CLEAN FUELS SPECIALREPORT
Designing atmospheric crude
distillation for bitumen service
Oil sands add complexity to separation units and require a new approach
M. GRANDE and M. GUTSCHER, Fluor Canada Ltd., Calgary, Alberta, Canada
B
itumen blends derived from the Alberta oil sands are becom-
ing a significant feedstock for North American refiners. In
2009, Canada produced about 1.5 million bpd of raw bitu-
men with about 0.46 million bpd of bitumen blends exported to
the US.1,2 This export figure becomes even larger when consider-
ing bitumen blends that are commingled with conventional heavy
oil and are, therefore, classified as conventional heavy oil, such as
Western Canadian Select (WCS). The steep production decline
from Mexico’s Cantarell field and Venezuela’s recent shift toward
non-US markets, such as China, could make securing supplies
from Canada more attractive.3 Many US refineries in the Gulf
Coast area are already configured to process heavy oil and a pipe-
line network is already established to transport oil sands produc-
tion to refineries located within Canada as well as in the US West,
Midwest and Gulf Coast areas.1 Additional pipeline capacity has
been recently completed to the US Midwest with additional pro-
posals for other areas, including the Gulf Coast, indicating that
more refiners will have access to feedstocks containing bitumen.
BACKGROUND
Bitumen from the Alberta oil sands has an extremely high
viscosity (typically approaching 1 x 106 cSt at 15°C) and a high
asphaltene content approaching 20 wt% C5 insoluble. Conse-
quently, transportation of bitumen is accomplished by forming
blends with a diluent comprised of gas condensates or naphtha
(C5+) that is termed dilbit, with synthetic crude oils termed syn-
bit, or a combination thereof referred to as syndilbit. The blend-
ing ratio for dilbit is typically about 70:30 bitumen to diluent by
volume; whereas for synbit, the blending ratio is typically 50:50.
These blending ratios are based on meeting pipeline specifications
of 18°API and 350 cSt. Bitumen from the Alberta oil sands is
similar in gravity but typically much more viscous than the “extra
heavy oil” produced from Venezuela’s Orinoco Belt.
Challenges with bitumen. Some other challenging proper-
ties of bitumen from the Alberta oil sands include:
• Higher fouling tendencies and a lower thermal stability than
other higher hydrogen-content crudes due to a high aromatic con-
tent, particularly asphaltenes
• Large atmospheric residue (AR defined as 343+°C TBP) con-
tent of approximately 85 vol%
• High total acid number (TAN) value of approximately 2.5 to 3.5
mg KOH/g, a high sulfur content of approximately 4.5 wt% to 5 wt%,
and a high nitrogen content of approximately 0.3 wt% to 0.55 wt%
• Increased salt hydrolysis in the fired heater as desalting a
dilbit feed has not been proven commercially reliable.
Processing issues. Processing bitumen blends, particularly
dilbit containing Athabasca bitumen from the Alberta oil sands
that is the focus of this discussion, requires specific considerations
that impact the design of a crude unit within an upgrader or the
revamp of such a unit within an existing refinery. Revamp consid-
erations may include existing crude units that will process various
bitumen blends with other conventional feedstocks. In the case of
an upgrader, this unit is often referred to as the diluent recovery
unit (DRU) because the recovered naphtha/gas condensate is
recycled as transportation diluent. Refiners processing dilbit or
other feeds may also sell a portion of the recovered naphtha/con-
densate as transportation diluent as opposed to further refining
this material for the gasoline pool or as a petrochemical feedstock.
Due to a shortage of diluent in Alberta in 2009, more than 60,000
bpd of diluent was returned to Alberta by rail from the US.1 The
completion of the Enbridge Southern Lights diluent pipeline will
provide the capacity to deliver 180,000 bpd of diluent to Alberta
from the US Midwest. Furthermore, with the use of the Capline
pipeline, diluent from the US Gulf Coast area will be able to con-
nect with the new Enbridge pipeline via the Chicap pipeline.1
DRU COLUMN DESIGN
The main objectives of a DRU column are to recover transpor-
tation diluent remaining in the column feed (after preflash) and to
fractionate distillates, such as atmospheric gasoil (AGO), from the
bitumen feed that can be processed directly in a hydroprocessing
unit. To achieve these objectives, a typical column configuration, as
shown in Fig. 1, consists of a diluent rectification section, an AGO
pumparound section, an AGO product-side stripper, an AGO
wash section and an atmospheric residue (AR) stripping section.
Naphtha rectification section. The degree of fractionation
required between the recovered naphtha in the DRU column
overhead and the AGO product is dependent on whether the
recovered naphtha will be further refined or will be returned as
transportation diluent. If the recovered naphtha is further frac-
tionated and refined, the downstream naphtha processing units
will determine the naphtha endpoint and the sharpness of frac-
tionation required. When the recovered naphtha is returned for
transportation purposes, the degree of fractionation between the
recovered naphtha and the AGO product is typically determined
HYDROCARBON PROCESSING FEBRUARY 2011
I 63
 CLEAN FUELS
HERMETICALLY SEALED
SUBMERSIBLE PUMPS
based on the percentage of diluent recovery desired while main-
taining a total recovered diluent composition that is essentially the
Not the length is important … same as the originating feed diluent, i.e., provide sufficient frac-
tionation gap between the diluent and the AGO products. As the
…but the technique initial boiling point of bitumen typically resides in the kerosine
boiling range, providing this fractionation gap is easily achievable
■ Abstain based on the typical boiling range of transportation diluent.
from drive shafts being long and susceptible to troubles If the naphtha is recycled for use as transportation diluent, the
■ Spare recovered naphtha from the DRU column overhead, together
needless shaft and guide bearings
with that of the preflash section, is typically routed to a reboiled
stripper to remove hydrogen sulfide (H2S) and other light mate-
■ Forget rials. The level of H2S stripping is dependent on the amount of
complex and cost-intensive seal technology cracked H2S formed in the fired heater and is a function of the
feed sulfur content and film temperatures reached in the fired
■ Require
heater. Significant diluent losses to the overhead of a stripper may
best available technology for a long service life be incurred if a stringent vapor pressure specification also applies.
and high availability For these cases, the recovered naphtha may be processed through
a refluxed column (i.e., a debutanizer) that will also achieve the
required H2S specification. The rectification section of a refluxed
column ensures that a high diluent recovery is maintained.

