CHAPTER 3

METHODOLOGY

3.1 Equipment in the simulation of Distillation Process

3.1.1 Feed Tank

The feed tank is to store the feed of distillation process which is a liquid, vapor or a liquid vapor.
At any point in the column, it will join, but it is important to decide and use the optimum feed tray
position. The device can supply more than one source and draw more than one product.

3.1.2 Pump

The common pumps in oil and gas industry are the Centrifugal Pumps. By translating rotational
kinetic energy to the hydrodynamic energy of the fluid flow, centrifugal pumps are used to transport
fluids. Usually, the rotational energy comes from a generator or electric motor. They are a sub-class of

complex axisymmetric work-absorbing turbomachinery. In a flowing fluid, a centrifugal pump

transforms rotational energy, often from a motor, into energy. A part of the energy goes into the fluid's
kinetic energy. Fluid reaches through the eye of the casing axially, is stuck in the impeller blades, and is
rotated outward tangentially and radially until it exits through the diffuser portion of the casing through
all circumferential areas of the impeller. In going through the impeller, the fluid gains both velocity and
pressure. The casing portion of the doughnut-shaped diffuser, or scroll, decelerates the flow and raises

the friction further. The figure 3.1 and figure 3.2.1 shown the pump in distillation process:
 Figure 3.1 : Centrifugal Pump [ CITATION ltd20 \l Figure 3.1.2 : Pump in the simulation.
1033 ].

3.1.3 Heater

In the simulation process, heater increase the feed fluid temperature before it entered the distillation
column. Thus, the fluids will efficiently separate in the distillation column follows by their boiling
point. Figure 3.1.3 shown the heater in simulation of distillation process:

Figure 3.1.3 : Heater in the simulation.

3.1.4 Distillation Column

 Several modules are made up of distillation columns, each of which is used either to transfer heat
energy or to increase the transfer of material. A standard distillation column consists of several main
components that are a vertical shell where component separation is carried out, internal columns such
as trays or plates or packings used to enhance component separation, a reboiler to provide the requisite
vaporization for the distillation phase, a condenser to cool and condense the vapor leaving the top of
the column and a condenser to cool and condense the vapor leaving the top of the column. Figure 3.1.4

and 3.1.5 shown the distillation column:

Figure 3.1.4: Distillation Column individual parts [ CITATION Figure 3.1.5: Distillation Column in
Jam07 \l 1033 ]. the simulation.
3.1.5 Reboiler

Reboilers are heat exchangers that are typically used to heat the bottom of industrial distillation
columns. To create the vapors that are returned to the column to induce the distillation separation,
the liquid is boiled from the bottom of the distillation column. The heat supplied to the column by
the reboiler at the bottom of the column is removed by the condenser at the top of the column. Many
reboilers are of the form of shell and tube heat exchanger and as a rule, steam is used as a heat source
in such reboilers. Figure 3.1.6 shown the reboiler in refinery plant example:

Figure 3.1.6: Reboiler example [ CITATION RCC16 \l 1033 ].

3.1.6 Condenser
A condenser is a device or machine for condensing a gas material into the liquid state by cooling in
systems requiring heat transfer. In that way, the latent heat is emitted into the atmosphere by the
material. In many industrial systems, condensers are used for effective heat refuse. A condenser is used
to transfer heat to a secondary fluid or ambient air from a working fluid. In the refinery, the condenser
is used to condense the vapor product to liquid. The condenser is usually reached by steam above the
secondary fluid at a temperature. As the vapor cools, it exceeds the temperature of equilibrium,
condenses into fluids and releases vast volumes of latent heat. The volume of vapor reduces as the
process takes place alongside the condenser and fluid rises.

3.2 Flow Chart

3.3 Methods in Simulations

3.3.1 Peng-Robinson Equations

In the commercial simulation package, Peng-Robinson Equations is a desired thermodynamic package.
Peng-Robinson Equations is the most enhanced model in ASPEN HYSYS. In terms of Temperature and
Pressure, it has the largest applicability range. There is also special treatments for some key
components and the parameter database is largest binary interaction.

3.3.2 Size of Distillation Column

The diameter is 1.5m and the height is 5.5m. In this process, there are 10 trays inside the distillation
column. The distillation column is to separate the mixture of Petrol ranges C5-C10 and Kerosene
ranges C12-C16. In the simulation, two distillation towers are provided to separate the mixture
efficiently.

3.3.3 Reflux Ratio

Reflux is the substance concentrated to a pot flask by the rising vapor. The reflux ratio is the ratio of the
boil-up rate to the start-up rate. This is the ratio between the quantity of reflux returned from the

distillation column and the quantity of reflux stored in the receiver. The higher the reflection ratio,
the more vapor or liquid in the distillation column will come into contact. Higher reflux ratios thus
typically indicate higher distillate purity. This also indicates that the distillate collection pace is slower. In
the simulation, the reflux ration is 3:1. Thus, 3 parts of the reflux is go to the bottom of the tower and
the collected distillate is 1 part.

3.3.4 Mass Flow Rate

The amount of the feed fluid flows in a given time is 5000 kg/h in the simulation. Increase in flow rate
will result the efficiency of the product to separate.

3.4 Summary on Simulation of the Process

Figure 3.2: Simulation of Petrol and Kerosene distillation process using ASPEN HYSYS.

Above figure 3.2 shown the process in simulation, this process is to separate Petrol and Kerosene to
each fraction. In this project, the feed pressure is 1 atm, temperature is 170 ℃ and the mass flowrate is
5000 kg/h. From the feed, the fluid flow into the pump to increase the pressure of the fluid. When it

reach the heater, it will heat up the fluid before the feed fluid enter the distillation column to give it
a desired temperature for the separation process. Hot product will enter the distillation column, the
process of separating the Petrol and Kerosene into each fraction by their boiling point where it happen

in the tower. Therefore, the product will be collected at the top and bottom of the distillation units.
Table 3.1 bellow shown the compositions of each fractions:

Fractions Feed Petrol Kerosene

Composition Composition Composition
C5 0.0500 0.1729 0.0000
C6 0.0500 0.1729 0.0000
C7 0.0500 0.1729 0.0000
C8 0.0500 0.1728 0.0000
C9 0.0500 0.1657 0.0000
C10 0.2000 0.1428 0.0000
C12 0.0500 0.0000 0.0000
C13 0.0500 0.0000 0.0008
C14 0.0500 0.0000 0.0165
C15 0.1000 0.0000 0.2196
C16 0.3000 0.0000 0.6667
Table 3.1: The compositions of each fractions.

As we can see from above table, Petrol that ranges from C5-C10 is produce in the first

distillation column at the top product which is lighter boiling point. The Kerosene ranges from C12-
C16 is collected at the bottom of the tower at second distillation column. There are two distillation
columns in the simulation because the first distillation column does not manage to separate the
petrol and kerosene product efficiently. Thus, the top product of second distillation column also not
produce the efficient amount of the kerosene. This result can we see at figure 3.3 shown the
composition of the distillation process in ASPEN HYSYS:

Figure 3.3: The composition of the distillation process in ASPEN HYSYS