Vapour Compression for Propane-Propylene Splitters
Jayanthi Vijay Sarathy, M.E, CEng, MIChemE, Chartered Chemical Engineer, IChemE, UK
Propane-Propylene (C3) splitters are used in
Petrochemical industries to distil propylene
from propane prior to export. C3 Splitter
columns are traditionally operated with low
pressure steam (LPS) passed to the column’s
reboiler to heat up the C3 mixture thereby
causing the splitting operation. However the
use of Low Pressure steam is energy-
demanding. A C3 splitter is equipped with a
cooler and flash tank at the column top that
condenses the column top vapours but in
doing so, loses precious heat of condensation.
In recent years, the concept of using a heat
pump, such as a compressor has become a
standard practice that eliminates the
necessity of using low pressure steam.
C3 Splitter with Vapour Compression
Vapour compression methods for C3
stripping operations are ideal for compounds
that have low relative volatilities. Below is a
schematic of a C3 splitter with vapour
compression of product (propylene). Low
pressure steam that was used to vaporize the
bottoms propylene product is replaced by
installing a column top compressor and
routing a portion of the discharge to vaporize
the bottoms propane via the reboiler.
Figure 1. C3 Splitter with Compression
As per Ref [2], for a C3 splitter to operate
effectively, the temperature difference
between the column top and bottom should
not be more than 250F (13.90C). Additionally,
the bottom heat of vaporization should be
close to overhead vapour’s heat of
condensation with a pressure drop less than
15 psi (1 bar) across the column internals.
The heats of vaporization for propylene and
propane are nearly close at 157.6 Btu/lb and
151.7 Btu/lb respectively. The excess energy
required to be supplied by the compressor is
around 11%-12% of reboiler duty [Ref 2]
which represents a high energy savings. Low
pressure strippers also offer the advantage of
fewer trays, shorter column height and lower
column wall thickness that represents a
capital savings with higher relative
volatilities to effectuate product separation.
Low pressure C3 Stripper columns operate
between 90 psig (6.2 barg) to 110 psig (7.6
barg) depending on the Technology Licensor.
For the heat pump, the choice of compressor
used can be centrifugal type with a typical
pressure ratio of 1.8 [Ref 2] and effectively
regulates the column top pressures when the
throughput varies. The operation of the
centrifugal compressor can be fixed type or
variable speed type with the latter
representing greater control but with higher
installation costs.
C3 Column Top Pressure Control Methods
Suction Throttling Method
The Suction throttling method involves using
a control valve (e.g. butterfly valve) placed at
suction side of the centrifugal compressor.
But these are suitable only for fixed speed
drives like Asynchronous Induction Motors
where the driver speed cannot be
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manipulated. Below is a process schematic of
a C3 column top compressor that works on
the principle of suction throttling. A cooler on
the anti-surge line cuts down the inline
pressure loss in the compressor discharge
and also reduces the compressor discharge
side equipment and piping volumes,
contributing to the fast response of the anti-
surge system. The PIC on the compressor
discharge receives discharge pressures from
discharge side pressure transmitter (PT) to
alter the suction throttle valve opening.
Figure 2. Suction Throttling for C3 Column Top
Compressor
For C3 column operation, when the operating
pressure at the column top increases, the
suction throttle valve is altered based on the
compressor discharge pressure. The
operational advantage would be as follows,
1. For the case where the column top
pressure increases, it results in more
propylene flow into the compressor. This
causes the motor to draw in more
amperage to sustain the required higher
torque but can trip the electric motor and
subsequently the compressor. Therefore,
the suction throttle valve in such an event
closes accordingly to ensure the discharge
pressure required is maintained without
tripping the compressor.
2. In the event, the C3 column pressure falls,
and for a fixed speed of the motor and
reduced throughput from the column top,
the compressor discharge pressure would
rise causing the column top flash tank
pressure and the bottom reboiler pressure
to exceed design limits. Therefore as an
abatement measure, the suction throttle
valve would open further to maintain the
required compressor discharge pressure.
3. For both cases of C3 column top pressure
increasing/decreasing, the anti surge
valve (ASV) also acts in tandem with the
suction throttle valve via the Anti-surge
controller. This ensures that the
compressor operating point does not cross
the surge control line (SCL).
4. From an energy savings perspective, the
pinching operation of the suction throttle
valve would make the compressor operate
closer to the surge line where the power
absorbed is lower.
Variable Speed Motor (VSM) Method
As an alternative, variable speed motor
eliminates the need for a suction throttle
valve and can cater to the tower top
propylene vapours during column
fluctuations by altering the motor speed
based on the discharge pressure of the
compressor. The discharge side pressure
controller PIC cascades its output (OP) to
assign a set point to the speed controller (SC)
and controls the motor speed. In doing so,
both output flow and pressure are regulated.
Figure 3. Variable Speed Motor for C3 Column Top
Compressor
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In real situations, C3 splitter columns can also equipment selection to understand how
experience fluctuations in operating much vapour recycling can occur via the
pressures due to any changes in the anti-surge valve during such low
upstream side of the C3 splitter. This would turndown conditions.
also mean the C3 splitter column would take a
3. In vapour compression methods, when the
while to again attain equilibrium across trays use of steam is eliminated to vaporize the
and the vapour compressor at the tower top bottoms product, the tower top vapours
would also need to synchronize itself with from the compressor are used to
the column operating pressures. Comparing effectuate vaporization of the bottoms
suction throttling methods over Variable product in the reboiler. In the event of the
speed methods, the following points are column operating pressure exceeding the
described below. stipulated values, variable speed drives
1. Suction throttling methods though can be reduce the compressor speed and hence
used but suffer from an operability range discharge pressure, thereby supplying a
of the throttle valve. This often requires reduced throughput to the reboiler. This
the anti surge valve (ASV) to open consequently reduces the reboiler
frequently to avoid the compressor temperatures, reboiler vaporization rates,
operating point from crossing the surge avoids product degradation and aids in
control line (SCL). A disadvantage of the bringing the operating pressure of the C3
suction throttling method is, during a splitter columns within the allowable
reduction in the column top pressure, limits.
when the compressor operates closer to
References
the surge line though saving power, the
1. ‘Design Guidelines for Propylene Splitters
risk of the operating point crossing the
Efficiencies’, Karl Kolmetz, KLM
surge line is high. Any further fluctuation
Technology Group
in the column top pressure is detrimental
in creating a Level 1 emergency equipment 2. ‘Be Smart About Column Design’, Mark
shutdown (ESD-1) scenario and Pilling, P.E, Daniel R. Summers, P.E, Sulzer
subsequent upsetting of the column Chemtech, USA, AIChE November 2012
pressure profile. Additionally due to
excessive pressure drop across small
throttle valve openings, the risk of Joule-
Thompson cooling can produce
condensate particles which can erode the
compressor’s impellers.
2. Variable speed compressors also cater
well during turndown conditions, as much
as 30%. However this must be considered
during the process design basis stage
when setting the design and operating
limits of the C3 splitter column. For such
low turndown conditions, the compressor
vendor must also be consulted prior to

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