OPTIMIZATIO OF DISTILLATIO COLUM
USIG GRAD COMPOSITE CURVES I
ASPE PLUS
SUBMITTED BY
PHANI BHUSHAN C.S.
MURTHY J.S.
VENKATA SM JOSYULA
Under the Esteemed guidance of
Dr.B.Srinivas
Head of the Department
Department of Chemical Engineering
Gayatri Vidya Parishad College of Engineering
(Affiliated to Jawaharlal Nehru Technological University, Kakinada , A.P.)
Madhurawada, Visakhapatnam-530 041.
1
IDEX
Sl # Chapter Page o
1 ITRODUCTIO 4
2 COLOUM GRAD COMPOSITE CURVES(CGCC) 6
3 CASE STUDY 12
4 COCLUSIO 25
5 REFERECES 26
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ABSTRACT
This project relates to the design of distillation column. In particular, it relates
to the optimization of a base case design. Column optimization involves options
such as different reflux ratios, side condensing/ reboiling and feed
preheating/cooling. We need to establish heat loads and temperature levels for
such modifications and identify the heat combined options. This project
presents a methodology based on a combination of thermodynamics and
practical aspects of column modification. The methodology gives the Engineer
targets for design options ahead of design. In addition it provides targets for the
best combination of options. The methodology is applicable to non-ideal multi
component systems and complex distillation configurations. The design of
stand-alone distillation columns demands the determination of the minimum
energy requirement for the separations. Moreover, different feed thermal
conditions should be considered to optimize the energy consumption. We use
CGCC for the optimization of the distillation column using Aspen Plus
simulator.
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1. ITRODUCTIO
Optimization is the act of obtaining best result under any given circumstances.
It is defined as the process of finding the conditions that give the maximum or
minimum value of a function. The ultimate goal of optimization is to minimize
the effort required or to maximize the desired benefit. Optimization of a
distillation column is to determine the optimal operating conditions for an
existing column to achieve specific performance at minimum energy usage
given the feed.
Distillation is a method of separating the components of a solution which
depends upon the distribution of the substances between a gas and a liquid
phase, applied to cases where all components are present in both phases. In
distillation mass transfer occurs in both directions, simultaneously, with the
more volatile component vaporizing and passing from liquid to the vapour
phase and the less volatile component condensing. The vapour phase is created
by supplying heat as separating agent. Separation is achieved because of the
difference in the vapour pressure of the components at a given temperature. The
feed is introduced more or less centrally into a vertical cascade of stages.
Vapour rising in the section above the feed is washed with liquid to remove or
absorb the less volatile component. This section is called enriching or rectifying
section. The washing liquid in this section is provided by condensing the vapour
issuing from the top, which is rich in more volatile component. The liquid
returned to the top of the tower is called reflux and the material permanently
removed is the distillate, which maybe a vapour or a liquid rich in more volatile
component. In the section below the feed the liquid is stripped off volatile
component by vapour produced at the bottom by partial vaporization of the
bottom liquid in the reboiler. This section is called the stripping or exhausting
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section. The liquid removed, rich in less volatile component is the residue or the
bottoms.
Distillation is one of the most important and energy-intensive, but energy-
inefficient unit operations in the process industry. It accounts for three
percentage of total energy consumption in a country like U.S.A. This study aims
at optimizing the energy consumption of distillation process using a systematic
and reliable energy targeting procedure useful for the energy analysis developed
by Dhole and Linnhoff. Starting from a converged simulation of a distillation
process, called base case design graphical techniques are used to predict the
energy requirements and behaviour for variations in different parameters.
Techniques based on the thermodynamic analysis of a distillation column are
extremely important for developing energy targeting tools. Through a critical
review of different energy optimisation techniques available in the literature, the
temperature-enthalpy (T-H) diagram of a distillation column is identified as the
key representation for energy analysis. The column grand composite curve or
CGCC (also a T-H diagram of a distillation column) may be determined by the
net enthalpy deficit at each stage by generating envelopes from either the
condenser end (top-down approach) or the reboiler end (bottom-up approach).
