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Retrofit of low-temperature gas separation section of an olefin plant

Article · April 2011

DOI: 10.1109/ICMSAO.2011.5775606

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 Proceedings of Fourth International Conference on Modeling, Simulation and Applied Optimization, ICMSAO'11
Kuala Lumpur, April 2011
Retrofit of Low-Temperature Gas Separation Section of an Olefin Plant
N. Tahouni1*, N. Bagheri1, J. Towfighi2 and M. H. Panjeshahi1
1. School of Chemical Engineering, University of Tehran, Tehran, Iran
2. Department of Chemical Engineering, Tarbiat Modares University, Tehran, Iran
*ntahuni@ut.ac.ir
Abstract
Retrofit and optimization of low-temperature gas
separation processes is a challenging task owing to
complicated interactions between the core process
(separation columns), refrigeration cycles, and the
associated heat exchanger network. In this paper, the
performance of cold section of an olefin plant is
optimized. A comprehensive screening of all effective
changes using genetic algorithm suggests some retrofit
modifications. Having incorporated the best operating
column parameters along with available refrigeration
levels, a 11.3% improvement in utility cost was
achieved.
Keywords: Low-temperature distillation column, Retrofit,
Energy saving
1. Introduction
Low-temperature processes are the most important
route for the separation and purification of gas mixtures,
especially when high recoveries are necessary. The low-
temperature gas separations need refrigeration systems
to supply sub-ambient conditions. There are complex
interactions between the separation system, the process
responsible for compression/refrigeration, and heat
exchanger network.
A typical low-temperature gas separation process
is shown in Figure 1[1].
Figure 1. A typical low-temperature gas separation
process [1]
Energy saving in separation processes can be
performed by reducing the irreversibilities and
increasing the heat integration between different
separation columns.
A way for reducing irreversibilities is optimizing
the parameters such as pressure, reflux ratio, feed
condition… through the columns. The computer
simulation is the best way for having a complete
optimization, as there are complex relationships
between the parameters.
1.1 Retrofit of separation columns
Retrofit methods suggest some modifications for
existing separation columns to reduce the operation
costs by increasing the efficiency in energy utilization
[2]. Three levels of retrofit methods in column
separation systems have been reported in literature:
1. External Modifications: We have to start with this
kind of modification owing to their little capital
investment. Our strategy is improving the way of heat
integration between columns, utilities and associated
heat exchanger network (HEN). This can lead to
remove the existing inefficiencies and optimizing the
operating parameters. The external modifications do
not change the column hardware and its internals [3].
2. Internal Modifications: In this level of retrofit the
separation column and its internals are investigated to
find more complex opportunities to reduce energy
costs. All the internals or nozzles of the main column,
side strippers, pump around loops, reboilers, direct
steam … are subject to modify. However, having
reduced the modification costs, the expensive and
impractical changes are ignored [3].
3. Configurational Modifications: The most
complicated and costly alternatives are considered in
the third level. It includes of some changes in column
configuration by adding a pre-fractionator, a post-
fractionator or a pre-flash train.
In this study we only concentrate on external
modifications (parameter optimizing), which do not
change the column hardware and its internals and also
require little investment [3].
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 Proceedings of Fourth International Conference on Modeling, Simulation and Applied Optimization, ICMSAO'11
Kuala Lumpur, April 2011
1.2 Parameter optimization
There are some methods for retrofit and parameter
optimization of distillation columns, use of the column
grand composite curve (CGCC) is one of these methods.
It is based on the thermodynamic concepts and mainly
seeks the thermodynamic losses in an existing design
and operation. In this method operating curves come
closer to the equilibrium curve.
Use of the CGCC: The CGCC is readily used for
targeting of three types of column modifications. Figure
2 describes the targeting procedure [4].
1. Reflux ratio optimization: The scope for reduction
in reflux ratio can be obtained from horizontal distance
between the CGCC pinch point and the vertical axis
(Figure 2a). By reducing the reflux ratio, the CGCC
will move to the vertical axis, so reboiler and
condenser loads will reduce [4].
2. Feed conditioning: Feed condition usually causes a
sharp enthalpy change in the CGCC profile near the
feed location. It causes sudden “quenching” or heating
in the column and will increases the reboiler and
condenser load [4].
Figure 2. Targeting for various column modifications
using the CGCC [4].
It is easy to see sharp enthalpy change in the stage-
enthalpy representation. As shown in Figure 2b, the
extent of sharp enthalpy change on the reboiler side
determines the approximate heat load for feed
preheating. By successful feed preheating and cooling
we can reduce the reboiler and condenser loads.
3. Side condensing/ reboiling: As it is described in the
Figure 2c, potential for side condensing and reboiling
and their temperatures level can be obtained.
Feed conditioning modification in this method always
offers a more moderate temperature level than side
condensing/reboiling. Feed conditioning is also an
external modification unlike side condensing/reboiling.
And as described before the external modifications are
easier and require little or no capital investment
Thus the sequence for these modifications is
recommended as follows:
1. Reflux and pressure modifications.
2. Feed preheating/cooling.
3. Side condensing/reboiling
It is important that we identify appropriate feed stage
location before targeting for any aforementioned
modification. Because feed positioning may cause a
sharp enthalpy change in CGCC, similar to feed
preheating and cooling [4].
2. Case study
The case study shown in Figure 3 has been
extracted from the low-temperature section of an olefin
plant.
The whole olefin process is made of five sections
including cracking, compression, hydrogenation,
purification, and cold section. We only focus on low-
temperature sections i.e. purification and cold sections.
The existing plant is made of three simple
distillation columns, two reactors, and four flash drums
that process a gas mixture in low-temperature
conditions to produce ethylene. The main feed gas (301)
contains mostly light hydrocarbons and hydrogen. The
composition of feed is given in Table 1.
The heavy components (C3+) are separated in
column1 (D stream). There is a recycle stream (313)
that goes to stage1 in column1. Stream 313 is a section
of second reactor outlet. Top product of column1 goes
to two reactors to remove exiting Acetylene in the top
product by converting that to Ethylene and Ethane.
Other components (stream 311-501) enter the flash
drums (E-5001-4). Most of H2 and CH4 are separated
in these flash drums and the remains are separated in the
column2. Finally, the main product i.e. ethylene is
separated from ethane in the last column. Ethylene
stream (B) is so pure of ethylene at -65°C and 21 bar.
Product specifications are listed in Table2.
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 Proceedings of Fourth International Conference on Modeling, Simulation and Applied Optimization, ICMSAO'11
Kuala Lumpur, April 2011