AGO PA and product stripping. The AGO pumparound

(PA) section removes a significant portion of cooling duty lower
in the column to help condense the AGO product and the AGO
wash oil sent to the wash section. The heat removed in the AGO

Preflash vapor
Offgas

Recoverd
Sour water naphtha
if 2 or 20 meters – we are flexible

support and Stripping

steam AGO product
cable pipe
Stripping
steam
pressure / AR product
discharge line Column feed
from fired heater

FIG. 1 Typical DRU column configuration.

extremely short
drive shaft 20 120

15 114
Fired heater COT, COTMax +/- °C

10 108
Diameter DBase, %

COT
5 102

0 96

-5 90
Diameter
-10 84

-15 78
25 35 45 55 65 75 85
Diluent preflash diluent feed, %
HERMETIC-Pumpen GmbH ™ P.O. Box 1220 ™ D-79191 Gundelfingen
info.hp@lederle-hermetic.com ™ www.lederle-hermetic.com FIG. 2 Impact of diluent preflash on fired-heater COT and column
diameter.

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64
 CLEAN FUELS SPECIALREPORT

PA section reduces the vapor traffic and the resulting required
column diameter of the diluent rectification section while pro-
viding higher heat recovery than that available from the col-
umn overhead. The AGO withdrawn from the DRU column is
steam stripped in a product side stripper for flash point reduction.
The TAN content of the AGO material is typically about 2 mg
KOH/g. This TAN content requires upgraded metallurgy for this
column section, as well as for the hot portions of the AGO PA
and product circuits.
AGO wash section. The degree of fractionation required
between AGO and AR products is based on the desired distillate
yield and endpoint specification (ASTM 95% temperature). The
yield of AGO and its associated endpoint is determined by the
level of distillate hydrotreating required to meet distillate product
specifications while minimizing AGO material in the AR product.
The objectives of the wash zone are to minimize AGO product
endpoint by rectifying the flash zone vapor, and to de-entrain AR
in the flash zone vapor. Minimizing the endpoint for a desired
yield will improve the quality of the AGO product that is fed to a
hydroprocessing unit. The wash section also minimizes the amount
of solids/ultra fines, which can be particularly troublesome with
mined bitumen feedstocks, from entering the AGO product draw.
The selected wash-oil rate and design of wash section internals
is important to ensure that the listed objectives are achieved.
The wash-oil rate should be based on the governing require-
ment between the required rectification for the AGO endpoint
specification and the required overflash for de-entrainment of AR/
solids. Overflash is defined as the true reflux, excluding entrained
liquid that exits the wash section. Good fractionation between
the AGO and AR products is best achieved with a combination
of a low specific surface area (grid) type packing that is placed as a
bottom layer followed by a higher specific surface area (structured)
type packing as a top layer. The resulting combination improves
the de-entrainment and fractionation ability while maintaining a
reasonable packed-bed height and minimizing fouling. The larger
open area (relative to trays) also allows packing to better handle
a sudden increase in vapor rate, such as an upset that can occur if
a liquid water slug is carried over in the feed to the fired heater.
Bottoms stripping. Bottoms stripping improves the frac-
tionation between AGO and AR products and allows for decreas-
ing the fired-heater coil outlet temperature (COT) or increasing
the preflash for a fixed AGO yield. Trays are best suited to achieve
multiple stages of fractionation in this section.
The bottoms stripping section requires a smaller diameter rela-
tive to the upper sections based on the steam and stripped hydro-
carbon vapor loading. However, to minimize column height, using
a full-diameter sump is more practical for providing the required
AR product residence time. An internal cylinder may be utilized
with multi-pass trays (preferably two-pass) that minimize liquid
stagnant zones with suitable active and fractional hole areas that
will minimize fouling and maximize tray efficiency.
PREFLASH TARGET CONSIDERATIONS
Due to the large amount of transportation diluent in the dilbit
feed, a preflash system is often applied. The preflash removes a
substantial portion of this diluent to lower the flow through the
remaining preheat circuit and the fired heater, as well as to reduce
the DRU column diameter.
The main process parameters involved in achieving distillate
lift are diluent slip (diluent that is remaining in the column feed),
stripping steam and fired-heater duty at the permissible COT.
Diluent slip and stripping steam assist in stripping distillate mate-
rial in the bitumen feed that allows for a lower fired-heater COT or
an incremental gain in AGO yield. The fired-heater COT required
for reliable operation in bitumen service is typically lower than that
encountered when processing light conventional crudes.
Consequently, optimizing the preflash target requires assessing
the impact that the diluent slip and stripping steam rate have on the
fired-heater COT and column diameter. This assessment should
also include the costs associated with producing the steam required
and treating the resulting sour water produced. These concepts in
optimizing the preflash section can also be applied to the revamp
of an existing crude distillation unit (CDU) to unload the upper
portions of the column and column-overhead system. These areas
may become bottlenecks due to the high naphtha content of dilbit
feeds even with preflash processing schemes.
Column diameter assessment. The impact that the
diluent preflash has on the DRU column diameter and fired-
heater COT is illustrated in Fig. 2 This figure is based on the
column configuration discussed earlier with a fixed stripping
steam rate as well as a fixed AGO yield and endpoint specification.
Fig. 2 illustrates that the fired-heater COT is reduced as
diluent preflash decreases at a fixed stripping steam rate. However,

