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Article history: For an N-component separation, distillation systems with less than N-1 columns have the potential to
Received 26 May 2008 save both energy and capital costs compared to the conventional simple column configurations where N-1
Received in revised form 20 October 2008 columns are employed. Recently, for four-component separations, Kim and Wankat [J.K. Kim, P.C. Wankat,
Accepted 15 December 2008
Quaternary distillation systems with less than N-1 columns, Ind. Eng. Chem. Res. 43 (2004) 3838–3846]
Available online 25 December 2008
analyzed a few distillation systems with less than N-1 columns and presented tentative heuristics for
selecting the best configuration among those studied.
Keywords:
In this paper, a method for the systematic synthesis of all the distillation systems with less than N-
Multicomponent distillation
Energy saving
1 columns is presented. Starting from the simple column configurations for the separation of an N-
Distillation sequences component mixture, a four-step procedure is formulated which systematically generates all the possible
Process synthesis distillation systems with less than N-1 columns. First, the subspace of the possible thermally coupled
configurations corresponding to the simple column configurations is generated. Then, the subspace of the
possible thermodynamically equivalent structures corresponding to the thermally coupled configurations
is produced. Finally, the subspace of the distillation systems with less than N-1 columns corresponding
to the thermodynamically equivalent structures is achieved. The method is simple, easy-to-use and can
systematically synthesize all the possible distillation systems with less than N-1 columns. It is shown that
a large number of such distillation systems with less than N-1 columns have been achieved for the first
time. This constitutes a complete new subspace. A case study shows the advantages of such distillation
systems with less than N-1 columns over the other schemes. The significance to formulate a complete
subspace of such systems is that, on the one hand, it can be used to further develop more reliable heuristics
by simulations. On the other hand, an optimization framework can be formulated to screen the possible
optimal system for a specific application.
© 2008 Elsevier B.V. All rights reserved.
1. Introduction configurations sharply increases. This was one of the main reasons
that urge the researchers’ work in searching general rules (heuris-
Distillation is one of the most studied and utilized separation tics) able to make a preliminary screening in order to select a lower
methods in the industrial practice. Between the end of the 1940s number of alternatives to be analyzed. The selected configurations
and the beginning of 1950s the principal research area was the can be subsequently analyzed with a rigorous method to find the
development of methodologies to give a good physical description best sequence in terms of energy requirement [4,5]. Anyway heuris-
of the process [1,2]. After that, in the 1970s, most of the research tic rules are based on practical considerations from different plant
work was focused on the study of different possible arrangements to experiences or from the generalization of the results of a large set
separate an N-component mixture using simple columns [3], thus of process design simulations studies, so their indications are not
columns with one feed, a distillate and a bottom product with asso- completely always valid and can lead to not optimal solutions [6].
ciated respectively one condenser and one reboiler. For the separa- The problem of the analysis of all the possible separation
tion of an N-component mixture into N pure products, as the num- sequences became more complex when some researchers, with
ber of components increases, the number of possible simple column the aim to reduce the energy consumption of distillation plants,
started to propose again the application of the divided wall col-
umn patented by Wright in 1949 [7]. This new type of configuration
∗ Corresponding author. Tel.: +45 27509036; fax: +45 65507354. extends the searching space also to the thermally coupled distilla-
E-mail address: BGR@kbm.sdu.dk (B.-G. Rong). tion sequences. Because the reduction of the energy consumption
0255-2701/$ – see front matter © 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.cep.2008.12.005
908 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920
[18]. Fig. 3 presents all of the thermally coupled configurations gen- bution between the sections. Moreover, a better controllability of
erated from the simple column configurations shown in Fig. 2. In the system can be obtained [20]. For an n-component mixture,
total, 15 thermally coupled configurations are generated. the number of thermodynamically equivalent structures (TES) of
a given sequence can be predicted utilizing the following formula
2.3. Step 3: The thermodynamically equivalent configurations developed by Rong et al. [19]:
TES = 2NTC (3)
From the thermally coupled configurations, the thermodynam-
ically equivalent ones can be generated through moving a column where NTC is the number of thermal couplings. At the beginning,
section associated to a condenser and/or a reboiler that provides the subspace of thermodynamically equivalent structures is usually
the common reflux flow rate or the vapour boil up between two not explored when the best saving structure is searched, because
consecutive columns. Following this procedure, the elimination of as said before, the energy requirement of these structures is the
a condenser or a reboiler associated with a submixture from a sim- same of the thermally coupled configurations from which they are
ple column in a distillation sequence, makes the rectifying or the derived [10]. However after a promising thermally coupled config-
stripping section of the subsequent column movable. For this reason uration is identified, only the corresponding thermodynamically
the number of movable sections is equal to the number of thermal equivalent structures should be considered for a possible capi-
couplings in the considered sequence [19]. A configuration in this tal cost reduction. Fig. 4 presents all of the thermodynamically
subspace has the same energy requirement as the corresponding equivalent structures generated from the thermally coupled config-
thermally coupled structure. Nevertheless, the capital cost saving urations shown in Fig. 3. In total, 25 thermodynamically equivalent
can be achieved by a better liquid and vapour flow rate redistri- structures are generated.