Figure 3. Olefin plant cold-end separation

Table 1. Feed compositions for olefin plant, cold-end To meet the cooling requirements for all sub-
separation (301) ambient coolers, heaters, condensers and reboilers, the
Component Composition (%mole) existing refrigeration cycles are used.
H2 0.3599 In this plant, there are two refrigeration cycles of
CH4 0.0327 ethylene and propylene with three and four levels of
C2H2 0.0014 refrigeration of -30, -65, -101 °C and 12, 3, -20, -35 °C,
C2H4 0.3348 respectively.
In each cycle, the refrigeration levels and shaft
C2H6 0.2540
power consumptions - the most part of utility cost - are
C3H6 0.0039 summarized in Table 3.
C3H8 0.0044 The objective is optimizing the operating
1,3C4H6 0.0057 parameters to minimize the utility costs including the
C4H8 0.0004 compressor shaft powers, cooling water and low
C4H10 0.0005 pressure steam (LPS) consumptions. We have fixed the
GASOLIN 0.0003 arrangement of separation columns and the level of
BENZENE 0.0015 refrigerations to avoid the complexity. Moreover, as
TOLUEN 0.0002 there is no opportunity for heat integration between
CO 0.0001 condensers and reboilers of distillation columns and the
Feed Flow rate: Temperature: Pressure: heat exchanger network, we have focused on parameter
optimization.
2509.93 kmol/hr 15°C 18 bar
First, the base case is simulated by ASPEN and
HYSYS simulators. Then, the optimization is carried
Table 2. Product specifications for olefin plant, cold- out by Colom software, which is a program for design
end separation and optimization of column separations [5]. The
Product Component Product specification optimization procedure is a simultaneous optimization
A H2 , CH4 99% recovery of H2 and of column parameters along with refrigeration cycles
CH4 and associated heat sink/source exchangers, which is
B C2H4 99% recovery of Ethylene carried out by Genetic Alrorithm [1, 6, 7].
Afterwards, the effect of suggested modifications
C C2H6 99% recovery of Ethane is elaborated by simulating the optimum case.
D C3+ 99% recovery of C3H6
3. Results and discussions
Table 3. Specifications of existing refrigeration Table 4 reviews and compares the optimization
cycles results of column pressures, reflux ratios, and feed
Cycle Compressor refrigeration conditioning. Also, Figure 4 depicts the olefin plant
power (kW) levels (°C) cold-end separation after optimization.
For increasing the columns pressures, it is needed
Ethylene 16138.89 -30, -65, -101 to install 1 compressor (COMP) and 2 heaters (EVAP1,
Propylene 18122.224 12, 3, -20, -35 EVAP2). The new application utility consumption is not
so much in comparing with whole plant.