20 120 3.6 120

Steam rate
15 114 3.3 114
Fired heater COT, COTMax +/- °C

Stripping steam rate, wt% AR

10 108 3.0 108

Diameter, % DBase
Diameter DBase, %

Diameter
5 102 2.7 102

0 96 2.4 96

-5 90 2.1 90
COT
-10 84 1.8 Diameter 84

-15 78 1.5 78
1.25 1.75 2.25 2.75 3.25 3.75 4.25 25 35 45 55 65 75 85
Stripping steam rate, % AR Diluent preflash, % diluent feed

FIG. 3 Impact of stripping steam rate on fired-heater COT and FIG. 4 Impact of diluent preflash and stripping steam on column
column diameter. diameter.

HYDROCARBON PROCESSING FEBRUARY 2011

I 65
SPECIALREPORT CLEAN FUELS
this reduction is obtained at the expense of significantly increasing
the column diameter due to the additional diluent feed (vapor
traffic) to the column.
The higher (and lighter) content of diluent in the column feed
provides marginal incremental lift with single-stage separation
that occurs in the flash zone. This single-stage separation, coupled
with the resulting relative volatility of the diluent mixture, does
not effectively reduce the required fired-heater COT when the
resulting impact on column diameter is considered. Consequently,
fired-heater designs that allow for an incrementally higher COT
while maintaining suitable film temperatures and residence times
will significantly reduce the required column diameter due to the
allowable diluent reduction in the column feed.
Achieving this incrementally higher COT may also have a sig-
nificant impact when considering the revamp of an existing CDU.
Any modifications to the fired heater that will achieve a higher
COT will allow for a higher preflash (practicality needs to be deter-
mined on a case-by-case basis). This higher preflash will unload the
upper portions of the column and column-overhead system that
may result in a higher dilbit feed throughput to the existing unit.
The impact that the stripping steam rate has on column diame-
ter and fired-heater COT is illustrated in Fig. 3. This figure is based
on the column configuration discussed earlier with a fixed-column
feed diluent content as well as a fixed AGO yield and endpoint
specification. Fig. 3 illustrates that the fired-heater COT is signifi-
cantly reduced as the stripping steam rate increases. Furthermore,
the corresponding column diameter increase is not as significant
as that required to achieve the same effect by increasing the diluent
content in the column feed (see Fig. 2). The stripping steam pro-
vides more incremental lift due to its higher relative volatility and
multiple stages of fractionation provided in the stripping section.
Another advantage that the stripping section stages provide
is sharper fractionation between the AGO and AR products.
Consequently, the combined vapors from the stripping and flash
sections require less rectification in the wash section. If the wash-
oil rate is dictated by the AGO endpoint (i.e., the rectification
requirement discussed earlier), the required wash-oil rate will
decrease. This decrease will further lower the required fired-heater
COT because less bitumen material needs to be lifted to supply
the required wash-oil rate.
The disadvantage of significantly increasing the stripping
steam rate is the increased operating costs associated with supply-
ing steam and treating the additional produced sour water. Fur-
thermore, the water dew point of the column overhead increases
and needs to be addressed in the design of the overhead system.
With the fired-heater COT set to the constraint established,
the required column diameter vs. diluent preflash and stripping
steam rate may be determined. Fig. 4 illustrates this relationship.
Single-stage preflash system Two-stage preflash system