910 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920
Fig. 3. (Continued) .
2.4. Step 4: Generation of the intensified structures with less than equivalent structures shown in Fig. 4. In total, 31 systems with less
N-1 columns than N-1 columns are generated.
Fig. 4. (Continued) .
914 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920
Fig. 4. (Continued) .
M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920 915
Fig. 4. (Continued) .
Table 1 • Group 3. Configurations with only one column (Fig. 5 d3.3.3, i3.3.3,
Feed conditions.
s3.3.3).
Component Molar fraction [%] Physical characteristic
A, n-butane 30 Temperature [K] 334.55 It is seen that each configuration of the distillation systems with
B, n-pentane 40 Vapour fraction 0 less than N-1 columns in group 2 has one thermal coupling, which
C, n-hexane 25 makes them have one less heat exchanger than the configurations
D, n-octane 5
in group 1 (except schemes in Figs. di3.1.1 and id3.1.1). A distinct
feature of each of the configurations in group 3 is that it has only
one column equipment.
consistent with results from the heuristics by Tedder and Rudd
[14]. 3.2. Comparison with the previous work
Following the described procedure, the number of columns in
the final configuration is reduced by one or more compared to the It is interesting to review the literature work for systems
number of N-1 columns. In some cases, the number of heat exchang- with less than N-1 columns in the context of the complete
ers is also reduced by one or more compared to those of the partially subspace presented in this work. For instance, in the work
coupled configurations. of Kim and Wankat [22], 11 configurations with less than N-
The method described is readily generalized to the separation 1 columns for four-component mixtures were analyzed. Some
of any number of components. In the literature, some configura- tentative heuristics were summarized based on simulations for
tions with less than N-1 columns were investigated for 3 and 4 different mixtures with different compositions. It is clear that
components [21,22]. However, the whole subspace of possible con- the analyzed 11 configurations are the cases in group one with-
figurations has not been systematically identified for four or more out thermal coupling in the complete subspace with less than
component mixtures. N-1 columns in Fig. 5 (i.e. id1.1.1; i2.1.1; s1.1.1; di2.1.1; i1.1.1;
di1.1.1; s2.1.1; d2.1.1; id2.1.1; d1.1.1; s3.3.3 in Fig. 5). However,
3.1. Classification of the intensified structures two configurations in group three were missed (i.e. d3.3.3, i3.3.3
in Fig. 5). Moreover, the configurations of group two with ther-
By analyzing all the configurations presented, it is possible to mal couplings are not considered which are equal importance
classify the subspace in three main groups: as the studied 11 configurations when developing the general
heuristics.
