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This case study presents an example of resolving tray blockage caused by phosphates in a crude oil distillation unit (CDU) using fouling-resistant tray technology. Phosphate esters contained in high TAN crude oil and corrosion inhibitors decompose inside the tower and adhere to the openings as phosphates. This leads to the obstruction of vapor flow and results in the following issues: - Abnormal increase in differential pressure (DP) due to blockage of openings - Liquid accumulation in the LK-HK section - Deterioration of product quality such as color and flash point - Increase in tower pressure → decrease in evaporation rate → deterioration in yield - Resulting in a reduction in processing capacity To continue operations, a portion of the internal reflux was first bypassed (LKPA → HKPA) to adjust the section load. DP improved, and quality was restored. Furthermore, as a long-term measure, Koch-Glitsch's Superflux fouling-resistant trays were adopted. Key features: - Self-cleaning effect due to fixed valves - Suppression of solid retention and stable froth flow - Directional valves that reduce peripheral retention - Long-term stable operation even under severe fouling conditions Inspection after implementation showed that the phosphorus content, which was previously over 21%, was reduced to below 2%, and DP stabilized at 0.4 kg/cm². The fouling suppression effect was confirmed.

The performance of a distillation column is greatly influenced by the contact efficiency between vapor and liquid on the trays, and the valve structure is a crucial factor directly related to energy efficiency, processing capacity, and operating range. Conventional sieve holes and T-type movable valves are effective, but they have challenges such as: - Vapor tends to be biased upward - Insufficient mixing near the deck - Limitations in stability during load fluctuations The latest FLEXIPRO floating valve features a design based on CFD analysis and actual machine testing, providing the following advantages: - Suppression of liquid entrainment with downward vapor flow - Improved mass transfer efficiency through strong mixing at the deck level - Uniformization of froth through forward extrusion action - Significant reduction of weeping at low loads with an extrusion molding structure - A wide operating range (approximately twice the turn-down of T valves) As a result, it is possible to achieve up to a 35% increase in processing capacity and energy savings compared to conventional valves. In the case of a diisobutylene separator, effects such as approximately 30% reduction in equipment weight have been confirmed through tower diameter reduction, tower height reduction, and tray spacing optimization, leading to CAPEX reduction.

The FLEXIPRO valve tray is the latest generation of fixed valve tray technology developed by Koch-Glitsch, achieving improvements in capacity, separation efficiency, and operating range beyond the conventional FLEXITRAY and PROVALVE. This technology was born from an advanced development process utilizing CFD analysis, 3D CAD, and metal 3D printing, designed to meet the industry's demands for "high efficiency, low pressure drop, high reliability, and wide operating range" with a single valve. ■ Key Technical Features - Newly developed fixed valve structure: high reliability and stable performance - Side curtain + louver shape: improved efficiency through enhanced mixing - Extruded deck openings: suppression of liquid backflow/weeping - High capacity performance: up to 27% improvement compared to conventional (FRI test) - High efficiency: over 90% tray efficiency - Wide operating range (4:1): strong against load fluctuations ■ Achievements and Third-Party Evaluation The FLEXIPRO valve has been confirmed to have high performance in the U.S. FRI test, achieving a 7% capacity improvement compared to the conventional PROVALVE (calculated at the same pitch).

This product is a solution composed of high-performance internal devices (Proflux Severe Service Grid, high-performance Structured Packing, Enhanced Vapor Horn) developed to achieve high reliability, low pressure loss, and high processing capacity in "Severe Service" applications such as heavy oil processing and vacuum distillation towers. The wash bed and flash zone of the vacuum distillation tower operate under harsh conditions with high temperatures (700–760°F), high fouling, and significant coking risks, making cleaning performance, de-entrainment performance, and fouling resistance extremely important. This solution achieves a 10% increase in processing capacity, a significant reduction in pressure loss, and improvement in HVGO quality that cannot be obtained through conventional equipment "like-for-like replacement (RIK)," and significant operational benefits have been confirmed at the Canada CCRL refinery.