Preflash vapor
Dilbit Column Dilbit
feed feed feed
FIG. 5 Preflash configurations.
66
I FEBRUARY 2011 HydrocarbonProcessing.com
This figure is based on the column configuration discussed earlier
with a fixed AGO yield and end-point specification.
Fig. 4, as expected from Figs. 2 and 3, illustrates that column
diameter is reduced when diluent preflash is maximized. This
trend is observed up to a preflash value of approximately 80%.
At this high level of preflash, limitations of the overhead system
to maintain column reflux and a margin above water dew point
become a concern. For a two-stage condensing configuration (as
shown in Fig. 1), as the amount of preflash increases, the hydrocar-
bon flowrate at the column overhead decreases and the steam rate
increases. This combined effect significantly increases the steam
partial pressure, which reduces the amount of condensable material
available for column reflux at a fixed condensing temperature. At
a diluent preflash of about 80%, the net overhead liquid product
available from the reflux drum is fully consumed by the reflux
requirement. To increase preflash beyond 80%, the reflux tempera-
ture must be reduced and/or AGO PA duty must be shifted to the
overhead system. Reducing the reflux temperature is not desirable
as this quickly eliminates any margin between the reflux tempera-
ture and the water dew point temperature of the column overhead.
This reduced reflux temperature may lead to water condensing in
the first-stage overhead drum. Shifting the PA duty to the overhead
condenser increases the vapor traffic in the naphtha-rectification
section, which will increase the required column diameter, revers-
ing the trend of increasing preflash. Furthermore, shifting the PA
duty reduces the amount of high-level heat that can be recovered
from the column through heat integration.
PREFLASH TARGET OPTIMIZATION
Considering the impact that preflash has on the DRU column
diameter, the overall preflash target can be optimized with the
remaining unit capital and operating costs. This optimization
should consider the cost of steam required for stripping, the
operating cost to treat the resulting produced sour water and any
environmental issues/limitations in water usage.
The preflash target will also have implications on the heat-inte-
gration scheme. As the diluent preflash is increased, the preheat
temperature required for preflash can increase significantly. For
the example utilized in the earlier figures, the preheat temperature
required for a total diluent preflash of 55% is 185°C and increases
to 235°C for a total diluent preflash of 80%. These temperatures
are at the second stage of a two-stage preflash drum configuration.
The preheat temperature(s) required to achieve the desired pre-
flash can have a significant impact on the heat-recovery arrange-
ment and on the utility heat and/or fired heater duty. Therefore,
the resulting heat integration scheme, including the cost benefits
of using utility heat and the desired flexibility in preheat/preflash
control, should be considered.
Preflash configuration. The preflash
target may be achieved with either a single-
Preflash vapor
or multiple-stage preflash configuration, as
illustrated in Fig. 5. A preflash column is
Column not generally required due to the significant
feed volatility gap between the portion of trans-
portation diluent preflashed and the bitu-
men. Preflash drum(s) will provide adequate
separation within the range of preflash levels
presented in the earlier examples without
impacting the desired fractionation between
the diluent and the AGO products.
 CLEAN FUELS SPECIALREPORT