The CGCC developed using ASPEN PLUS simulator is used for energy
targeting of a distillation column.
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2. COLUM GRAD COMPOSITE CURVES (CGCC)
Thermal analysis is used in identifying design targets for improvements in
energy consumption and efficiency. This analysis is based on the concept of
minimum thermodynamic condition for a distillation column. The minimum
thermodynamic condition pertains to thermodynamically reversible column
operation. In this condition, a distillation column would operate at minimum
reflux, with an infinite number of stages, and with heaters and coolers placed at
each stage with appropriate heat loads for the operating and equilibrium lines to
coincide. In other words, the reboiling and condensing loads are distributed over
the temperature range of operation of the column. The stage-enthalpy (Stage-H)
or temperature-enthalpy (T-H) profiles for such a column therefore represent the
theoretical minimum heating and cooling requirements in the temperature range
of separation. These profiles are called the Column Grand Composite Curves
(CGCCs).
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The Aspen Plus Column Targeting tool generates the CGCCs based on the
Practical Near-Minimum Thermodynamic Condition (PNMTC) approximation
(Dhole and Linnhoff). The enthalpies used in plotting the CGCCs are calculated
at a given stage of the column by assuming that the equilibrium and operating
lines coincide at this stage. This PNMTC approximation takes into account the
losses or inefficiencies introduced through practicalities of column design,
while preserving the meaning of the CGCC. The equations for equilibrium and
operating lines are solved simultaneously at each stage for designated light key
and heavy key components. The Aspen Plus Column Targeting tool has a built-
in capability to select light key and heavy key components for each stage of the
column.
The CGCCs are helpful in identifying the targets for potential column
modifications. These modifications include:
1. Feed location
2. Reflux ratio modifications
3. Feed conditioning (heating or cooling)
4. Side condensing or reboiling
2.1 GEERATIG CGCC
CGCC is constructed from an already converged simulation based on
Practical Near-Minimum Thermodynamic Condition (PNMTC). The
outputs from simulations provide molar flows and compositions on a
stage by stage basis. Let us consider a light and heavy key model. By
key components we mean the two main separating components in the
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feed mixture whose separation is specified. The more volatile of these
components is the light key and the less volatile is the heavy key. As a
close approximation to PNMTC, we simultaneously solve the
equilibrium and the operating line equations for the key components.
For equilibrium compositions we use the stage by stage compositions
as provided by the simulator output (asterisked). The compositions of
liquid and vapor streams emerging from the same stage are the
equilibrium compositions at the stage temperature. Thus in order to
solve the equilibrium line and the operating line equations
simultaneously, we need to incorporate the equilibrium compositions
of the vapor and liquid streams emerging from the same stage into our
mass balance equations i.e.,
GminY*L - LminX*L= DL
GminY*H - LminX*H = DH
These equations establish the minimum vapor flow (Gmin) and the liquid flow
(Lmin) at the stage temperature. In order to obtain the T-H representation for
PNMTC we need to express the minimum vapor and liquid flows in terms of
enthalpies which are usually provided by the simulation outputs. The enthalpies
of equilibrium vapor and liquid streams are termed here as H*G and H*L
respectively. The enthalpies for the minimum vapour and liquid flows from the
molar flows
HGmin = H*G(Gmin/G*)
HLmin = H*L(Lmin /L*)
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Where G* and L* represent the molar flows of the equilibrium vapor and liquid
streams. After calculating HGmin and HLmin , we setup enthalpy balances at each
of this stage temperatures and evaluate the net enthalpy deficit ( Hdef) at each of
these temperatures. Thus for an envelop before the feed stage we obtain
Hdef= HLmin - HGmin + HD
And for an envelope at and after the feed stage we obtain
Hdef= HLmin - HGmin + (HD - HFeed )
The following figure demonstrates how the individual enthalpy deficits are
cascaded to construct the CGCC. The values of the stage temperatures and the
corresponding heat deficits are plotted in the T-H dimensions as shown below.