• Group 1. Configurations without thermal coupling (Fig. 5 d1.1.1, Another significant issue is concerned with the saving of com-
d2.1.1, i1.1.1, i2.1.1, di1.1.1, di2.1.1, id1.1.1, id2.1.1, s1.1.1, s2.1.1). putation expenses when developing heuristics for screening the
• Group 2. Configurations with thermal coupling (Fig. 5 d3.1.1, d3.2.1, best system with less than N-1 columns among the possible alter-
d3.3.1, d3.3.2, i3.1.1, i3.2.1, i3.3.1, i3.3.2, di3.1.1, di3.2.1, di3.3.1, natives. Usually as done in Kim and Wankat [22], for a given feed
id3.1.1, id3.2.1, id3.3.1, s3.1.1, s3.2.1, s3.3.1, s3.3.2). mixture and composition, the simulations were first done for all
Table 2
Design and operational parameters of the simple column configurations.
C1 C2 C3 C1 C2 C3 C1 C2 C3 C1 C2 C3 C1 C2 C3
Nt 35 33 49 39 38 38 39 26 40 35 60 40 55 38 45
Nf 20 16 26 20 18 22 20 14 16 20 28 16 26 21 26
RR 2.00 1.41 0.50 0.14 0.70 1.50 0.14 1.90 1.37 2.00 0.26 1.34 0.73 1.48 0.45
D [m] 0.70 0.72 0.48 0.83 0.81 0.61 0.83 0.68 0.70 0.70 0.71 0.71 0.82 0.54 0.44
Qc [kW] 1428.90 2025.22 1933.17 1731.07 1496.32
Qr [kW] 1530.10 2126.25 2034.22 1832.63 1598.32
CC [$/year] 29706 37672 34173 50272 31959
916 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920
Fig. 5. (Continued) .
918 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920
Fig. 5. (Continued) .
of the simple column configurations. Then, the simulations were tems, there is a correspondence between the best simple column
also done for all of the considered configurations with less than sequence and the structures derived from it. Thus the primary aim
N-1 column. By simulations for a number of feed cases and compo- of this work is to derive the complete subspace that until now has
sitions, a valuable heuristics was obtained by comparing the best not been thoroughly explored. On the other hand, the method saves
new alternative with the best simple column configuration based the correspondence between the different subspaces allowing the
on total annual costs for each of the calculated cases. As pointed designer to analyze only the configurations obtained from the best
out by Smith and Linnhoff [23] for integrated sequences and by simple column sequence. This will considerably reduce the compu-
Rong and Kraslawski [17] for thermally coupled distillation sys- tational efforts for the development of heuristics.
M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920 919
Table 3
Design and operational parameters for the thermally coupled configurations derived from the direct simple column sequence.
d1 d2 d3
C1 C2 C3 C1 C2 C3 C1 C2 C3
Nt 35 33 49 35 33 49 35 33 49
Nf 20 16 26 20 16 26 20 16 26
RR 1.69 1.41 0.36 2 1.38 0.72 1.74 1.06 2.45
D [m] 0.67 0.97 0.46 0.70 0.72 0.90 0.67 0.93 1.22
Qc [kW] 1355.11 1462.31 1651.03
Qr [kW] 1455.47 1563.35 1751.86
CC [$/year] 30561 34747 41356
3.3. A case study The best thermally coupled configuration derived from the
direct sequence is d1 in Fig. 3, anyway its performance is overcome
To have an impression on the synthesized complete subspace, by configuration d2.1.1 in Fig. 5, that with the same reboiler and
a four-component mixture of normal butane, pentane, hexane and condenser duty a 6% saving in the annualized capital cost is realized.