To minimize fouling and provide reliable parallel flow control
for multiple heat-exchanger services and fired heater, single liquid
phase dilbit preheat is desired. Single-phase dilbit preheat should
be maintained through to the inlet of the preflash flow control
valve(s) and the inlet of the fired-heater pass control valves. To
suppress vaporization at the required preheat temperatures, an
adequate pump head must be supplied with the dilbit control
valve(s) placed at the back (i.e., hot) end of the preheat circuit(s),
immediately upstream of each stage of preflash.
Design. Dilbit feeds contain water and light-diluent compo-
nents that significantly increase the feed vapor pressure (par-
ticularly water). To achieve higher levels of preflash, the required
preheat temperatures increase, resulting in very large increases in
the feed vapor pressure. An advantage of the two-stage configu-
ration is that the desired total preflash can be controlled at the
second stage, allowing the first-stage preheat temperature to be
single-stage system. These reductions are achieved at the expense
of adding a second-stage flash drum and pump. The intent is to
reduce cost with the reduction in heat-exchanger design pressures
and piping flange ratings permitted by a two-stage configuration.
Fig. 6 illustrates the reductions in vapor pressure achievable
with a two-stage system by plotting the resulting vapor pressure
vs. the desired preflash with a single- and a two-stage flash-drum
configuration. For the two-stage configuration, the first-stage flash
is maintained constant with the objective of only removing all free
water resulting in a first-stage preflash of approximately 27%. To
achieve the total desired preflash, any additional diluent flash is
generated with the second stage.
4,000
Single stage
3,500
3,000