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2.2 USE OF CGCC
The CGCC is readily used for targeting for different possible column
modifications. A horizontal distance between the CGCC pinch point and the
vertical axis represents the scope for reduction in reflux ratio. The CGCC pinch
point indicates the minimum reflux condition for the column. As we reduce the
reflux ratio, the CGCC will move towards the vertical axis, thus reducing the
reboiler as well as the condenser load. The next modification to consider is feed
conditioning. Inappropriate feed condition usually causes a sharp enthalpy
change in the profile near the feed location. For example, a feed which is
excessively sub-cooled, causes sudden quenching. This will result in a sharp
enthalpy change on the reboiler side. Such a sharp enthalpy change is
particularly easy to see in the stage-enthalpy representation. The extent of sharp
enthalpy change on the reboiler side determines the approximate heat load for
feed preheating. Analogous arguments apply for feed cooling. Successful feed
preheating and cooling will reduce the reboiler and condenser loads
respectively. After feed conditioning we consider side condensing / reboiling.
Feed conditioning always offers a more moderate temperature level than side
condensing or reboiling. Also feed conditioning is external to the column unlike
side condensing or reboiling. Thus the sequence for considering different
column modifications is recommended as follows:
1. Reflux ratio modifications
2. Feed conditioning (heating or cooling)
3. Side condensing or reboiling
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While setting the targets for the above mentioned modifications it is assumed
that the feed stage location for the column has been appropriately chosen
beforehand. Inappropriate feed positioning could cause sharp enthalpy changes
in the CGCC similar to feed preheating and cooling. Therefore, appropriate feed
stage location should be identified before targeting for any column
modification.
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3. CASE STUDY
Separation of hydrocarbons from multi component feed:
The following are the specifications for the problem
PROPERTIES FEED TOP BOTTOM
PRODUCT PRODUCT
MOLAR 1000 398 602
FLOW(molhr-1 )
PRESSURE(kPa) 200 200 200
TEMPERATURE(C) 100 140.3 203.8
VAPOUR 0 1 0
FRACTION
Mole Fractions
Component Feed Top Bottom
n-Heptane 0.2 0.503 0.000003
n-Octane 0.2 0.487 0.01
n-nonane 0.2 0.01 0.326
n-decane 0.2 0.000038 0.332
n-C15 0.2 0 0.332
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3.1 BASE CASE
The following is the flowsheet for the process
The Process flow sheet is drawn as shown above in ASPEN PLUS simulator.
Appropriate Material streams are connected to the distillation column.
Appropriate inputs are given to the Simulator.
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The following is the feed specifications for the base case column:
The following is the column specifications:
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The feed location is on plate 9 as shown below:
The CGCC looks like:
Design 1
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3.2 REFLUX MODIFICATIOS
The horizontal gap between the T-H CGCC pinch point and the ordinate
represents the scope for reduction in heat duties through reduction in reflux
ratio. As the reflux ratio is reduced (while increasing the number of stages to
preserve the separation), the CGCC will move towards the ordinate, thus
reducing both the condenser and reboiler loads. The T-H CGCC for Design 2 of
our distillation column is shown in the following figure. This figure also
identifies the scope for reduction in condenser and reboiler duties by reducing
the reflux ratio.
The CGCC looks like:
Design 2
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Comparision between the results obtained for Design 1 and Design2 are shown
below
Parameter Design 1 Design 2
No. of stages 18 30
Reflux ratio 3.27 0.75
Feed location 9 16
Feed temperature 100 100
Condenser duty -40.98 -9.7
Condenser temperatur 140.84 143.25
Reboiler duty 83.3 51.78
Reboiler temperature(C) 207.56 205.7
Side condenser duty NA NA
Side condenser temperatu NA NA
Side reboiler duty NA NA
Side reboiler temperature(C) NA NA
*Heat duties are expressed in MMBtu/hr
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3.3 FEED PRECODITIOIG
Scope for adjustment of feed quality can be identified from sharp enthalpy
changes on the Stage-H or T-H CGCC. A feed that is excessively sub-cooled
will show a sharp enthalpy change on the reboiler side of the CGCC. The extent
of this change determines the approximate feed heating duty required. Similar
arguments also apply for feed cooling. Changes in the heat duty of feed pre-
heaters or pre-coolers will lead to similar duty changes in the column reboiler or
condeser loads, respectively. The Stage-H CGCC for Design 3 of our
distillation column is shown in the following figure. The enthalpy change on the
reboiler side is noticeably sharper. Therefore, our design can benefit from
addition of a feed pre-heater.
