sizing. 2011;
Available from: https://oilproduction.net/files/12-
ENGINEERING%20DESIGN%20GUIDELINES%20-%20distillation%20column%20-
%20Rev%2003%20web.pdf.
12. Fahim, M.A., T.A. Al-Sahhaf, and A. Elkilani, Fundamentals of petroleum refining. 2009:
Elsevier.
13. Bhatia, A., Control Valve Basics: Sizing and Selection. Continuing Education and
Development, Inc, 2014. 9.
14. Edition, F., Control Valve Handbook. 1965.
15. Control valve sizing guidelines
2016
Available from: https://enggcyclopedia.com/2016/10/control-valve-sizing-guidelines/.
16. Coker, A.K., Ludwig's applied process design for chemical and petrochemical plants. Vol.
1. 2011: Elsevier.
17. Lieberman, N.P. and E.T. Lieberman, A working guide to process equipment. 2008:
McGraw-Hill New York.
18. Kerry, F.G., Industrial gas handbook: gas separation and purification. 2007: CRC press.

26