octane with the characteristics reported in Table 1 is considered. Configurations d1.1.1, d3.1.1, d3.3.1 and d3.3.3, where the prod-
This feed mixture is the same already considered by Kim and uct B is withdrawn as vapour phase below the feed location, are
Wankat [22] considering a required molar purity of 99% for the not reported since for this stream it was not possible to reach the
butane, pentane and octane and 98% for the hexane. In the present purity target. Compared with the best simple column sequence,
work, all the simulations were performed by Aspen Plus 13.0. The configuration d2.1.1 realizes a saving of 5% in both condenser and
initial design parameters for the simple column sequences like the reboiler total duties and a reduction of 3.3% in the annual capi-
number of theoretical stages, the feed location, the actual reflux tal cost. Another attractive configuration is the d3.3.2 that was not
ratio and the distillate flow rate were obtained from short cut calcu- included in the Kim and Wankat analysis [22]. This configuration
lations using the Winn-Underwood-Gilliland method implemented realizes a 2% reduction in both condenser and reboiler duties with
in the DSTWU Aspen model. A reflux ratio of 1.1 times the mini- approximately the same annual capital cost compared to the direct
mum reflux ratio was considered for all the columns. The pressure simple column sequence. Configuration d3.2.1 has a higher reboiler
of each column was fixed at 3 atm. Then rigorous simulations were duty and also a higher annual capital cost compared to the best sim-
performed using the stage by stage model RADFRAC, optimizing the ple column sequence. However, it should be noted that the obtained
initial parameters obtained from the simplified calculation and con- values are better than the worst SC case.
sidering a single sieve tray pressure drop of 0.1 psi [24]. In Table 2, The case study calculation clearly showed that the subspace of
the main design and operational parameters for all the possible sim- distillation systems with less than N-1 columns can be more advan-
ple column configurations, together with the heat duties and the tageous than the best simple column configuration in terms of both
annual capital costs are summarized. The installation cost formu- energy and capital cost savings. It also showed that it is impor-
las based on the Douglas’ correlations [25] are reported in Appendix tant to consider the whole subspace when developing the general
A. From Table 2 it can be noticed that the direct configuration has heuristics.
the less energy consumption and also the less annual capital cost.
For the intensified structures, the column design parameters (feed
4. Conclusion
stage, number of stages and withdrawal location) are derived from
the corresponding simple column configuration. Sensitivity analy-
In the literature, only a few distillation systems with less than
ses are performed with the simulator to optimize the configuration
N-1 columns were studied, from which the potential for savings
for the minimum energy consumption. In the configurations where
of both energy and capital costs than the simple column sequences
one or more thermal couplings are present the flowrate of the inter-
were indicated. Some tentative heuristics were also summarized by
connecting streams (liquid and/or vapour) are utilized as searching
simulations of a few such distillation systems. In order to develop
variables in an optimization procedure to achieve the minimum
comprehensive and reliable heuristics, and in order to find the
energy consumption [26]. The thermally coupled configurations
optimal configuration for a specific application, it is paramount
and the subspace containing the intensified structures obtained
important to predefine all of such distillation systems with less
from the best simple column sequence are considered in detail and
than N-1 columns. Moreover, a method is needed to synthesize and
the results are reported in Tables 3 and 4, respectively.
predefine all of such distillation systems systematically.
In this paper, a systematic method for the generation of the
Table 4
subspace of distillation systems with less than N-1 columns is
Design and operational parameters for the selected configurations of the subspace
with less than N-1 columns. presented. The method is composed of four steps and each one
generates a subspace with different alternatives. The method is
d2.1.1 d3.2.1 d3.3.2
easy-to-use and can systematically generate the complete subspace
C1 C2 C1 C2 C1 C2 of the systems with less than N-1 columns for an N-component
Nt 35 56 35 56 75 16 mixture. This subspace includes configurations with simple side
Nf 20 16 20 16 35 16 stream columns and also configurations with thermal couplings.
Ns – 33 – 33 51 – The establishment of the correspondence between the alternatives
RR 2.00 1.47 1.69 2.25 3.11 0.91
among the subspaces is of particular importance in the method. The
D [m] 0.70 0.85 0.67 1.18 1.14 0.60
Qc a [kW] 1170.13 1326.21 1218.35 benefit to save the information between the families of configura-
Qr [kW] 1458.50 1615.43 1504.83 tions can lead to a less number of the alternatives to be compared
CC [$/year] 28730 33639 29571 to find the optimum configuration. A case study for the separa-
a
The value includes also the duty necessary to condensate the vapour from the tion of a four-component mixture illustrated the cost reduction for
side-stream. the configurations in the new subspace. It is showed that for the
920 M. Errico et al. / Chemical Engineering and Processing 48 (2009) 907–920