Design 3
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Comparision between the results obtained for Design 2 and Design 3 are shown
below
Parameter Design 2 Design 3
No. of stages 30 30
Reflux ratio 0.75 0.75
16 16
Feed location
Feed temperature 100 160
Condenser duty -9.7 -9.99
Condenser temperatur 143.25 145.84
Reboiler duty 51.78 31.37
Reboiler temperature(C) 205.7 203.7
Side condenser duty NA NA
Side condenser temperatu NA NA
Side reboiler duty NA NA
Side reboiler temperature(C) NA NA
*Heat duties are expressed in MMBtu/hr
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3.4 SIDE REBOILER
Feed conditioning is normally preferred to side condensing or side reboiling, as
such modifications are external to the column and potentially at a more
convenient temperature level. The scope for side condensing or side reboiling
can be identified from the area beneath or above the CGCC pinch point (area
between the ideal and actual enthalpy profiles). If a significant area exists, say
below the pinch, a side-condenser can be placed at an appropriate temperature
level. This allows heat removal from the column using a cheaper cold utility. A
similar converse argument applies to scope for placing a side reboiler.
Design 4
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Comparision between the results obtained for Design 3 and Design 4 are shown
below
Parameter Design 3 Design 4
No. of stages 30 30
Reflux ratio 0.75 0.75
Feed location 16 16
Feed temperature 160 160
Condenser duty -9.99 -10.02
Condenser temperatur 145.84 146.06
Reboiler duty 31.37 17.37
Reboiler temperature(C) 203.7 203.52
Side condenser duty NA NA
Side condenser temperatu NA NA
Side reboiler duty NA 14
Side reboiler temperature(C) NA 185.66
*Heat duties are expressed in MMBtu/hr
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3.5 COMPARISIO BETWEE VARIOUS DESIGS
Parameter Design 1 Design 2 Design 3 Design 4
No. of stages 18 30 30 30
Reflux ratio 3.27 0.75 0.75 0.75
Feed location 9 16 16 16
Feed temperature 100 100 160 160
Condenser duty -40.98 -9.7 -9.99 -10.02
Condenser temperatur 140.84 143.25 145.84 146.06
Reboiler duty 83.3 51.78 31.37 17.37
Reboiler temperature(C) 207.56 205.7 203.7 203.52
Side condenser duty NA NA NA NA
Side condenser temperatu NA NA NA NA
Side reboiler duty NA NA NA 14
Side reboiler temperature(C) NA NA NA 185.66
*Heat duties are expressed in MMBtu/hr
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3.6 COMPARISIO BETWEE THE CGCCs
a) BASE CASE
b) REFLUX MODIFICATIO
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c) FEED PREHEATIG
d) SIDE REBOILER
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4. COCLUSIO
Energy saving in separation systems, particularly in distillation systems, is a
research field that has attracted considerable innovative approaches. A
distillation system is an essential separation process yet it is inefficient in using
thermal energy, and may operate with adverse environmental impact as it
discharges a large amount of thermal energy into the environment.
Starting from a converged simulation we were able to develop column profiles
for column with multi components with variable relative volatilities. The
profiles identify appropriate column modifications and essentially set targets in
terms of heat loads and temperatures for the modifications.
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5. REFERECES
1. Distillation Column Targets- V.R.Dhole, B.Linnhoff
2. Thermodynamic analysis of Separation Systems- Yasar Demirel
3. Heat Network Synthesis- Uday V Shenoy
4. Pinch Analysis and Process Integration- Ian .C.Kemp
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