Vapor pressure, kPaA

selected independently of the total desired preflash. The preheat 2,500
temperature for the first stage can be selected with the objective
2,000
of only removing all of the free water normally present in the feed,
thereby minimizing the vapor pressure of the first stage. 1,500 Second stage
Minimizing this vapor pressure will minimize the result- 1,000
ing operating pressure required to suppress vaporization in the First stage
first-stage preheat circuit. The desired total preflash is then fully 500
accomplished in the second stage at a comparably lower vapor 0
pressure than that required with a single-stage configuration. 25 35 45 55 65 75 85
Diluent preflash, % diluent feed
Consequently, the head requirement of the preflash feed pumps
as well as the design pressures of downstream exchangers/piping FIG. 6 Effect of diluent preflash on vapor pressure.
in both stages for a two-stage system are reduced compared to a

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67
SPECIALREPORT CLEAN FUELS
Fig. 6 illustrates that the resulting exchanger design pressures,
piping flange ratings and combined pump-head requirements for
the single-stage preflash configuration become much greater than
for the two-stage configuration as the diluent preflash increases.
Consequently, a two-stage configuration may become more
appealing for higher levels of diluent preflash. For integrated mine-
upgrader facilities, where higher unit feed dilbit ratios are encoun-
tered, it may be desirable to achieve a much higher diluent preflash
to maintain a similar optimum diluent slip to the DRU column as
in a segregated upgrader/refinery facility. Therefore, a multi-stage
configuration is even more appealing for integrated mine-upgrader
facilities than for a stand-alone refinery or upgrader.
Free water issues. Free water that is not removed from a
diluted bitumen feed may cause significant damage to the fired
heater and/or to the DRU column due to the heater’s ability to
rapidly vaporize the free water. At the very least, if water is unex-
pectedly present at the heater inlet control valves, it will likely form
steam, thus creating two-phase flow and control difficulties with
the heater pass control valves. Consequently, a two-stage preflash
configuration that removes all feed water in the first-stage flash
offers an additional benefit. With this design, should a slug of feed
water enter the unit, the second-stage flash will reduce the risk of
free water breaking through to the final preheat circuit upstream
of the fired heater. However, both single- and two-stage preflash
configurations that are designed for a high level of diluent preflash
(i.e., hotter preflash temperatures) will operate with a margin above
the expected water dew point and will consequently provide some
flexibility in removing a higher than expected feed-water content.
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A higher than expected feed-water content will affect the per-
formance of the preflash section and column overhead system
for both preflash configurations. A higher feed-water content
will alter the preflash temperatures and may affect the amount
of diluent preflashed. The additional steam entering the column
overhead system from the preflash section may increase the over-
head system pressure, increase the offgas rate (resulting in lower
diluent recovery and possible venting to the flare) and signifi-
cantly increase sour-water production that could accumulate in
the overhead drum. These consequences for the preflash section
and column overhead system should be evaluated to determine
if design adjustments to minimize these impacts are warranted.
DRU COLUMN OVERHEAD SYSTEM DESIGN
The objectives of the overhead system are to condense the
DRU column overhead and preflash overheads; supply column
reflux; and separate water and any noncondensable gases present
due to cracking reactions (thermal decomposition) in the fired
heater. Design of the overhead system should mitigate corrosion
to maximize equipment service life while providing an operation-
ally reliable design. HP
Extended version avaiable online at HydrocarbonProcessing.com.
Marco Grande is a principal process engineer with Fluor Canada Ltd., Calgary,
Alberta, Canada. His experience is in bitumen/heavy-oil upgrading and downstream
refining. He holds a BSc degree in chemical engineering from the University of Alberta.
Matthew Gutscher is an engineer in training (EIT) in the process engineering
group with Fluor Canada Ltd., Calgary, Alberta, Canada. He has a BSc degree in
chemical engineering from the University of Alberta.
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