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 Proceedings of Fourth International Conference on Modeling, Simulation and Applied Optimization, ICMSAO'11
Kuala Lumpur, April 2011

Figure 4. Olefin plant cold-end separation after optimization

The most important effect of applying the new 5. References

optimization parameters is changing in heat exchangers
loads and temperatures. Most of the loads are decreased
and most of the temperatures are increased which results
in reduction of compressor power and cooling water
consumption.
Table 5 compares the utility costs of the base case
and the retrofitted case. It is shown an effective
reduction in utility cost by 11.3%.
[1] Wang J. and Smith R., “Synthesis and Optimization
of Low-Temperature Gas Separation Processes”, Ind.
Eng. Chem. Res., Vol. 44, No. 8, (2005), pp. 2856-
2870.
[2] Demirel Y., “Retrofit of Distillation Columns using
Thermodynamic Analysis”, Journal of Separation
Science and Technology, Vol. 41, (2006), pp.791–817,.

Table 4. Optimization data for Olefin plant [3] Alhammadi H. Y., “A Systematic Procedure for
Optimizing Crude Oil Distillation Systems”, Elsevier
Parameter Base Case After B.V, ESCAPE 18, (2008), pp.169-174.
Optimization
Pressure-Column1(bar) 17.6 17.6 [4] Dhole V. R. and Linnhoff B., “Distillation Column
Pressure-Column2 30.2 34.0 Targets”, Computers chem. Engng, Vol. 17, No. 5/6,
Pressure-Column3 20.5 23.5 (1993), pp. 549-560.
Reflux Ratio-Column1 0.3836 0.3836 [5] COLOM Software, 2010, Department of Process
Reflux Ratio-Column2 5.446 5.107 Integration, Manchester University, UK.
Reflux Ratio-Column3 5.533 5.880
[6] Tahouni N., Smith R. and Panjeshahi M. H.,
Feed Condition-Column1 gas gas
“Comparison of Stochastic Methods with Respect to
Feed Condition-Column2 liq liq
Performance and Reliability in Low Temperature Gas
Feed Condition-Column3 liq gas Separation Processes”, The Canadian Journal of
Chemical Engineering, Vol. 88, (2010), pp. 256-267..
Table 5. Comparison of utility costs-base case and
[7] Tahouni N., Panjeshahi M. H., and Ataei A.,
retrofitted case
“Comparison of Sequential and Simultaneous Design
Utility cost – Utility cost - and Optimization in Low-Temperature Liquefaction and
Parameter Base case After retrofit Gas Separation Processes”, Journal of the Franklin
(M$/yr) (M$/yr) Institute, in press.
Ethylene Cycle Wcomp=8.100 Wcomp=7.256
Propylene Cycle Wcomp=8.641 Wcomp=7.537
C.W 2.326 2.012
New Applications --- Wcomp=0.107
Total Utility Cost 19.067 16.912

4. Acknowledgment
The authors would like to express their gratitude
for financial support from Iran Fuel Conservation
Organization (IFCO) throughout this research work.

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